Comminution and densification of biomass particles

• US 8,465,627 B2
• Filed: 11/30/2009
• Issued: 06/18/2013
• Est. Priority Date: 11/28/2008
• Status: Active Grant

• Current Assignee: MARD Incorporated
• Original Assignee: Kior Inc.
• Inventors: Brady, Michael, Bartek, Robert, Stamires, Dennis, O'Connor, Paul
• Primary Examiner(s): Warden, Jill
• Assistant Examiner(s): Woodard, Joye L
• Application Number:
  US12/934,006
• Publication Number:
  US 20110114765A1
• Time in Patent Office: 1,296 Days
• Field of Search: 201/2.5, 201/9, 201/20, 201/38, 201/42, 201/7, 201/8, 445/05, 445/90, 446/06, 446/27, 449/05, 241/28, 585/240, 585/242
• US Class Current: 201/2.5
• CPC Class Codes: D21B 1/02 Pretreatment of the raw materials by chemical or physical means removal of bark B27L
• CPC Class Codes: D21B 1/021 by chemical means
• CPC Class Codes: Y02E 50/10 Biofuels, e.g. bio-diesel

Abstract

A method for reducing the mechanical strength of solid biomass material, in particular lignocellulosic biomass, comprises mixing the solid biomass material with an inorganic material and heating the solid biomass material mixture to a toasting temperature in the range of 105° C. to 140° C. during an exposure time of from 1 minute to 12 hours. Before or after the heat treatment, which is referred to as “toasting”, the biomass material mixture is subject to flash heating. The treatment significantly reduces the mechanical energy required for reducing the particle size of the solid biomass material and is suitable as a pretreatment prior to a conversion reaction of the solid biomass material.

Claims

1. A process for the conversion of a modified biomass material, said process comprising:

(a) mixing a solid biomass material with an inorganic material, thereby to produce a solid biomass material mixture;

(b) exposing the solid biomass material mixture to a toasting temperature in the range of from 105°

C. to 140°

C. during an exposure time of from 1 minute to 12 hours and under conditions wherein biomass conversion is avoided, thereby to produce a modified biomass material having reduced resistance to mechanical disintegration; and

(c) subjecting the modified biomass material to a conversion reaction,

wherein, prior to or following step (b), the solid biomass material mixture or the modified biomass material is subjected to flash heating.

2. The process of claim 1 wherein step (b) is carried out in the presence of steam or in an atmosphere that is substantially oxygen-free.

3. The process of claim 1 wherein step (a) comprises intimately mixing the solid biomass material with a particulate inorganic material.

4. The process of claim 3 wherein the particulate inorganic material comprises a catalyst.

5. The process of claim 4 further comprising the step of reducing the mineral content of the solid biomass material prior to step (a), wherein the step of reducing the mineral content comprises soaking the solid biomass material with an aqueous solvent and removing minerals by filtration;

and wherein;

step (b) is carried out in the presence of steam;

the solid biomass material is a lignocellulosic biomass material;

the particulate inorganic catalyst is selected from the group consisting of carbonates, hydroxides and oxides of alkali and earth alkaline metals, mixed metal oxides, layered cationic materials, natural clays, hydrotalcite-like materials, crystalline aluminosilicates, and combinations thereof;

step (b) is conducted in a fluidized bed, fixed bed, transported bed or ebullated bed type of reactor; and

the modified biomass material has a reduced resistance to mechanical disintegration.

6. The process of claim 1 wherein step (a) comprises impregnating the solid biomass material with the inorganic material in the form of a solution or colloidal suspension.

7. The process of claim 1 wherein step (a) comprises intimately mixing the solid biomass material with a particulate inorganic catalyst material, impregnating the solid biomass material with an inorganic material, or intimately mixing the solid biomass material with a particulate inorganic catalyst material and impregnating the solid biomass material with an inorganic material, said inorganic material being in the form of a solution or colloidal suspension, said step (a) being carried out before step (b).

8. The process of claim 7 wherein step (a) comprises intimately mixing the solid biomass material with a particulate inorganic catalyst material and impregnating the solid biomass material with an inorganic material, and further comprising the step of reducing the mineral content of the solid biomass material prior to step (a), wherein the step of reducing the mineral content comprises soaking the solid biomass material with an aqueous solvent and removing minerals by filtration;

and wherein;

the solid biomass material is a lignocellulosic biomass material;

the particulate inorganic catalyst is selected from the group consisting of layered anionic materials;

the inorganic material is selected from the group consisting of hydroxides and carbonates of sodium and potassium;

step (b) is conducted in a fluidized bed, fixed bed, transported bed or ebullated bed type of reactor; and

the modified biomass material has a reduced resistance to mechanical disintegration.

9. The process of claim 1 wherein the solid biomass material is contacted with an organic compound before or during step (b), wherein the organic compound is in the form of a solution, including a water phase derived from a pyrolysis process.

10. The process for the conversion of the modified biomass material of claim 1 wherein the conversion reaction of step (c) comprises pyrolysis, biomass catalytic cracking, hydrothermal upgrading, gasification, chemical conversion, hydrothermal conversion, hydropyrolytic conversion, enzymatic conversion, or a combination thereof.

11. A process for the conversion of the modified biomass material of claim 5 wherein the conversion reaction of step (c) comprises pyrolysis, biomass catalytic cracking, hydrothermal upgrading, gasification, chemical conversion, hydrothermal conversion, hydropyrolitic conversion, enzymatic conversion, or a combination thereof.

12. The process of claim 1 wherein before said flash heating said solid biomass material mixture or modified solid biomass material has a moisture content of at least 20 wt. %.

13. The process of claim 1 wherein:

said step of flash heating occurs prior to step (b);

wherein the flash heating comprises increasing the temperature from 80°

C. or below to 120°

C. or above in less than 30 seconds, and

wherein the flash heating is followed or accompanied by a pressure drop.

14. The process of claim 12 wherein:

said step of flash heating occurs after step (b) and said modified solid biomass material is contacted with an aqueous liquid sufficient to increase the moisture content to at least 20 wt. % prior to said flash heating;

wherein the flash heating comprises increasing the temperature from 80°

C. or below to 120°

C. or above in less than 30 second; and

wherein the flash heating is followed or accompanied by a pressure drop.

15. The process of claim 12 wherein the flash heating further comprises contacting the solid biomass material mixture or modified solid biomass material prior to said flash heating with a swelling aid selected from the group consisting of water soluble bases, water soluble acids, water soluble salts, and mixtures thereof to provide a moisture content of at least 20 wt. %.

16. The process of claim 15 wherein the swelling aid comprises at least one cation selected from the group consisting of K, NH4, Na, Ba, Mn, Mg, Ca, Li, and Zn, or at least one anion selected from the group consisting of ClO3, SO4, SO3, NO3, Cl, Br, ClO4, I;

CNS, HSO4, OH, HCO3, HSO3, and (OH)CO3.

17. The process of claim 15 wherein the swelling aid comprises at least one compound selected from the group consisting of a salt of:

1) an alkali metal, an alkaline-earth metal, a transition metal, or a rare earth metal; and

     2) an aluminum-containing anion; and

combinations thereof.

18. The process of claim 1 further comprising reducing the mineral content of the solid biomass material prior to step (a), wherein the step of reducing the mineral content comprises soaking the solid biomass material with an aqueous solvent and removing minerals by filtration.

19. The process of claim 1 further comprising contacting the solid biomass prior to step (a) with an aqueous solution, wherein the aqueous solution is selected from the group consisting of water soluble bases, water soluble acids, water soluble salts and mixture thereof.

20. The process of claim 1 further comprising subjecting the solid biomass material to flash heating prior to step (a).

21. A process for the conversion of a modified biomass material, said process comprising:

(a) mixing a solid biomass material with an inorganic material, thereby to produce a solid biomass material mixture;

(b) exposing the solid biomass material mixture to a toasting temperature in the range of from 105°

C. to 140°

C. during an exposure time of from 1 minute to 12 hours and under conditions wherein biomass conversion is avoided, thereby to produce a modified biomass material having reduced resistance to mechanical disintegration; and

(c) subjecting the modified biomass material to a conversion reaction,

wherein prior to or following step (b), the solid biomass material mixture or modified solid biomass material is exposed to a pressure swing explosion by;

(i) exposing, at a high pressure, said solid biomass material mixture or modified biomass material to a compound selected from the group consisting of steam, ammonia and CO₂; and

(ii) allowing the pressure to be reduced to a low pressure;

wherein the pressure and temperature of said compound in step (i) are such that at least a portion of said compound is liquefied; and

wherein said low pressure in step (ii) is below said high pressure of step (i) and sufficiently low such that substantially all of said compound is in the form of a gas.