ADVANCED BIOREFINERY PROCESS

• US 20100012583A1
• Filed: 08/31/2007
• Published: 01/21/2010
• Est. Priority Date: 09/01/2006
• Status: Active Grant

• Current Assignee: RA Energy
• Original Assignee: RA Energy
• Inventors: Stuart, Earnest
• Granted Patent: US 8,133,393 B2
• Time in Patent Office: Days
• US Class Current: 210/633
• CPC Class Codes: C12P 7/06 Ethanol, i.e. non-beverage
• CPC Class Codes: C12P 7/16 Butanols
• CPC Class Codes: Y02E 50/10 Biofuels, e.g. bio-diesel

Abstract

The present invention is a method for refining native biomass to extremely fine and highly disrupted particles using high shear and/or cavitation in combination with high temperature and high or low pH conditions which dissolve biomass to a high percentage. The method of the present invention results in a high percentage of hydrolysis, in many cases near theoretical levels, in short residence times while minimizing inputs over other methods, using low chemical inputs, and optionally with no chemical inputs in certain stages compared to existing processes. The method of the present invention also uses minimal electrical energy inputs and conserves heat energy within the process and reduces equipment requirements while producing concentrated products.

Claims

1-16. -16. (canceled)

17. A method of refining biomass, comprising the steps of:

disrupting biomass gross structure to create extreme surface area and to breach cell wall integrity by applying high-shear, cavitation, a catalyst and increasing heat to the biomass to dissolve at least some cell and cellular components;

modulating the heat used to disrupt and dissolve the biomass based on the type of biomass, characteristics of its cell structure and the biomass components;

dissolving at least 70% of the biomass using high shear, cavitation, and a catalyst, for a period of time in a range of between 1 second and ten minutes, for producing liquid product streams of dissolvable biomass components of at least 6% concentration and repeating high shear and cavitation until at least 70% of the biomass is dissolved; and

separating select un-dissolved fiber streams from dissolved components.

18. The method of claim 17, wherein said dissolving step includes dissolving a percentage of biomass selected from the group consisting of 80%, 90%, and 100%.

19. The method of claim 17, wherein said dissolving step includes altering the time, biomass concentration and amount of cavitation until at least 70% of the biomass is dissolved.

20. The method of claim 17, wherein said modulating step includes modulating the heat used to disrupt and dissolve the cellular structures selected from the group consisting of cellular coatings, intermediate structural constructs, primary structural constructs, and elements contained within the cell.

21. The method of claim 17, wherein said dissolving step includes dissolving hemicellulose xylan, arabinan, mannan, galactan, and glucan into their monomeric forms at temperatures between ambient and 220°

C.

22. The method of claim 21, wherein said dissolving step includes adding a catalyst selected from the group consisting of a mineral acid catalyst and base catalyst.

23. The method of claim 22, wherein dissolving step includes adding the mineral acid catalyst in an amount in the range of about 0.0025% to 1.5% wt/wt to the slurry.

24. The method of claim 17, wherein said dissolving step includes dissolving at least 70% of the biomass using high shear and cavitation, for a period of time in the range of between 1 second and 1 minute.

25. The method of claim 17, wherein said dissolving step includes dissolving at least 70% of the biomass using high shear and cavitation, for a period of time selected from the group consisting of a range of between 1 minute and 2 minutes, a range of between 2 minutes and 5 minutes, a range of between 5 minutes and 10 minutes, and a range of between 10 minutes and 30 minutes.

26. The method of claim 17, wherein the dissolving step includes producing liquid product streams of dissolvable biomass components of a concentration selected from the group consisting of 35%, 25%, 15%, and 6%.

32. The method of claim 17, wherein the dissolving step includes producing liquid product streams of dissolvable biomass components of a concentration selected from the group consisting of 35%, 25%, 15%, and 6%.

27. A method of refining biomass, comprising the steps of:

disrupting biomass gross structure to create extreme surface area and to breach cell wall integrity by applying high-shear, cavitation and increasing heat to the biomass to dissolve at least some cell and cellular components; and

dissolving at least 70% of the biomass using high shear and cavitation at rates of between 1 second and ten minutes, thereby producing liquid product streams of dissolvable biomass components of at least 6% concentration and repeating until 60% of the biomass is dissolved.

28. The method of claim 27, wherein said dissolving step includes altering the time, biomass concentration and amount of cavitation until at least 70% of the biomass is dissolved.

29. The method of claim 27, wherein said dissolving step includes adding a catalyst during said dissolving step.

30. The method of claim 29, wherein said dissolving step includes adding a catalyst selected from the group consisting of a mineral acid catalyst and base catalyst.

31. The method of claim 30, wherein dissolving step includes adding the mineral acid catalyst in an amount in the range of about 0.0025% to 1.5% wt/wt to the slurry.

33. A method of dissolving hemicellulose in biomass, comprising the steps of:

disrupting biomass gross structure to create extreme surface area and to breach cell wall integrity by applying high-shear, cavitation and increasing heat to the biomass to dissolve at least some cell and cellular components; and

dissolving at least 70% of the hemicellulose using high shear and cavitation for producing liquid product streams of dissolvable biomass components of at least 6% concentration and repeating high shear and cavitation until at least 70% of the hemicellulose is dissolved; and

recovering products of the dissolving step.

34. The method of claim 33, further including dissolving at least 70% of the cellulose present in the biomass using high shear and cavitation for producing liquid product streams of dissolvable biomass components of at least 6% concentration and repeating high shear and cavitation until at least 70% of the cellulose is dissolved.

35. The method of claim 34, wherein the dissolving step includes producing liquid product streams of dissolvable biomass components of a concentration selected from the group consisting of 35%, 25%, 15%, and 6%.

36. The method of claim 34, wherein said dissolving steps includes adding a catalyst during said dissolving step.

37. The method of claim 36, wherein said dissolving steps include adding a catalyst selected from the group consisting of a mineral acid catalyst and base catalyst.

38. The method of claim 37, wherein dissolving step includes adding the mineral acid catalyst in an amount in the range of about 0.0025% to 1.5% wt/wt to the slurry.

39. The method of claim 38, wherein said dissolving step includes dissolving at least 70% of the biomass using high shear, cavitation, and the catalyst, for a period of time in a range of between 1 second and ten minutes, for producing liquid product streams of dissolvable biomass components and repeating high shear and cavitation until at least 70% of the hemicellulose and 70% of the cellulose is dissolved.

40. The method of claim 39, further including hydrolyzing the cellulose with celluloytic enzymes.