Modular biomass treatment unit

• US 8,558,043 B2
• Filed: 03/04/2010
• Issued: 10/15/2013
• Est. Priority Date: 03/04/2009
• Status: Active Grant

• Current Assignee: MARD Incorporated
• Original Assignee: Kior Inc.
• Inventors: Yanik, Steve, O'Connor, Paul, Bartek, Robert
• Primary Examiner(s): BHAT, NINA NMN
• Application Number:
  US12/717,744
• Publication Number:
  US 20100281759A1
• Time in Patent Office: 1,321 Days
• Field of Search: 585/14, 585/240, 585/241, 446/05, 446/06, 202/118, 202/117, 202/262, 202/235
• US Class Current: 585/240
• CPC Class Codes: C10G 2300/1014 of vegetal origin
• CPC Class Codes: C10G 2300/1037 Hydrocarbon fractions
• CPC Class Codes: C10G 3/42 Catalytic treatment
• CPC Class Codes: C10G 3/49 containing crystalline aluminosilicates, e.g. molecular sieves
• CPC Class Codes: C10L 1/04 essentially based on blends of hydrocarbons
• CPC Class Codes: C10L 9/083 Torrefaction
• CPC Class Codes: Y02E 50/10 Biofuels, e.g. bio-diesel
• CPC Class Codes: Y02P 30/20 using bio-feedstock

Abstract

A modular biomass treatment unit includes a first module having a pretreater and a first frame for transportation to and operation at a site adjacent to a solid biomass growth source. The pretreater is operable to process solid biomass to produce a plurality of solid biomass particles for conversion into a fuel or specialty chemical. The first frame supports the pretreater during transportation to and operation at the site adjacent to the solid biomass growth source. The modular biomass treatment unit can also include additional modules each comprising a reactor, a separator, and a frame for transportation to and operation at a site such as the site adjacent to the solid biomass growth source.

Claims

1. A modular biomass treatment unit comprising:

a first module comprising a pretreater and a first frame for transportation to and operation at a site adjacent to a solid biomass growth source;

wherein the pretreater is operable to process solid biomass to produce a plurality of solid biomass particles for conversion into a fuel or specialty chemical;

wherein the first frame supports the pretreater during transportation to and operation at the site adjacent to the solid biomass growth source;

a second module comprising a reactor and a second frame for transportation to and operation at the site adjacent to the solid biomass growth source;

wherein the reactor is operable to deoxygenate the plurality of solid biomass particles, to produce a liquefied product comprising a biocrude;

wherein the second frame supports the reactor during transportation to and operation at the site adjacent to the solid biomass growth source;

a third module comprising a second reactor and a third frame for transportation to and operation at the site adjacent to the solid biomass growth source;

wherein the second reactor is operable to refine the biocrude to produce a refined product, deoxygenate remaining solid biomass to produce additional liquefied product, or both refine the biocrude and deoxygenate remaining solid biomass;

wherein the third frame supports the second reactor during transportation to and operation at the site adjacent to the solid biomass growth source.

2. The modular biomass treatment unit of claim 1, wherein the pretreater comprises a contactor adapted for one or more of forming a mechano-chemical interaction between at least a portion of the solid biomass particles and a catalyst, and impregnating at least a portion of the solid biomass particles with a catalyst.

3. The modular biomass treatment unit of claim 1, wherein the pretreater comprises one or more of a demineralizer adapted for removing minerals from the solid biomass, and a dryer adapted for dewatering and torrifying the solid biomass.

4. The modular biomass treatment unit of claim 1, further comprising a solid biomass harvester.

5. The modular biomass treatment unit of claim 1, wherein the first module comprises skids and is sized to fit within one or more shipping containers.

6. The modular biomass treatment unit of claim 1, wherein the second module further comprises

a separator which is operable to separate the biocrude for conversion into a fuel or specialty chemical from the liquefied product;

and

wherein the second frame further supports the separator during transportation to and operation at the site adjacent to the solid biomass growth source.

7. The modular biomass treatment unit of claim 6, wherein the third module further comprises

a second separator which is operable to separate a fuel or specialty chemical from the refined product, separate the biocrude for conversion into a fuel or specialty chemical from the liquefied product, or both separate a fuel or specialty chemical from the refined product and separate the biocrude;

and

wherein the third frame further supports the second separator during transportation to and operation at the site adjacent to the solid biomass growth source.

8. The modular biomass treatment unit of claim 1, wherein the second module comprises a coupling mechanism for detachably engaging with the first module, comprises skids, and is sized to fit within one or more shipping containers.

9. The modular biomass treatment unit of claim 1, wherein the third module comprises a coupling mechanism for detachably engaging with one or more of the first module and the second module, comprises skids, and is sized to fit within one or more shipping containers.

10. The modular biomass treatment unit of claim 1, wherein the pretreater further comprises a vessel for roasting or toasting biomass.

11. A method for treating solid biomass at one or more sites adjacent to a solid biomass growth source comprising:

receiving one or more first modules, each module comprising a pretreater supported by a frame, at one or more sites adjacent to a solid biomass growth source;

connecting the one or more first modules to utilities at the one or more sites adjacent to the solid biomass growth source;

processing solid biomass from the solid biomass growth source in the one or more pretreaters supported by first frames, to produce a plurality of solid biomass particles for conversion into a fuel or specialty chemical; and

wherein each pretreater comprises a dryer adapted for dewatering and torrifying the solid biomass; and

further comprises a component selected from the group consisting of;

a) a contactor adapted for one or more of forming a mechano-chemical interaction between at least a portion of the solid biomass particles and a catalyst, and impregnating at least a portion of the solid biomass particles with a catalyst;

b) a demineralizer adapted for removing minerals from the solid biomass; and

c) both a) and b).

12. The method of claim 11, further comprising:

processing the plurality of solid biomass particles and a catalyst in a conventional petroleum refinery unit, wherein the catalyst and the unit are each adapted for processing solid biomass particles;

or

co-processing the plurality of solid biomass particles, a catalyst, and a conventional petroleum-based feedstock in a conventional petroleum refinery unit, wherein the catalyst and the unit are each adapted for co-processing solid biomass particles and a conventional petroleum based feedstock.

13. The method of claim 11, wherein processing the solid biomass comprises roasting or toasting the solid biomass.

14. A method for treating solid biomass at a site adjacent to a solid biomass growth source comprising:

receiving a first module comprising a pretreater supported by a first frame at a site adjacent to a solid biomass growth source;

connecting the first module to utilities at the site adjacent to the solid biomass growthsource;

processing solid biomass from the solid biomass growth source in the pretreater supported by the first frame, to produce a plurality of solid biomass particles for conversion into a fuel or specialty chemical; and

wherein the pretreater comprises a dryer adapted for dewatering and torrifying the solid biomass; and

further comprises a component selected from the group consisting of;

a) a contactor adapted for one or more of forming a mechano-chemical interaction between at least a portion of the solid biomass particles and a catalyst, and impregnating at least a portion of the solid biomass particles with a catalyst;

b) a demineralizer adapted for removing minerals from the solid biomass; and

c) both a) and b).

15. The method of claim 14, further comprising:

receiving a second module comprising a reactor and a separator supported by a second frame at a second site, the second site adjacent to the solid biomass growth source or adjacent to

a petroleum refinery;

connecting the second module to utilities at the second site;

deoxygenating the plurality of solid biomass particles in the reactor supported by the second frame to produce a liquefied product; and

separating a biocrude for conversion into a fuel or specialty chemical from the liquefied product in the separator supported by the second frame.

16. The method of claim 15, further comprising:

receiving a third module comprising a second reactor and a second separator supported by a third frame at the second site;

connecting the third module to utilities at the second site;

refining the biocrude in the second reactor supported by the third frame to produce a refined product, deoxygenating remaining solid biomass particles in the second reactor supported by the second frame to produce additional liquefied product, or both refining the biocrude and deoxygenating remaining solid biomass particles; and

separating a fuel or specialty chemical from the refined product in the second separator or, separating the biocrude for conversion into a fuel or specialty chemical from the liquefied product in the second separator, or both separating a fuel or specialty chemical from the refined product and separating the biocrude in the second separator.

17. The method of claim 14, further comprising:

receiving a second module comprising a reactor supported by a second frame at a second site, the second site adjacent to the solid biomass growth source or adjacent to a petroleum refinery;

connecting the second module to utilities at the second site; and

deoxygenating the plurality of solid biomass particles in the reactor supported by the second frame to produce a liquefied product comprising a biocrude.

18. The method of claim 17, further comprising:

receiving a third module comprising a second reactor supported by a third frame at the second site;

connecting the third module to utilities at the second site; and

refining the biocrude of the liquefied product in the second reactor to produce a refined product, deoxygenating remaining solid biomass particles in the second reactor to produce additional liquefied product, or both refining the biocrude and deoxygenating remaining solid biomass particles in the second reactor.

19. A method for treating solid biomass from a solid biomass growth source comprising:

receiving a first module comprising a pretreater supported by a first frame at a first site adjacent to a first sector of a solid biomass growth source;

connecting the first module to utilities at the first site;

processing solid biomass from the first sector in the pretreater to produce a first plurality of solid biomass particles for conversion into a fuel or specialty chemical;

receiving the first module at a second site adjacent to a second sector of the solid biomass growth source;

connecting the first module to utilities at the second site;

processing solid biomass from the second sector in the pretreater to produce a second plurality of solid biomass particles for conversion into a fuel or specialty chemical; and

wherein the pretreater comprises a dryer adapted for dewatering and torrifying the solid biomass; and

further comprises a component selected from the group consisting of;

a) a contactor adapted for one or more of forming a mechano-chemical interaction between at least a portion of the solid biomass particles and a catalyst, and impregnating at least a portion of the solid biomass particles with a catalyst;

b) a demineralizer adapted for removing minerals from the solid biomass; and

c) both a) and b).

20. The method of claim 19, further comprising:

receiving a second module comprising a reactor and a separator supported by a second frame at the first site;

connecting the second module to utilities at the first site;

deoxygenating the first plurality of solid biomass particles in the reactor, to produce a first liquefied product;

separating a first biocrude for conversion into a fuel or specialty chemical from the first liquefied product in the separator;

receiving the second module at the second site;

connecting the second module to utilities at the second site;

deoxygenating the second plurality of solid biomass particles in the reactor to produce a second liquefied product; and

separating a second biocrude for conversion into a fuel or specialty chemical from the second liquefied product in the separator.

21. The method of claim 19, further comprising:

receiving a second module comprising a reactor supported by a second frame at the first site;

connecting the second module to utilities at the first site;

deoxygenating the first plurality of solid biomass particles in the reactor, to produce a first liquefied product;

receiving the second module at the second site;

connecting the second module to utilities at the second site; and

deoxygenating the second plurality of solid biomass particles in the reactor to produce a second liquefied product.

22. A method for treating solid biomass from a solid biomass growth source comprising:

receiving a first module comprising a first pretreater supported by a first frame at a first site adjacent to a first sector of a solid biomass growth source;

connecting the first module to utilities at the first site;

processing solid biomass from the first sector in the first pretreater, to produce a first plurality of solid biomass particles for conversion into a fuel or specialty chemical;

receiving a second module comprising a second pretreater supported by a second frame at a second site adjacent to a second sector of the solid biomass growth source;

connecting the second module to utilities at the second site;

processing solid biomass from the second sector in the second pretreater, to produce a second plurality of solid biomass particles for conversion into a fuel or specialty chemical; and

receiving the first and second plurality of solid biomass particles in a reactor, deoxygenating the first and second plurality of solid biomass particles in the reactor to produce a liquefied product;

wherein the first and second pretreaters each comprise a dryer adapted for dewatering and torrifying the solid biomass; and

further comprise a component selected from the group consisting of;

a) a contactor adapted for one or more of forming a mechano-chemical interaction between at least a portion of the solid biomass particles and a catalyst, and impregnating at least a portion of the solid biomass particles with a catalyst;

b) a demineralizer adapted for removing minerals from the solid biomass; and

c) both a) and b).

23. The method of claim 22 further comprising separating a biocrude for conversion into a fuel or specialty chemical from the liquefied product.

24. A water-based biomass treatment unit for converting algae or other aquatic biomass into a biocrude at a site adjacent to an aquatic biomass source comprising:

a first module comprising a pretreater and a first frame for transportation to and operation at a site adjacent to an aquatic biomass source;

wherein the pretreater is operable to process aquatic biomass to produce an aquatic biomass preparation for conversion into a biocrude;

wherein the first frame supports the pretreater during transportation to and operation at the site adjacent to the aquatic biomass source;

a second module comprising a reactor, a separator, and a second frame for transportation to and operation at the site adjacent to the aquatic biomass source;

wherein the reactor is operable to deoxygenate the aquatic biomass preparation, to produce a liquefied product;

wherein the separator is operable to separate a biocrude for conversion into a fuel or specialty chemical from the liquefied product; and

wherein the second frame supports the reactor and separator during transportation to and operation at the site adjacent to the aquatic biomass source.

25. The water-based biomass treatment unit of claim 24, further comprising:

a third module comprising a second reactor, a second separator, and a third frame for transportation to and operation at the site adjacent to the aquatic biomass;

wherein the second reactor is operable to refine the biocrude to produce a refined product, deoxygenate remaining aquatic biomass preparation to produce additional liquefied product, or both refine the biocrude and deoxygenate remaining aquatic biomass preparation;

wherein the second separator is operable to separate a fuel or specialty chemical from the refined product, separate a biocrude for conversion into a fuel or specialty chemical from the liquefied product, or both separate a fuel or specialty chemical from the refined product and separate a biocrude; and

wherein the third frame supports the second reactor and the second separator during transportation to and operation at the site adjacent to the aquatic biomass source.

26. A battlefield-based biomass treatment unit for converting biomass into a biocrude at a site adjacent to a battlefield comprising:

a first module comprising a pretreater and a first frame for transportation to and operation at a site adjacent to a battlefield;

wherein the pretreater is operable to process biomass to produce a biomass preparation for conversion into a biocrude;

wherein the pretreater comprises a dryer adapted for dewatering and torrifying the solid biomass; and

further comprises a component selected from the Group consisting of;

a) a contactor adapted for one or more of forming a mechano-chemical interaction between at least a portion of the solid biomass particles and a catalyst, and impregnating at least a portion of the solid biomass particles with a catalyst;

b) a demineralizer adapted for removing minerals from the solid biomass; and

c) both a) and b);

wherein the first frame supports the pretreater during transportation to and operation at the battlefield;

a second module comprising a reactor, a separator, and a second frame for transportation to and operation at the battlefield;

wherein the reactor is operable to deoxygenate the biomass preparation, to produce a liquefied product;

wherein the separator is operable to separate a biocrude for conversion into a fuel or specialty chemical from the liquefied product; and

wherein the second frame supports the reactor and separator during transportation to and operation at the battlefield.

27. The battlefield-based biomass treatment unit of claim 26, further comprising:

a third module comprising a second reactor, a second separator, and a third frame for transportation to and operation at the battlefield;

wherein the second reactor is operable to refine the biocrude to produce a refined product, deoxygenate remaining biomass preparation to produce additional liquefied product, or both refine the biocrude and deoxygenate remaining biomass preparation;

wherein the second separator is operable to separate a fuel or specialty chemical from the refined product, separate a biocrude for conversion into a fuel or specialty chemical from the liquefied product, or both separate a fuel or specialty chemical from the refined product and separate a biocrude; and

wherein the third frame supports the second reactor and the second separator during transportation to and operation at the battlefield.