WO2015019362A1 - Preparation of ethanol from lignocellulosic materials - Google Patents

Preparation of ethanol from lignocellulosic materials Download PDF

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Publication number
WO2015019362A1
WO2015019362A1 PCT/IN2014/000433 IN2014000433W WO2015019362A1 WO 2015019362 A1 WO2015019362 A1 WO 2015019362A1 IN 2014000433 W IN2014000433 W IN 2014000433W WO 2015019362 A1 WO2015019362 A1 WO 2015019362A1
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Prior art keywords
stream
ethanol
biomass
final
fermented
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PCT/IN2014/000433
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English (en)
French (fr)
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WO2015019362A8 (en
Inventor
Waman Joshi Satyendra
Ganpat Kashid MOHAN
Subhash Rathi SHRIKANT
Baburao Deshpande GHANSHYAM
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Praj Industries Limited
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Priority to BR112016002565A priority Critical patent/BR112016002565A2/pt
Publication of WO2015019362A1 publication Critical patent/WO2015019362A1/en
Publication of WO2015019362A8 publication Critical patent/WO2015019362A8/en

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    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12P—FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
    • C12P7/00—Preparation of oxygen-containing organic compounds
    • C12P7/02—Preparation of oxygen-containing organic compounds containing a hydroxy group
    • C12P7/04—Preparation of oxygen-containing organic compounds containing a hydroxy group acyclic
    • C12P7/06—Ethanol, i.e. non-beverage
    • C12P7/14—Multiple stages of fermentation; Multiple types of microorganisms or re-use of microorganisms
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M21/00—Bioreactors or fermenters specially adapted for specific uses
    • C12M21/12—Bioreactors or fermenters specially adapted for specific uses for producing fuels or solvents
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M23/00—Constructional details, e.g. recesses, hinges
    • C12M23/58—Reaction vessels connected in series or in parallel
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M43/00—Combinations of bioreactors or fermenters with other apparatus
    • C12M43/02—Bioreactors or fermenters combined with devices for liquid fuel extraction; Biorefineries
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M45/00—Means for pre-treatment of biological substances
    • C12M45/06—Means for pre-treatment of biological substances by chemical means or hydrolysis
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M45/00—Means for pre-treatment of biological substances
    • C12M45/09—Means for pre-treatment of biological substances by enzymatic treatment
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12P—FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
    • C12P19/00—Preparation of compounds containing saccharide radicals
    • C12P19/02—Monosaccharides
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E50/00—Technologies for the production of fuel of non-fossil origin
    • Y02E50/10—Biofuels, e.g. bio-diesel

Definitions

  • the invention relates to a process and system for the preparation of ethanol from lignocellulosic materials and more particularly from lignocellulosic materials like com cob, corn stover, sugarcane/ beet bagasse or any other lignocellulosic materials.
  • Lignocellulosic materials [LCM] from the agriculture industry are waste by-products. It is mostly used inefficiently as an energy source or fed to animals; however a large part is wasted as such without any use.
  • LCM is a complex structure of cellulose, hemicellulose and lignin forming a composite which depending on its source is differentially resistant to hydrolysis compared with other carbohydrate based materials like starch. LCM form structural ' components of plants and has varying composition based on its location in host or type of the host.
  • LCM biomass refers to plant biomass that is composed of cellulose, hemicellulose, and lignin. This biomass comes in many different types such as wood, wood residues, municipal waste,, agricultural residues and energy crops like fast growing tall and woody grasses. In all these categories the carbohydrate polymers (cellulose and hemicelluloses) are tightly bound to the lignin by hydrogen and covalent bonds forming the strong structures of LCM.
  • carbohydrate polymers cellulose and hemicelluloses
  • One barrier to the production of ethanol from LCM is that a large fraction of the sugars necessary for fermentation present in the form of lignocelluloses. LCM has evolved to resist degradation and to confer hydrolytic stability and structural robustness to the cell walls of the plants.
  • LCM hydrolysis treatment also called pretreatment
  • pretreatment is a major step in the processing of LCM for the preparation of ethanol.
  • current methods of the pretreatment use acids, alkalis or other chemicals like ammonia at high temperatures to hydrolyze the hemicellulose part of LCM liberating xylose sugar in the first step.
  • the cellulose rich remaining part is subjected to enzymatic or chemical hydrolysis to liberate glucose sugar and remaining lignin rich part is burned to generate energy.
  • These two sugars are then fermented to make ethanol or used to prepare other bio-based chemicals.
  • the invention disclosed herein in addresses several problems of previous methods like: 1] high concentration of inhibitors in hydrolysates, 2] low efficiency of the hydrolysis of LCM at benign conditions and 3] low efficiency of conversion of LCM derived sugars to ethanol in the fermentative process.
  • a novel method is disclosed having advantages like: 1] low level of inhibitors that do not limit the growth of microbes, 2] more benign and economic processing conditions of LCM and 3] higher efficiency of conversion of sugars to ethanol in a novel two step fermentation process.
  • FIGURE 1 depicts a block diagram of mass flow during the production of ethanol from a LCM. Different elements of the process are identified and directional movement of different additives and streams formed during the process are shown to describe the features of one embodiment of the present invention.
  • FIGURE 2 is an exemplary plan of the invention showing several 100 features that control the process of production of ethanol from a lignocellulosic feedstock.
  • the whole system may be divided into five units, namely: 1] hydrolysis unit (TV), 2] enzymatic hydrolysis and C6 [hexose sugar] fermentation unit (' ⁇ '), 3] distillation and ethanol recovery unit ('C'), 4] C5 [pentose sugar] fermentation unit ( ⁇ '), and 5] evaporation unit ( ⁇ ').
  • said distillation and ethanol recovery unit used to recover, ethanol from C6 fermented wash as well as C5 fermented wash leading to recovery of ethanol made from both glucose and xylose sugars.
  • a person skilled in the art may appreciate variations of the system to achieve the 110 conversion of sugars to ethanol as disclosed herein.
  • LCM biomass in one embodiment of the disclosed invention as illustrated in FIGURE 1 to produce ethanol from , LCM biomass, said biomass like corn cob, bagasse, stover or other similar agricultural material is size reduced to a particulate matter.
  • This particulate matter of about 40 mm size is then soaked and washed in water to remove any soil or other contaminating agents.
  • said soaked biomass is pretreated in the presence of one or more acids [inorganic or organic] at certain high pressure and
  • a hydrolyzed stream of LCM is obtained, which is subsequently subjected to a neutralization and enzymatic hydrolysis process.
  • the pretreatment on said LCM releases xylose from the hemicellulosic part, while crystalline cellulose fibres are loosen so that it may be further treated with cellulolytic enzymes.
  • the said hydrolyzed stream is first neutralized with an alkali like NaOH or CaOH to increase the pH to about 6 and then one or more celllulases are added, and reaction is allowed for several hours at desired conditions.
  • This step releases glucose from the cellulose fibres leading to substantial increase of glucose in formed first stream.
  • the said first stream is then subjected to a hexose fermenting yeast like a Saccharomyces sp. leading to conversion of said hexose to ethanol forming a first fermented stream.
  • This stream contains ethanol produced from said glucose present in said first stream.
  • said first fermented stream is subjected to a first distillation to separate aqueous ethanokleading to formation of a spent stream.
  • the aqueous ethanol so afforded is further processed to obtain anhydrous ethanol or other ethanol products.
  • said spent stream is collected and under
  • the steps of said process are: 1] the feedstock [30] comprising size reduced and washed corn cob or bagasse particulate material is pretreated in a hydrolysis unit ['A']. Before this a soak tank is used for wetting and removing of foreign matters from said particulate biomass.
  • the LCM biomass is size reduced using a mechanical mechanism comprises a device for cutting, chopping or shredding.
  • a plug screw type hydrolyser [1] is fed with said feedstock stream [30]; in the said hydrolyser said feedstock is treated with high pressure steam [21] at about 140 to 210 °C in the present of one or more acids supplied from a tank [2].
  • the hemicellulose present in LCM is hydrolyzed leading to release of xylose in a hydrolyzed stream [26].
  • This hydrolyzed stream [26] is directed to a flash tank [3] to remove excess water from it, which is condensed by a condenser [13] and reused in the process.
  • the hydrolyzed stream [31] obtained from said flash tank [3] comprising most of solids in the form of cellulose and lignin and soluble xylose is directed to a reactor or digestion tank [5] which has provisions for supply of an alkali and cellulolytic enzymes in unit [' ⁇ ']
  • said hydrolyzed stream [31] is neutralized with addition of suitable alkali solution to increase the pH to make it more suitable for actions of hydrolyzing enzymes.
  • said stream rich in cellulose is hydrolyzed by action of cellulases for desired time period leading to the formation of a first stream [32].
  • This first stream [32] is then subjected to a first fermentation in a fermentor or bioreactor [6] by a hexose sugar fermenting yeast like S. cerevisiae leading to the production of ethanol from glucose present in said stream and formation of a first fermented stream [33].
  • This stream [33] is subjected to distillation and ethanol recovery unit [7; '], wherein ethanol is recovered and a spent stream [34] rich in xylose sugar is subjected to a second fermentation by a pentose fermenting yeast like P. stipitis in a second fermentor or bioreactor [8; ⁇ '] leading to the production of ethanol from xylose present in said stream and formation of a final fermented stream [35].
  • This stream [35] is subjected to distillation and ethanol recovery unit [7; 'C'], wherein ethanol is recovered and a waste stream [36] is formed.
  • Alcohol vapours [41] from said unit ['C'] are condensed [42] in an
  • the said distillation and ethanol recovery unit ['C'] comprises several elements that efficiently distil out ethanol from streams [33] and [35] containing as low as 1 % ethanol by weight and simultaneously rectifies said stream [42] to more concentrated ethanol stream [43].
  • the said waste stream [36] with solids comprising lignin is subjected to a filter press [9] to remove wastewater [37] from said solids [44].
  • the solids [44] are burnt in a boiler [14] to generate energy, while wastewater [37] is sent to a flash tank [1 1] to remove vapours [38] that are condensed in a condenser
  • a vacuum pump [51] maintains a negative pressure in said system for effective operation of different units of the apparatus.
  • first step a batch of about 118 Kg of corncobs having total solids of about 92% by weight, cellulose of about 33% by weight, hemicelluloses of about 27% by weight and lignin of about 13% by weight was used as a feedstock. It was subjected to mechanical shearing for size reduction to less than 40 mm particles affording about 108 Kg of the particulate material. This particulate material was soaked in water for about 30 min. Then about 360 Kg slurry [also called mixture] containing about
  • this pretreated hydrolysate rich with C5 sugars along with C6 solids [cellulose + lignin] was subjected to enzymatic hydrolysis by cellulases. Before enzymatic hydrolysis, it was neutralized with NaOH to increase pH to about 5. Then a commercially available cellulase cocktail [about 20 mg/g of cellulose] was added to the pretreated material and allowed digest said solids at desired
  • first step a batch of about 35 Kg of sugarcane bagasse having total 270 solids of about 90% by weight, cellulose of about 35% by weight, hemicelluloses of about 21 % by weight and lignin of about 21 % by weight was used, as a feedstock. It was subjected to mechanical shearing for size reduction to less than 40 mm particles affording about 122 Kg of the particulate material. This particulate material was soaked in water for about 30 min. Then about 489 Kg slurry containing about 25% by weight total solids was prepared and continuously introduced into a plug screw type hydrolyser. Here the slurry was mixed with about 240 litres of the admixture of oxalic and sulphuric acids. This admixture of mixed acids contained about 1 % by weight oxalic acid and about
  • pretreated hydrolysate rich with C5 sugars along with C6 solids [cellulose + lignin] was subjected to enzymatic hydrolysis by cellulases. Before enzymatic hydrolysis, it was neutralized with NaOH to increase pH to about 5. Then a commercially available cellulase cocktail [about 30 mg/g of cellulose] was added to the pretreated material and allowed digest said solids at desired conditions for about 120 h at 52 °C. After said enzymatic hydrolysis, glucose of about 3.3% by weight was ' afforded in the stream with cellulose hydrolysis efficiency of about 52%.
  • the stream contained xylose of about 3.5% by weight and glucose of about 3.3% by weight.
  • yeast S. cerevisiae which fermented glucose present in said stream to ethanol leading to ethanol concentration in the stream at about 1 .3% by weight.
  • glucose to ethanol conversion efficiency was about 90% of theoretical maximum efficiency after about 36 h of fermentation time.
  • This process also removes inhibitors of fermentation present in said stream as S. cerevisiae is more robust microbe and can sustain wide variations in the growth conditions and toxicants present in the fermentation medium. It also moderates these inhibitors such that subsequently other yeasts may be grown in the same medium.
  • this spent stream was again subjected to a second fermentation by yeast P. stipitis, which fermented xylose present in said stream to ethanol leading to ethanol concentration in the stream at about 1.2% by weight.
  • xylose to ethanol conversion efficiency was about 65% of theoretical maximum efficiency after about 80 h of fermentation time.
  • this second fermented stream was further subjected to distillation to obtain ethanol. This two-part fermentation and distillation afforded ethanol from both xylose and glucose sugars in a more efficient and economic way than previously disclosed.

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  • Life Sciences & Earth Sciences (AREA)
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PCT/IN2014/000433 2013-08-06 2014-06-27 Preparation of ethanol from lignocellulosic materials WO2015019362A1 (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105384171A (zh) * 2015-12-18 2016-03-09 齐鲁工业大学 利用木糖醇制备工艺后的玉米秸秆废渣制备活性炭的方法

Citations (6)

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Publication number Priority date Publication date Assignee Title
US4840903A (en) * 1985-08-08 1989-06-20 The United States Of America As Represented By The United States Department Of Energy Process for producing ethanol from plant biomass using the fungus paecilomyces sp.
US5125977A (en) * 1991-04-08 1992-06-30 The United States Of America As Represented By The United States Department Of Energy Two-stage dilute acid prehydrolysis of biomass
WO1995008648A1 (en) * 1993-09-24 1995-03-30 Midwest Research Institute Prehydrolysis of lignocellulose
WO1995013362A1 (en) * 1993-11-08 1995-05-18 Purdue Research Foundation Recombinant yeasts for effective fermentation of glucose and xylose
US5536325A (en) * 1979-03-23 1996-07-16 Brink; David L. Method of treating biomass material
US5628830A (en) * 1979-03-23 1997-05-13 The Regents Of The University Of California Enzymatic hydrolysis of biomass material

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5536325A (en) * 1979-03-23 1996-07-16 Brink; David L. Method of treating biomass material
US5628830A (en) * 1979-03-23 1997-05-13 The Regents Of The University Of California Enzymatic hydrolysis of biomass material
US4840903A (en) * 1985-08-08 1989-06-20 The United States Of America As Represented By The United States Department Of Energy Process for producing ethanol from plant biomass using the fungus paecilomyces sp.
US5125977A (en) * 1991-04-08 1992-06-30 The United States Of America As Represented By The United States Department Of Energy Two-stage dilute acid prehydrolysis of biomass
WO1995008648A1 (en) * 1993-09-24 1995-03-30 Midwest Research Institute Prehydrolysis of lignocellulose
WO1995013362A1 (en) * 1993-11-08 1995-05-18 Purdue Research Foundation Recombinant yeasts for effective fermentation of glucose and xylose

Non-Patent Citations (2)

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Title
LEE JW ET AL.: "Scale-up study of oxalic acid pretreatment of agricultural lignocellulosic biomass for the production of bioethanol", BIORESOURCE TECHNOLOGY, vol. 102, no. 16, August 2011 (2011-08-01), pages 7451 - 6, XP028232544, DOI: doi:10.1016/j.biortech.2011.05.022 *
LEE JW ET ET AL.: "Efficiencies of acid catalysts in the hydrolysis of lignocellulosic biomass over a range of combined severity factors", BIORESOURCE TECHNOLOGY, vol. 102, no. 10, May 2011 (2011-05-01), pages 5884 - 90, XP028407848, DOI: doi:10.1016/j.biortech.2011.02.048 *

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105384171A (zh) * 2015-12-18 2016-03-09 齐鲁工业大学 利用木糖醇制备工艺后的玉米秸秆废渣制备活性炭的方法

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BR112016002565A2 (pt) 2017-08-01
IN2013MU02596A (enrdf_load_stackoverflow) 2015-06-19

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