Methods for co-production of ethanol and silica from equisetum

• US 8,026,086 B2
• Filed: 03/20/2008
• Issued: 09/27/2011
• Est. Priority Date: 12/03/2007
• Status: Expired due to Fees

• Current Assignee: 1695492 Ontario, Inc.
• Original Assignee: Ontario Inc. (Magna International Incorporated)
• Inventors: Rywak, Anthony A.
• Primary Examiner(s): Lilling; Herbert J.
• Application Number:
  US12/051,925
• Publication Number:
  US 20090142819A1
• Time in Patent Office: 1,286 Days
• Field of Search: None
• US Class Current: 435/161
• CPC Class Codes: C12P 3/00 Preparation of elements or inorganic compounds except carbon dioxide recovery of carbon dioxides as by-products C12F3/02
• CPC Class Codes: C12P 5/023 Methane
• CPC Class Codes: C12P 7/10 substrate containing cellulosic material
• 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

Abstract

A method for the co-production of silica and at least one other useful industrial chemical such as ethanol, comprises the steps of: pre-treating siliceous plant matter derived from plants, such as horsetail weeds from the genus Equisetum, to create a feedstock having exposed cellulose; placing the feedstock in a reactor containing a biological agent effective to break down the cellulose into at least one useful organic chemical reaction product and a silica-containing co-product; separating the at least one useful organic chemical product from the reactor; separating the silica-containing co-product from the reactor; and refining the silica-containing co-products into silica or other industrially useful silicon containing products. The biological agent may be an anaerobic thermophyllic bacteria, enzymes, or a co-mixture of enzymes and yeast.

Claims

1. A method for the co-production of silica and at least one other useful industrial chemical product, comprising the steps of:

a) pre-treating siliceous plant matter to create a feedstock having exposed cellulose, wherein the siliceous plant matter is derived from members of the genus Equisetum;

b) placing the feedstock in a reactor containing a biological agent effective to break down the cellulose into at least one useful organic chemical reaction product and a silica-containing co-product, wherein the biological agent comprises a culture of anaerobic thermophyllic bacteria, and wherein the useful organic chemical reaction product is selected from the group comprising ethanol, methane and hydrogen;

c) separating the at least one useful organic chemical product from the reactor;

d) separating the silica-containing co-product from the reactor; and

e) refining the silica-containing co-product into silica or other industrially useful silicon-containing products.

2. The method defined in claim 1, wherein the step of pre-treating the siliceous plant material comprises a pretreatment step selected from a group consisting of chopping, crushing, shredding, pureeing, grinding, water soaking with or without surfactants, heat treatment in the presence or absence of chemicals below, at or above atmospheric pressure, microwave exposure, ultrasound, and treatment with biological agents such as mold and fungi.

3. The method defined in claim 1, wherein the step of separating the useful organic chemical reaction product comprises a separation process selected from a group consisting of distillation below, at or above atmospheric pressure, and removal by continuous flow of inert gas over the reaction solution.

4. The method defined in claim 1, wherein step of separating the silica-containing co-product comprises a separation process selected from a group consisting of precipitation, filtration, centrifugation, flocculation and belt-pressing.

7. The method defined in claim 1, wherein the step of refining the silica-containing co-product comprises the steps of rinsing the silica-containing co-product with water, acids or solvent, treating the carbon-containing silicate with aqueous oxidants including hydrogen peroxide and ozone, and heating under an oxidizing atmosphere to remove organics at a temperature between 300.degree. C. and 1600.degree. C., thereby producing a high purity silica.

9. The method defined in claim 1, wherein the industrially useful silicon-containing products include elemental silicon, silicon tetrachloride and silicon carbide.

5. A method for the co-production of silica and at least one other useful industrial chemical product, comprising the steps of:

a) pre-treating siliceous plant matter to create a feedstock having exposed cellulose;

b) placing the feedstock in a reactor containing a biological agent effective to break down the cellulose into at least one useful organic chemical reaction product and a silica-containing co-product;

c) separating the at least one useful organic chemical product from the reactor;

d) separating the silica-containing co-product from the reactor; and

e) refining the silica-containing co-product into silica or other industrially useful silicon-containing products;

f) wherein the step of refining the silica-containing co-product comprises the steps of rinsing the silica-containing co-product with water, acids or solvent, heating the silica-containing co-product under an inert atmosphere containing anhydrous HCl at a temperature between 400.degree. C. and 1600.degree. C. for the purposes of converting any residual organic materials to elemental carbon and further removing any unwanted inorganic elements, so as to produce a high purity silica mixed with elemental carbon.

8. The method defined in claim 5, wherein the step of refining the silica-containing co-product comprises the further steps of blending the high purity silica with a carbon source, converting the carbon source to elemental carbon at a precise ratio by heating the silica under a controlled atmosphere, then processing the carbon-containing silica to create the industrially useful silicon-containing products.

13. The method defined in claim 5, wherein the siliceous plant matter is derived from members of the genus Equisetum.

14. The method defined in claim 13, wherein the useful organic chemical reaction product is selected from the group comprising ethanol, methane, hydrogen and acetates.

15. The method defined in claim 14, wherein the biological agent comprises a cultural of an anaerobic thermophyllic bacteria.

16. The method of claim 5, wherein the biological agent comprises a co-mixture of enzymes and yeast.

17. The method defined in claim 5, wherein the biological agent comprises enzymes affective to break down the cellulose into constituent sugars.

6. A method for the co-production of silica and at least one other useful industrial chemical product, comprising the steps of:

a) pre-treating siliceous plant matter to create a feedstock having exposed cellulose;

b) placing the feedstock in a reactor containing a biological agent effective to break down the cellulose into at least one useful organic chemical reaction product and a silica-containing co-product;

c) separating the at least one useful organic chemical product from the reactor;

d) separating the silica-containing co-product from the reactor; and

e) refining the silica-containing co-product into silica or other industrially useful silicon-containing products;

f) wherein the step of refining the silica-containing co-product comprises the steps of dissolving silica in the silica-containing co-product in a strong base leaving a carbon component of the silica-containing siliceous product undissolved, filtering the supernatant liquid, precipitating the silica from the supernatant liquid by adding an acid, isolating the silica, heating the silica product under an inert atmosphere containing anhydrous HCl at a temperature between 400.degree. C. and 1600.degree. C., treating the silica with aqueous oxidants including hydrogen peroxide and ozone, and heating the silica under an oxidizing atmosphere to remove organics at a temperature between 300.degree. C. and 1600.degree. C., thereby producing a high purity silica.

18. The method defined in claim 6, wherein the siliceous plant matter is derived from members of the genus Equisetum.

19. The method defined in claim 18, wherein the useful organic chemical reaction product is selected from the group comprising ethanol, methane, hydrogen and acetates.

20. The method defined in claim 19, wherein the biological agent comprises a cultural of an anaerobic thermophyllic bacteria.

21. The method of claim 6, wherein the biological agent comprises a co-mixture of enzymes and yeast.

22. The method defined in claim 6, wherein the biological agent comprises enzymes affective to break down the cellulose into constituent sugars.

10. A method for the co-production of amorphous silica and ethanol, comprising the steps of:

a) pre-treating siliceous plant matter derived from plants of the genus Equisetum to create a feedstock having exposed cellulose and hemicellulose;

b) placing the feedstock in a chemicobiological reactor containing a biological agent, effective to break down the cellulose into ethanol and a silica-containing co-product, wherein the biological agent comprises a culture of anaerobic thermophyllic bacteria;

c) separating the ethanol from the reactor;

d) separating the silica-containing co-product from the reactor; and

e) refining the silica-containing co-product into silica or other industrially useful silicon-containing products.

11. The method defined in claim 10, wherein the step of separating the ethanol from the reaction solution comprises distillation below, at or above atmospheric pressure.

12. The method defined in claim 10, wherein step of separating the silica-containing co-product comprises a process selected from a group consisting of precipitation, filtration, centrifugation, flocculation and belt-pressing.