Method and apparatus for conversion of cellulosic material to ethanol

• US 10,155,966 B2
• Filed: 02/02/2016
• Issued: 12/18/2018
• Est. Priority Date: 07/19/2005
• Status: Active Grant

• Current Assignee: Inbicon A/S
• Original Assignee: Inbicon A/S
• Inventors: Christensen, Borge Holm, Gerlach, Lena Holm
• Primary Examiner(s): Drodge, Joseph W
• Application Number:
  US15/013,366
• Publication Number:
  US 20160153010A1
• Time in Patent Office: 1,050 Days
• Field of Search: 44307, 44450, 44589, 44590, 44605, 44606, 44620, 100 38, 100 73- 75, 100 92, 127 34- 37, 127 42, 127 43, 127 65, 162 9, 162 18, 162 19, 162 24, 210632-634, 210760, 210766, 210770, 210774, 210806, 210808, 422600, 422608, 422616, 422618, 422630, 422638, 422642, 422644, 422646, 435132-136, 435161-165
• CPC Class Codes: B01J 19/245 placed in series
• CPC Class Codes: B01J 2219/00006 Large-scale industrial plants
• CPC Class Codes: C08B 1/003 Preparation of cellulose solutions, i.e. dopes, with different possible solvents, e.g. ionic liquids solutions used in the manufacture of monocomponent artificial filaments or cellulose or derivatives thereof D01F2/02
• CPC Class Codes: C08B 15/00 Preparation of other cellulose derivatives or modified cellulose , e.g. complexes
• CPC Class Codes: C08B 37/0057 beta-D-Xylans, i.e. xylosaccharide, e.g. arabinoxylan, arabinofuronan, pentosans; (beta-1,3)(beta-1,4)-D-Xylans, e.g. rhodymenans; Hemicellulose; Derivatives thereof
• CPC Class Codes: C08H 6/00 Macromolecular compounds derived from lignin, e.g. tannins, humic acids
• CPC Class Codes: C08H 8/00 Macromolecular compounds derived from lignocellulosic materials pretreatment thereof B27N
• CPC Class Codes: C12M 21/12 for producing fuels or solvents C12M21/04 takes precedence; liquid carbonaceous fuels C10L1/00, solid fuels C10L5/00
• CPC Class Codes: C12M 45/02 by mechanical forces; Stirring; Trituration; Comminuting crushing, pulverizing, disintegrating in general B02C
• CPC Class Codes: C12M 45/04 Phase separators; Separation of non fermentable material; Fractionation
• CPC Class Codes: C12M 45/09 by enzymatic treatment
• CPC Class Codes: C12M 45/20 Heating; Cooling heating or cooling apparatus for laboratory uses B01L7/00
• CPC Class Codes: C12P 19/02 Monosaccharides 2-ketogulonic acid C12P7/60
• CPC Class Codes: C12P 19/14 produced by the action of a carbohydrase (EC 3.2.x), e.g. by alpha-amylase , e.g. by cellulase, hemicellulase
• CPC Class Codes: C12P 21/00 Preparation of peptides or proteins single cell protein C12N1/00
• CPC Class Codes: C12P 2201/00 Pretreatment of cellulosic or lignocellulosic material for subsequent enzymatic treatment or hydrolysis
• CPC Class Codes: C12P 2203/00 Fermentation products obtained from optionally pretreated or hydrolyzed cellulosic or lignocellulosic material as the carbon source ethanol C12P7/10
• CPC Class Codes: C12P 7/10 substrate containing cellulosic material
• CPC Class Codes: C12P 7/14 Multiple stages of fermentation; Multiple types of microorganisms or re-use of microorganisms
• CPC Class Codes: C12P 7/56 Lactic acid
• CPC Class Codes: C13B 20/165 : using membranes, e.g. osmosis, ultrafiltration electrodialysis C13B20/18
• CPC Class Codes: C13K 1/02 : obtained by saccharification of cellulosic materials manufacture of fodder A23K10/32
• CPC Class Codes: D21C 9/18 : De-watering de-watering in general F26B; Elimination of cooking or pulp-treating liquors from the pulpD21C9/002, D21C9/02 take precedence; paper-making machines D21F; strainers in digesters D21C7/00; presses in general B30B
• CPC Class Codes: Y02E 50/10 : Biofuels, e.g. bio-diesel

Abstract

The present invention provides an apparatus and a method for conversion of cellulosic material, such as chopped straw and corn stover, and household waste, to ethanol and other products. The cellulosic material is subjected to continuous hydrothermal pre-treatment without addition of chemicals, and a liquid and a fiber fraction are produced. The fiber fraction is subjected to enzymatic liquefaction and saccharification. The method of the present invention comprises:

• • performing the hydrothermal pre-treatment by subjecting the cellulosic material to at least one soaking operation, and conveying the cellulosic material through at least one pressurized reactor, and subjecting the cellulosic material to at least one pressing operation, creating a fiber fraction and a liquid fraction;
  • selecting the temperature and residence time for the hydrothermal pretreatment, so that the fibrous structure of the feedstock is maintained and at least 80% of the lignin is maintained in the fiber fraction.

Claims

1. An apparatus for the treatment of cellulosic material, said apparatus comprising:

a first pressurized reactor section comprising a reactor pressure zone configured to operate at an elevated pressure;

a separation device attached to the first pressurized reactor section, wherein said separation device is configured to create a fibre fraction and a liquid fraction from the cellulosic material, wherein said separation device is a pressing device;

a discharge device capable of discharging the fibre fraction from the first pressurized reactor section to a second pressurized reactor section operable at a lower pressure than the first pressurized reactor section;

a liquid fraction unloading mechanism configured to unload the liquid fraction from the first pressurized reactor section to a closed collection zone; and

a closed collection zone configured to receive the liquid fraction from the first pressurized reactor section through the unloading mechanism.

2. The apparatus of claim 1, wherein said liquid fraction unloading mechanism comprises a sluice device for removal of liquid following discharge after the first pressurized reactor section.

3. The apparatus of claim 1, wherein said separation device is a screw press.

4. The apparatus of claim 1, further comprising a cleaning device configured to clean the the cellulosic material, attached upstream of said first reactor section.

5. The apparatus of claim 1, further comprising a soaking apparatus attached upstream of the first pressurized reactor section.

6. The apparatus of claim 5, wherein a separation device is attached between the soaking apparatus and the first pressurized reactor section.

7. The apparatus of claim 1, wherein the first pressurized reactor section and the second pressurized reactor section are in separate zones of a single reactor.

8. The apparatus of claim 1, wherein the first pressurized reactor section and the second pressurized reactor section are in separate reactors.

9. The apparatus of claim 1, further comprising a means for counter current cooling of the fibre fraction after the first pressurized reactor section.

10. The apparatus of claim 1, further comprising an ethanol fermentation device attached downstream of the second pressurized reactor section for fermentation of the separated liquid fraction.

11. An apparatus for the treatment of lignocellulosic material, said apparatus comprising:

a first pressurized reactor section comprising a reactor pressure zone at an elevated pressure and comprising a lignocellulosic biomass;

a separation device attached to the first pressurized reactor section, wherein said separation device is configured to create a fibre fraction and a liquid fraction from the lignocellulosic material, wherein said separation device is a pressing device;

a discharge device configured to discharge the fibre fraction from the first pressurized reactor section to a second pressurized reactor section, wherein the second pressurized reactor section is at a different pressure than the first pressurized reactor section;

a liquid fraction unloading mechanism configured to unload the liquid fraction from the first pressurized reactor section to a closed collection zone; and

a closed collection zone configured to receive the liquid fraction from the first pressurized reactor section through the unloading mechanism.

12. The apparatus of claim 11, further comprising a soaking apparatus attached upstream of the first pressurized reactor section.

13. The apparatus of claim 11, wherein the first pressurized reactor section and the second pressurized reactor section are in separate zones of a single reactor.

14. The apparatus of claim 11, further comprising an ethanol fermentation device attached downstream of the second pressurized reactor section for fermentation of the separated liquid fraction.