PROCESS FOR PRODUCING HIGH VALUE PRODUCTS FROM BIOMASS

• US 20110056126A1
• Filed: 08/13/2010
• Published: 03/10/2011
• Est. Priority Date: 08/13/2009
• Status: Abandoned Application

• Current Assignee: GeoSynfuels, LLC
• Original Assignee: GeoSynfuels, LLC
• Inventors: Andersen, Lisa B., Harvey, J. T., Flemming, Andrew W., Spilchen, Timothy P., Singer, Christine A., Evans, John H. IV
• Application Number:
  US12/856,576
• Publication Number:
  US 20110056126A1
• Time in Patent Office: Days
• US Class Current: 44/606
• CPC Class Codes: C10L 5/442 Wood or forestry waste
• CPC Class Codes: C12P 7/065 with microorganisms other than yeasts
• 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: D21C 5/005 Treatment of cellulose-containing material with microorganisms or enzymes
• CPC Class Codes: Y02E 50/10 Biofuels, e.g. bio-diesel
• CPC Class Codes: Y02E 50/30 Fuel from waste, e.g. synthetic alcohol or diesel
• CPC Class Codes: Y02P 30/20 using bio-feedstock

Abstract

A process for converting biomass into high value energy products is provided comprising the steps of: debarking, chipping, and screening wood; separating a plurality of hemicellulose from a plurality of cellulose and lignin; hydrolyzing the plurality of hemicellulose into monosaccharides; fermenting the monosaccharides using immobilized Pachysolen tannophilus; removing the lignin from the plurality of cellulose and lignin; and making a paper pulp from the plurality of cellulose.

Claims

1. A process for converting wood into ethanol and paper pulp, the process comprising the steps of:

a. producing a liquid hydrolysate comprising hemicellulose hydrolysate and a biomass residue from debarked wood chips;

b. separating liquid hydrolysate from the biomass residue;

c. fermenting monosaccharides in the separated liquid hydrolysate using immobilized Pachysolen tannophilus; and

d. removing lignin from the biomass residue to form a paper pulp.

2. The process according to claim 1, wherein the producing step comprises the step of cooking the wood chips in a pressure reactor.

3. The process according to claim 1, wherein the separating step comprises pressing the biomass residue to express a portion of the liquid hydrolysate from the biomass residue.

4. The process according to claim 2, wherein the separating step comprises pressing the cooked wood chips to express a portion of the liquid hydrolysate from the cooked wood chips and the cooked wood chips comprise the biomass residue.

5. The process according to claim 1, wherein the Pachysolen tannophilus is immobilized in calcium alginate.

6. The process according to claim 5, wherein the calcium alginate is in the form of beads.

7. The process according to claim 6, wherein the calcium alginate beads have a diameter of about 3 mm.

8. The process according to claim 1, wherein more than 80% of the monosacchamides in the separated liquid hydrolysate are converted to ethanol.

9. A process for converting wood into ethanol and biofuel, the process comprising the steps of:

a. producing a liquid hydrolysate comprising hemicellulose hydrolysate and a biomass residue from debarked wood chips;

b. separating liquid hydrolysate from the biomass residue;

c. forming a solid high-energy density product from the biomass residue; and

d. fermenting monosaccharides in the separated hydrolysate.

10. The process according to claim 9, wherein the separating step comprises pressing the biomass residue to express a portion of the liquid hydrolysate from the biomass residue.

11. A high-energy density biofuel comprising a compacted biomass residue including cellulose and lignin and which is substantially free of hemicellulose, the compacted biomass residue having an energy density greater than 7,000 Btu/lb.

12. A high-energy density biofuel according to claim 11, wherein the compacted biomass has a water content of less than 25%.

13. A high-energy density biofuel according to claim 11, wherein the compacted biomass has a water content of less than about 45%

14. A high-energy density biofuel according to claim 13, wherein the compacted biomass comprises 10% or less by weight of hemicellulose.

15. A high-energy density biofuel according to claim 14, wherein the compacted biomass has an energy density greater than 7,500 Btu/lb.

16. A process for converting biomass fiber source into ethanol and a high value product, the process comprising the steps of:

a. producing a liquid hydrolysate comprising hemicellulose hydrolysate and a biomass residue from the biomass fiber source;

b. separating liquid hydrolysate from the biomass residue;

c. fermenting monosaccharides in the separated liquid hydrolysate using at least one microbial species immobilized in an immobilization medium; and

d. creating a high value product from the biomass residue.

17. The process of claim 16, wherein the biomass fiber source is bagasse and the high value product is a high-energy density product.

18. The process of claim 16, wherein the biomass fiber source is wood and the high value product is paper.

19. The process of claim 16, wherein the at least one microbial species includes a first microbial species and a second microbial species wherein a fermentation characteristic of the second microbial species is complimentary to a fermentation characteristic of the first microbial species.

20. The process of claim 19, wherein the first microbial species is a yeast and the second microbial species is a bacteria.

21. The process of claim 19, wherein the second microbial species more efficiently ferments a particular monosaccharide than the first microbial species.

22. The process of claim 19, wherein a metabolic rate with respect to a particular monosaccharide of the second microbial species is substantially different than the first microbial species.

23. The process of claim 16, wherein the at least one microbial species includes a first microbial species immobilized in a first immobilization medium and a second microbial species immobilized in a separate immobilization medium from the first.

24. The process of claim 23, wherein the first microbial species is contained in a first fermentation vessel and the second microbial species is contained in a second fermentation vessel wherein during the fermentation step the liquid hydrolysate is passed through both the first fermentation vessel and the second fermentation vessel.

25. The process according to claim 16, wherein the at least one microbial species includes a first microbial species and a second microbial species wherein both the first microbial species and the second microbial species are immobilized together in a calcium alginate bead.

26. The process according to claim 16, wherein after the separating step the process further comprising the step of:

conditioning the liquid hydrolysate.

27. The process according to claim 26, wherein the conditioning step includes removing a high value product from the biomass hydrolysate.

28. The process according to claim 27, wherein the high value product is selected from a group consisting of sulfuric acid, acetic acid, phenolic compounds, polyphenolic compounds, nutraceutical products, cosmeceutical products, pharmaceutical products, furans, furfural, and 5-hydroxymethylfurfural.

29. The process according to claim 27, wherein the high value product is removed by adsorption.

30. The process according to claim 27, wherein the high value product is removed by filtration.

31. A process for converting sugarcane bagasse into ethanol and a high-energy density biofuel, the process comprising the steps of:

a. producing a liquid hydrolysate comprising hemicellulose hydrolysate and a biomass residue from sugarcane bagasse;

b. separating liquid hydrolysate from the biomass residue;

c. fermenting monosaccharides in the separated liquid hydrolysate using immobilized microbes; and

d. reducing the moisture content of the biomass residue to produce a high-energy density biofuel.

32. The process according to claim 31, wherein after the separating step the process further comprising the step of:

recovering fermentation inhibiting high value products from the liquid hydrolysate.