Continuous counter-current organosolv processing of lignocellulosic feedstocks

• US 8,193,324 B2
• Filed: 11/26/2008
• Issued: 06/05/2012
• Est. Priority Date: 05/31/2007
• Status: Active Grant

• Current Assignee: Suzano Canada Inc. (Suzano S.A.)
• Original Assignee: Lignol Innovations Ltd (Suzano S.A.)
• Inventors: Hallberg, Christer, O'Connor, Donald, Rushton, Michael, Pye, Edward Kendall, Berlin, Alex, MacLachlan, John Ross, Gjennstad, Gordon, Ma, Raymond
• Primary Examiner(s): Weber, Jon P
• Assistant Examiner(s): UNDERDAHL, THANE E
• Application Number:
  US12/324,311
• Publication Number:
  US 20090118477A1
• Time in Patent Office: 1,287 Days
• Field of Search: 435/41, 435/99, 530/500, 162/14
• US Class Current: 530/500
• CPC Class Codes: B01D 3/002 by continuous methods
• CPC Class Codes: B01D 3/143 by two or more of a fractionation, separation or rectification step
• CPC Class Codes: B01D 3/145 One step being separation by permeation
• CPC Class Codes: B01D 3/148 in combination with at least one evaporator
• CPC Class Codes: C07H 19/00 Compounds containing a hetero ring sharing one ring hetero atom with a saccharide radical; Nucleosides; Mononucleotides; Anhydro-derivatives thereof
• CPC Class Codes: C08H 8/00 Macromolecular compounds derived from lignocellulosic materials pretreatment thereof B27N
• CPC Class Codes: C12M 21/04 for producing gas, e.g. biogas digesters for manure with production of biogas A01C3/028, biological treatment of water, waste water or sewage C02F3/00, C02F11/02, preparation of natural gas or syngas C10L3/06, C10L3/10
• CPC Class Codes: C12M 45/06 by chemical means or hydrolysis
• CPC Class Codes: C12M 45/09 by enzymatic treatment
• 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 5/023 Methane
• CPC Class Codes: C12P 7/00 Preparation of oxygen-containing organic compounds
• CPC Class Codes: C12P 7/08 produced as by-product or from waste or cellulosic material substrate
• CPC Class Codes: C12P 7/16 Butanols
• CPC Class Codes: C12P 7/18 polyhydric
• CPC Class Codes: C12P 7/40 containing a carboxyl group including Peroxycarboxylic acids
• CPC Class Codes: C12P 7/54 Acetic acid vinegar C12J
• CPC Class Codes: C12P 7/56 Lactic acid
• 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 modular process for organosolv fractionation of lignocellulosic feedstocks into component parts and further processing of said component parts into one or more of a de-lignified cellulose stream, a sugar stream, small-chain alcohol streams and four structurally distinct classes of lignin derivatives. The modular process comprises a first processing module configured for digesting lignocellulosic feedstocks with an organic solvent thereby producing a cellulosic solids fraction and a liquid fraction, a second processing module configured for recovering small-chain alcohols and optionally a first class of lignin derivatives from the cellulosic solids fraction, a third processing module configured for recovering from the liquid fraction at least one of a second class and a third class of lignin derivatives or mixtures thereof, and waste stream comprising a fourth class of lignin derivatives. The fourth processing module may optionally recover the fourth class of lignin derivatives.

Claims

1. A modular biorefining process for separating a lignocellulosic feedstock into component parts and further processing of said component parts;

the modular process comprising;

a first processing module provided with a first series of steps for receiving, physically screening, and physico-chemically fractionating a lignocellulosic feedstock with an organic solvent separately provided thereto thereby extracting component parts therefrom, and separating said component parts into a first liquid fraction and a cellulosic solids fraction comprising a plurality of a first class of lignin derivatives therein;

a second processing module provided with a second series of steps for receiving therein said cellulosic solids fraction, de-lignifying said cellulosic solids fraction, and recovering therefrom a delignified cellulosic solids fraction;

a third processing module provided with a third series of steps comprising;

separating a first solids fraction from the first liquid fraction thereby producing a second liquid fraction, said first solids fraction comprising a plurality of a second class of lignin derivatives;

separating a second solids fraction from the second liquid fraction thereby producing a third liquid fraction, said second solids fraction comprising a plurality of a third class of lignin derivatives;

recovering from the third liquid fraction at least a portion of the organic solvent and a processed third liquid fraction; and

a fourth processing module provided with at least one step for recovery of a first semi-solid waste material therefrom said processed third liquid fraction.

2. A modular biorefining process according to claim 1, wherein the second series of steps comprises steps for controllably reducing the viscosity of the de-lignified cellulosic solids fraction, controllably digesting the reduced-viscosity de-lignified cellulosic solids fraction, and recovering therefrom a fourth liquid fraction comprising at least soluble sugars.

3. A modular biorefining process according to claim 2, wherein the second series of steps comprises at least one step for adding an enzyme preparation configured for controllably digesting the reduced-viscosity cellulosic solids fraction, said enzyme preparation comprising at least one enzyme selected from the group consisting of endo-β

-1,4-glucanases, cellobiohydrolases, cellulases, hemicellulases, β

-glucosidases, β

-xylosidases, xylanases, α

-amylases, β

-amylases, pullulases, and esterases.

4. A modular biorefining process according to claim 3, wherein the second series of steps additionally comprises steps for post-digestion recovery and recycling of a portion of the enzyme preparation.

5. A modular biorefining process according to claim 1, additionally provided with a fifth processing module comprising an anaerobic digestion module configured for receiving and processing therein said first semi-solid waste material into at least a collectable biogas and a liquid effluent.

6. A modular biorefining process according to claim 1, wherein the second processing module additionally comprises steps for recovering at least a portion of the first class of lignin derivatives.

7. A modular biorefining process according to claim 1, wherein the second series of steps comprises de-lignification of the cellulosic solids stream by one of an elemental chlorine-free (ECF) bleaching process and a total chlorine-free (TCF) bleaching process, and recovering therefrom a de-lignified cellulose pulp stream.

8. A modular biorefining process according to claim 7, wherein the second series of steps comprises a TCF bleaching process and includes at least the steps of:

washing the cellulosic solids stream with a mild alkali solution at a temperature ranging from about 60°

C. to about 80°

C. in a vessel pressurized with oxygen, followed by washing with water;

then washing the cellulosic solids stream with at least two washes with hydrogen peroxide, each wash followed by washing with water; and

recovering the de-lignified cellulose pulp stream.

9. A modular biorefining process according to claim 1, additionally comprising a step configured for decrystallizing cellulose from the de-lignified cellulose solids fraction.

10. A modular biorefining process according to claim 1, wherein the cellulose is decrystallized by commingling with at least one of phosphoric acid, trifloroacetic acid, monoethylamine, sodium hydroxide, ionic liquids.

11. A modular biorefining process according to claim 1, wherein the fourth processing module is additionally provided with steps for recovering from the processed third liquid fraction, one or more of an acetic acid-containing liquid fraction, a fourth class of lignin derivatives, a sugar syrup, and a semi-solid waste material.