Methods of extracting inorganic nutrients from pretreated biomass to form a fertilizer composition, and related systems

• US 10,618,850 B2
• Filed: 10/14/2016
• Issued: 04/14/2020
• Est. Priority Date: 10/15/2015
• Status: Active Grant

• Current Assignee: Poet Research Inc.
• Original Assignee: Poet Research Inc.
• Inventors: Hepner, Tad Scott, Robey, W. Wade, Redford, Steven G., Wirt, Adam R.
• Primary Examiner(s): Smith, Jennifer A
• Application Number:
  US15/293,446
• Publication Number:
  US 20170107159A1
• Time in Patent Office: 1,278 Days
• CPC Class Codes: C05B 17/00 Other phosphatic fertilisers, e.g. soft rock phosphates, bone meal
• CPC Class Codes: C05C 11/00 Other nitrogenous fertilisers
• CPC Class Codes: C05D 1/00 Fertilisers containing potassium C05D7/00 takes precedence
• CPC Class Codes: C05D 3/00 Calcareous fertilisers C05D7/00 takes precedence
• CPC Class Codes: C05D 5/00 Fertilisers containing magnesium C05D7/00 takes precedence
• CPC Class Codes: C05D 9/00 Other inorganic fertilisers
• CPC Class Codes: C05F 17/00 Preparation of fertilisers characterised by biological or biochemical treatment steps, e.g. composting or fermentation
• CPC Class Codes: C05F 17/964 Constructional parts, e.g. floors, covers or doors
• CPC Class Codes: C05F 5/008 Waste from biochemical processing of material, e.g. fermentation, breweries
• CPC Class Codes: Y02A 40/20 Fertilizers of biological origin, e.g. guano or fertilizers made from animal corpses
• CPC Class Codes: Y02P 20/145 the feedstock being materials of biological origin
• CPC Class Codes: Y02W 30/40 Bio-organic fraction processing; Production of fertilisers from the organic fraction of waste or refuse

Abstract

The present disclosure includes methods of making a fertilizer composition from pretreated biomass by removing one or more inorganic nutrients from a fermentation beer to form an aqueous fertilizer composition. The present disclosure also includes systems configured to make a fertilizer composition from pretreated biomass, where the systems include one or more apparatuses in fluid communication with a fermentation vessel, wherein at least one apparatus is configured to remove one or more inorganic nutrients from the fermentation beer to form an aqueous fertilizer composition.

Claims

1. A method of making a fertilizer composition from pretreated biomass, the method comprising:

a) fermenting the pretreated biomass to provide a fermentation beer, wherein the pretreated biomass is derived from a biomass feedstock comprising a grain, and wherein the fermentation beer comprises a solid component and an aqueous liquid component;

b) exposing the fermentation beer to a distillation process to form a whole stillage,

c) separating the whole stillage into wet cake and thin stillage;

d) passing after step c) the thin stillage through a membrane filter to form a permeate and a retentate, wherein the retentate comprises insoluble solids and the permeate comprises one or more inorganic nutrients in solution, and wherein the permeate forms the fertilizer composition.

2. The method of claim 1, wherein at least a portion of the fertilizer composition is heated to evaporate at least a portion of water from the fertilizer composition to form a concentrated liquid, fertilizer composition.

3. The method of claim 1, wherein water is removed from the retentate to form a concentrated retentate, and wherein the concentrated retentate is combined with the wet cake.

4. The method of claim 1, further comprising:

a) prior to exposing the fermentation beer to a distillation process, separating at least a portion of the aqueous liquid component from the fermentation beer to form an aqueous liquid stream and a remainder of the fermentation beer;

b) separating an oil fraction from the first liquid aqueous stream;

c) after step (b), combining the first liquid aqueous stream with the remainder of the fermentation beer, and

d) exposing the fermentation beer formed in step (c) to the distillation process to form the whole stillage.

5. The method of claim 1, wherein passing the thin stillage through the membrane filter comprises:

a) separating an oil fraction from the thin stillage; and

b) after step (a), passing the thin stillage through the membrane filter to form the permeate and the retentate.

6. The method of claim 1, wherein the pretreated biomass is derived from:

dry grinding whole corn to provide whole ground corn;

enzymatically saccharifying the whole ground corn to form the pretreated biomass.

7. The method of claim 1, wherein the one or more inorganic nutrients in solution comprise one or more inorganic elements endogenous to the biomass.

8. The method of claim 7, wherein the endogenous inorganic elements are selected from the group consisting of nitrogen, phosphorous, potassium, calcium, magnesium, sulfur, and combinations thereof.

9. A method of making a fertilizer composition from pretreated biomass, the method comprising:

a) fermenting the pretreated biomass to provide a fermentation beer, wherein the pretreated biomass is derived from a biomass feedstock comprising corn stover, wherein the fermentation beer comprises a solid component and an aqueous liquid component;

b) exposing the fermentation beer to a distillation process to form a bottom slurry comprising the solid component, water, and the one or more inorganic nutrients in solution;

c) separating at least a portion of the water and one or more inorganic nutrients in solution from at least a portion of solid component in the slurry to form an aqueous liquid stream and a lignin cake stream; and

d) passing the aqueous liquid stream through a membrane filter to form a permeate and a retentate, wherein the retentate comprises insoluble solids and the permeate comprises one or more inorganic nutrients in solution, and wherein the permeate forms the fertilizer composition.

10. The method of claim 9,

wherein the separating step comprises mechanically pressing at least a portion of the water and the one or more inorganic nutrients in solution from the solid component in the slurry to form the aqueous liquid stream;

and

further comprising filtering the permeate to remove sodium from the permeate.

11. The method of claim 10, further comprising:

adding ash to the permeate; and

filtering at least a portion of ash solids from the permeate.

12. The method of claim 10, wherein the pretreated biomass is derived from:

mixing sulfuric acid with water and ground corn stover to hydrolyze at least a portion of hemicellulase; and

enzymatically saccharifying at least a portion of cellulose to provide the pretreated biomass.

13. The method of claim 10, further comprising heating the permeate to evaporate at least a portion of water from the fertilizer composition to form a concentrated, liquid, aqueous fertilizer composition.

14. The method of claim 9, wherein water is removed from the retentate to form a concentrated retentate, and wherein the concentrated retentate is combined with the lignin cake stream.