Method of obtaining a product sugar stream from cellulosic biomass

• US 8,003,352 B2
• Filed: 07/15/2005
• Issued: 08/23/2011
• Est. Priority Date: 07/16/2004
• Status: Expired due to Fees

• Current Assignee: Iogen Energy Corporation (Iogen Corporation)
• Original Assignee: Iogen Energy Corporation (Iogen Corporation)
• Inventors: Tolan, Jeffrey S., Foody, Brian
• Primary Examiner(s): Saucier; Sandra
• Assistant Examiner(s): HANLEY, SUSAN MARIE
• Application Number:
  US11/658,338
• Publication Number:
  US 20090023187A1
• Time in Patent Office: 2,230 Days
• Field of Search: 435/72, 435/209, 536/127, 536/128
• US Class Current: 435/72
• 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 7/10 substrate containing cellulosic material
• CPC Class Codes: C12P 7/56 Lactic acid
• CPC Class Codes: Y02E 50/10 Biofuels, e.g. bio-diesel

Abstract

The invention relates to a process for obtaining a product sugar stream from a cellulosic biomass, comprising pretreating the cellulosic biomass to hydrolyze a portion of the cellulose and hemicellulose to produce glucose, acetic acid and a sugar monomer, adding base to the pretreated cellulosic biomass to produce inorganic salt and acetate salt; hydrolyzing the neutralized cellulosic biomass with cellulase enzymes and separating insoluble residue from the resulting sugar stream; treating the clarified sugar stream using exclusion chromatography at a pH of 5 to 10 to produce a product sugar stream.

Claims

1. A process for obtaining a product sugar stream from cellulosic biomass comprising cellulose and hemicellulose, the process comprising:

a) pretreating the cellulosic biomass at a pH of about 0.4 to about 2.0 by adding one or more than one acid to the cellulosic biomass to hydrolyze a portion of the cellulose and at least a portion of the hemicellulose in the cellulosic biomass to produce a pretreated cellulosic biomass comprising glucose, acetic acid and a sugar monomer selected from the group consisting of xylose, arabinose, mannose, galactose and a combination thereof;

b) adding one or more than one base to the pretreated cellulosic biomass to adjust the pretreated cellulosic biomass to a pH of about 4.0 to about 6.0, thereby producing a neutralized cellulosic biomass comprising inorganic salt and acetate salt;

c) hydrolyzing the neutralized cellulosic biomass with cellulase enzymes to produce a crude sugar stream;

d) separating insoluble residue from the crude sugar stream to produce a clarified sugar stream;

e) treating the clarified sugar stream by ion exclusion chromatography with a cation exchange resin at a pH from 5.0 to 10.0 to produce one or more than one raffinate stream comprising the inorganic salt and acetate salt and a product sugar stream comprising sugar, wherein the concentration of acetic acid plus acetate salt in the clarified sugar stream fed to the ion exclusion chromatography step is greater than 5 g/L; and

f) recovering the product sugar stream.

2. The process of claim 1 wherein, the ion exclusion chromatography of step e) is performed at a pH of between 6 and 10.

3. The process of claim 2 further comprising a step of recovering the one or more than one raffinate stream.

4. The process of claim 2 wherein, the ion exclusion chromatography of step e) is carried out using a Simulated Moving Bed (SMB) system or an Improved Simulated Moving Bed (ISMB) system.

5. The process of claim 2 wherein the clarified sugar stream is characterized by having a lignosulfonate content of from about 0 to about 4% of the total solids present in the clarified sugar stream.

6. The process of claim 2 wherein the cellulosic biomass is obtained from a feedstock selected from the group consisting of an agricultural waste, corn stover, wheat straw, barley straw, canola straw, oat straw, rice straw, soybean stover, a grass, switch grass, miscanthus, cord grass, reed canary grass, a forestry residue, aspen wood or sawdust, a sugar residue, bagasse and beet pulp.

7. The process of claim 2 wherein the acid is sulfuric acid and the inorganic salt comprises a sulfate salt.

8. The process of claim 2 wherein the dosage of the cellulase enzymes is about 5 to about 50 IU per gram of cellulose.

9. The process of claim 2 wherein pretreatment is selected from the group consisting of steam explosion and dilute acid prehydrolysis.

10. The process of claim 2 wherein the cellulosic biomass is pressed or leached prior step a.

11. The process of claim 4 wherein the SMB system or ISMB system is operated with 4 to 16 shifts of feed and collection positions per cycle.

12. The process of claim 11 wherein the SMB system or ISMB system is operated with 4 to 12 shifts of feed and collection positions per cycle.

13. The process of claim 3 wherein the recovered raffinate stream is used as a fertilizer.

14. The process of claim 2 wherein, in the step of adding (step b)), the one or more than one base is a soluble base.

15. The process of claim 14 wherein the soluble base is selected from the group consisting of sodium hydroxide, potassium hydroxide, ammonia and ammonium hydroxide.

16. The process of claim 2 wherein, in step d, the insoluble residue is separated from the crude sugar stream by microfiltration, plate and frame filtration, crossflow filtration, pressure filtration, vacuum filtration or centrifugation.

17. The process of claim 2 wherein the ion exclusion chromatography is performed at a pH of between 6.5 and 10.

18. The process of claim 2 wherein the ion exclusion chromatography is performed at a pH of between 6 and 8.

19. The process of claim 2 wherein the clarified sugar stream produced in step d) is concentrated prior to or during step e.

20. The process of claim 2 wherein the product sugar stream produced in step e) is concentrated.

21. The process of claim 2 wherein, in step e, one raffinate stream comprising the inorganic salt and acetate salt is produced.

22. A process for producing ethanol comprising:

a) obtaining cellulosic biomass comprising cellulose and hemicellulose from a feedstock selected from the group consisting of an agricultural waste, corn stover, wheat straw, barley straw, canola straw, oat straw, rice straw, soybean stover, a grass, switch grass, miscanthus, cord grass, reed canary grass, a forestry residue, aspen wood or sawdust, a sugar residue, bagasse and beet pulp;

b) pretreating the cellulosic biomass at a pH of about 0.4 to about 2.0 by adding one or more than one acid to the cellulosic biomass to hydrolyze a portion of the cellulose and at least a portion of the hemicellulose in the cellulosic biomass to produce a pretreated cellulosic biomass comprising glucose, acetic acid and a sugar monomer selected from the group consisting of xylose, arabinose, mannose, galactose and a combination thereof;

c) adding one or more than one base to the pretreated cellulosic biomass to adjust the pretreated cellulosic biomass to a pH of about 4.0 to about 6.0, thereby producing a neutralized cellulosic biomass comprising inorganic salt and acetate salt;

d) hydrolyzing the neutralized cellulosic biomass with cellulase enzymes to produce a crude sugar stream;

e) separating insoluble residue from the crude sugar stream to produce a clarified sugar stream;

f) treating the clarified sugar stream by ion exclusion chromatography with a cation exchange resin at a pH from 5.0 to 10.0 to produce one or more than one raffinate stream comprising the inorganic salt and acetate salt and a product sugar stream comprising sugar, wherein the concentration of acetic acid plus acetate salt in the clarified sugar stream fed to the ion exclusion chromatography step is greater than 5 g/L;

g) recovering the product sugar stream, and the one or more than one raffinate stream; and

h) fermenting the sugar in the product sugar stream to ethanol.

23. The process of claim 22 wherein, the ion exclusion chromatography of step e) is performed at a pH of between 6 and 10.

24. The process of claim 23 wherein, in step d, the dosage of cellulase enzymes is about 5 to about 50 IU per gram of cellulose.

25. The process of claim 23 wherein, in step b, pretreatment is selected from the group consisting of steam explosion and dilute acid prehydrolysis.

26. The process of claim 23 wherein the acid is sulfuric acid and the inorganic salt comprises a sulfate salt.

27. The process of claim 23 wherein, in step e, the insoluble residue is separated from the crude sugar stream by microfiltration, plate and frame filtration, crossflow filtration, pressure filtration, vacuum filtration or centrifugation.

28. The process of claim 23 wherein, in the step of pretreating (step b)), the clarified sugar stream is characterized by having a lignosulfonate content of from about 0 to about 4% of the total dry solids present in the clarified sugar stream.

29. The process of claim 23 wherein, prior to the step of pretreating (step b)), the cellulosic biomass is pressed or leached.

30. The process of claim 23 wherein, the ion exclusion chromatography of step f) is carried out using a Simulated Moving Bed (SMB) system or an Improved Simulated Moving Bed (ISMB) system.

31. The process of claim 30 wherein the SMB system or the ISMB system is operated with 4 to 16 shifts of feed and collection positions per cycle.

32. The process of claim 31 wherein the SMB system or the ISMB system is operated with 4 to 12 shifts of feed and collection positions per cycle.

33. The process of claim 23 wherein, the recovered raffinate stream is used as a fertilizer.

34. The process of claim 23 wherein, in the step of adding (step c)), the one or more than one base is a soluble base.

35. The process of claim 34 wherein the soluble base is selected from the group consisting of sodium hydroxide, potassium hydroxide, ammonia and ammonium hydroxide.

36. The process of claim 23 wherein, the ion exclusion chromatography of step f) is performed at a pH of between 6 and 8.

37. The process of claim 23 wherein, the ion exclusion chromatography of step f) is performed at a pH of between 6.5 and 10.

38. The process of claim 23 wherein the clarified sugar stream produced in step e) is concentrated prior to or during step f).

39. The process of claim 23 wherein the product sugar stream produced in step f) is concentrated.

40. The process of claim 23 wherein, in step f), one raffinate stream comprising the inorganic salt and acetate salt is produced.

41. A process for obtaining a product sugar stream from a crude sugar stream, the crude sugar stream produced from conversion of cellulosic biomass to sugar, the process comprising:

a) separating insoluble residue from the crude sugar stream to produce a clarified sugar stream;

b) treating the clarified sugar stream by ion exclusion chromatography with a cation exchange resin at a pH from 5.0 to 10.0 to produce one or more than one raffinate stream comprising sulfate and acetate salts, and a product stream comprising sugar, wherein the concentration of acetic acid plus acetate salt in the clarified sugar stream fed to the ion exclusion chromatography step is greater than 5 g/L; and

c) obtaining the product sugar stream.

42. The process of claim 41 wherein, during step c), the one or more than one raffinate stream is recovered.

43. The process of claim 41 wherein, the ion exclusion chromatography of step b) is carried out using a Simulated Moving Bed (SMB) system or an Improved Simulated Moving Bed (ISMB) system.

44. The process of claim 41 wherein, the ion exclusion chromatography of step b) is performed at a pH of between 6 and 10.

45. A process for obtaining one or more than one raffinate stream enriched in inorganic salt and acetate salt, the process comprising:

a) obtaining a clarified stream comprising sugar, inorganic salt and at least one of an acetate salt and acetic acid originating from a previous hydrolysis of the cellulosic biomass; and

b) treating the clarified stream by ion exclusion chromatography with a cation exchange resin at a pH from 5.0 to 10.0 to produce the one or more than one raffinate stream enriched in inorganic salt and acetate salt, and a stream comprising sugar, wherein the concentration of acetic acid plus acetate salt in the clarified stream fed to the ion exclusion chromatography step is greater than 5 g/L.

46. The process of claim 45, wherein the clarified stream comprising sugar is a still bottoms stream resulting from the steps of (i) fermentation of a sugar stream resulting from hydrolysis of the cellulosic biomass, said fermentation resulting in a fermentation broth comprising ethanol;

and (ii) distillation of the fermentation broth to produce concentrated ethanol and the still bottoms stream, wherein insoluble residue is removed in a solid-liquid separation step conducted prior to step b.

47. The process of claim 46, wherein the insoluble residue is removed prior to the step of fermentation (step i)).

48. The process of claim 46, wherein insoluble residue is removed from the still bottoms stream.