Integrated system and process for bioproduct production

• US 9,074,173 B2
• Filed: 07/01/2013
• Issued: 07/07/2015
• Est. Priority Date: 06/26/2009
• Status: Expired due to Fees

• Current Assignee: Talfryn SA
• Original Assignee: Cobalt Technologies, Inc.
• Inventors: Walther, David C., Meerman, Hendrik J., Burns-Guydish, Stacy M., Wilson, Richard W., Hogg, Eamon T., Luli, Gregory W., Eckert, Robert
• Primary Examiner(s): Martinell, James
• Application Number:
  US13/932,981
• Publication Number:
  US 20130337527A1
• Time in Patent Office: 736 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: C12M 21/12 for producing fuels or solvents C12M21/04 takes precedence; liquid carbonaceous fuels C10L1/00, solid fuels C10L5/00
• CPC Class Codes: C12M 23/58 Reaction vessels connected in series or in parallel combinations of bioreactors with other apparatus, C12M43/00
• CPC Class Codes: C12M 25/18 Fixed or packed bed
• CPC Class Codes: C12M 25/20 Fluidized bed in chemical or physical processes B01J8/18
• CPC Class Codes: C12M 43/02 Bioreactors or fermenters combined with devices for liquid fuel extraction; Biorefineries
• CPC Class Codes: C12M 45/06 by chemical means or hydrolysis
• CPC Class Codes: C12M 47/10 Separation or concentration of fermentation products bioreactors combined with means for distillation or extraction of liquid fuel C12M43/02
• CPC Class Codes: C12P 7/065 with microorganisms other than yeasts
• CPC Class Codes: C12P 7/16 Butanols
• CPC Class Codes: C12P 7/28 Acetone-containing products
• CPC Class Codes: Y02E 50/10 Biofuels, e.g. bio-diesel
• CPC Class Codes: Y02P 20/582 Recycling of unreacted starting or intermediate materials

Abstract

Processes and systems for production of bioproducts such as biofuels are provided. The bioproduct production processes and systems utilize pretreatment of a carbohydrate-containing feedstock to produce soluble sugar molecules and continuous conversion of the pretreated feedstock to a bioproduct by an immobilized fermenting microorganism.

Claims

1. A system for production of a bioproduct, comprising a feedstock hydrolysis unit and a bioreactor, wherein a carbon-containing feedstock is continuously hydrolyzed in said hydrolysis unit and the hydrolyzed feedstock is continuously fed to the bioreactor, wherein said bioreactor comprises a fermenting microorganism immobilized on a support, wherein said hydrolysis of the feedstock produces carbohydrate molecules that serve as a carbon source for said fermentation, wherein the microorganism continuously converts the hydrolyzed feedstock into a bioproduct, and wherein said feedstock material is deconstructed prior to hydrolysis.

2. A system according to claim 1, wherein said feedstock hydrolysis unit and said bioreactor are in fluid communication, wherein said hydrolysis unit is upstream from said bioreactor, and wherein the feedstock is continuously hydrolyzed and continuously fed to the bioreactor for the duration of the fermentation.

3. A system according to claim 2, comprising multiple bioreactors arranged in parallel, wherein said multiple bioreactors are in fluid communication with said hydrolysis unit, wherein the hydrolyzed feedstock is fed continuously into said bioreactors, wherein the fermentation of the microorganism occurs continuously in said bioreactors, and wherein the multiple bioreactors comprise the same or different microorganism(s).

4. A system according to claim 2, comprising multiple bioreactors arranged in series, wherein the first bioreactor in the series is in fluid communication with the hydrolysis unit and with a downstream bioreactor, wherein each subsequent bioreactor in the series downstream from the first bioreactor is in fluid communication with the previous upstream bioreactor in the series, wherein the hydrolyzed feedstock is fed continuously into the first bioreactor in the series, and wherein effluent from each bioreactor is fed to the next bioreactor downstream in the series.

5. A system according to claim 1, wherein said feedstock is a cellulosic material.

6. A system according to claim 5, wherein said feedstock is a lignocellulosic material.

7. A system according to claim 6, wherein said lignocellulosic material is pretreated to remove extractives.

8. A system according to claim 7, wherein said pretreatment to remove extractives comprises compression, water extraction, solvent extraction, alkaline extraction, enzymatic treatment, fungal treatment, oxygen treatment, or air drying, wherein said pretreatment occurs prior to or in conjunction with deconstruction.

9. A system according to claim 6, wherein said lignocellulosic material comprises wood chips, sawdust, saw mill residue, or a combination thereof.

10. A system according to claim 6, wherein said lignocellulosic material is wood selected from softwood, hardwood, or a combination thereof.

11. A system according to claim 6, wherein said lignocelluosic material is from a feedstock source that has been subjected to a disease or infestation.

12. A system according to claim 6, wherein said lignocellulosic material is deconstructed prior to harvest, wherein said deconstruction occurs due to one or more natural or intentional causes comprising drought, infestation, fire, or herbicide.

13. A system according to claim 6, wherein said lignocellulosic material comprises bagasse or straw.

14. A system according to claim 5, wherein said feedstock comprises cellulose and hemicellulose.

15. A system according to claim 1, wherein said deconstruction process comprises one or more process selected from presteaming, mechanical grinding, mechanical explosion, or a combination thereof.

16. A system according to claim 1, wherein said hydrolysis is performed by treatment with one or more acid.

17. A system according to claim 16, wherein said acid comprises nitric acid, formic acid, acetic acid, phosphoric acid, hydrochloric acid, or sulfuric acid.

18. A system according to claim 17, wherein said hydrolysis is performed with nitric acid.

19. A system according to claim 18, wherein said hydrolysis unit comprises a first hydrolysis module and a second hydrolysis module, wherein nitric acid hydrolysis comprises a first stage in the first hydrolysis module and a second stage in the second hydrolysis module, and wherein the temperature of the nitric acid in the first hydrolysis module is higher than the temperature of the nitric acid in the second hydrolysis module.

20. A system according to claim 19, wherein the hydrolysis product streams from the first and second hydrolysis modules are combined prior to introduction into the bioreactor.

21. A system according to claim 19, wherein the hydrolysis product streams from the first and second hydrolysis modules are introduced as separate hydrolyzed feedstock streams into separate bioreactors, wherein the first stage hydrolysate is introduced into a first bioreactor and the second stage hydrolysate is introduced into a second bioreactor, wherein the first and second bioreactors comprise the same or different microorganism(s).

22. A system according to claim 21, wherein the first bioreactor comprises a first microorganism and the second bioreactor comprises a second microorganism, wherein the first and second microorganisms are different, and wherein the first microorganism is optimized for growth and/or desired product production on the first stage hydrolysate and the second microorganism is optimized for growth and/or desired product production on the second stage hydrolysate.

23. A system according to claim 19, wherein flash steam is generated during the hydrolysis process, and wherein said flash steam is used to provide energy for one or more processes selected from deconstruction of said feedstock prior to hydrolysis, further hydrolysis of feedstock, and purification of the bioproduct.

24. A system according to claim 19, wherein flash steam is generated in said second stage hydrolysis, and wherein said flash steam is provided to the feedstock for deconstruction of said feedstock prior to hydrolysis and/or to said first hydrolysis module to provide energy for said first stage hydrolysis.

25. A system according to claim 19, wherein flash steam is generated in said second stage hydrolysis, wherein said flash steam is recompressed, and wherein said recompressed steam is provided to said first hydrolysis module to provide energy for said first stage hydrolysis and/or a downstream distillation process for product purification.

26. A system according to claim 19, wherein flash steam is generated in said second stage hydrolysis, wherein said flash steam is provided to a third hydrolysis module to provide energy for a third stage hydrolysis, wherein the temperature in the third hydrolysis module is lower than the temperature in the second hydrolysis module, and wherein said lower temperature permits hydrolysis of remaining oligomeric sugar molecules with less degradation than hydrolysis performed at a higher temperature.

27. A system according to claim 19, wherein hydrolysis of the feedstock produces a lignin-containing residue, and wherein the lignin-containing residue is used as an energy source for said process and/or for electricity generation.

28. A system according to claim 19, further comprising a conditioning unit, wherein said conditioning unit is in fluid communication with both the hydrolysis unit and the bioreactor, wherein said conditioning unit is downstream from the hydrolysis unit and upstream from the bioreactor, wherein hydrolyzed feedstock is conditioned in the conditioning unit to remove inhibitors of microbial growth and/or bioproduct production prior to introduction of the hydrolyzed feedstock into the bioreactor.

29. A system according to claim 28, wherein the hydrolysis and conditioning processes occur continuously for the duration of the fermentation.

30. A system according to claim 28, wherein removal of inhibitors comprises one or more process(as) selected from overliming, adsorption, and ion exchange.

31. A system according to claim 30, wherein said conditioning unit comprises an ion exchange resin, wherein removal of inhibitors is performed by contact of hydrolyzed feedstock with the ion exchange resin under conditions wherein the inhibitors are retained on the resin.

32. A system according to claim 30, wherein removal of inhibitors is performed by precipitation with an aluminum or iron salt.

33. A system according to claim 1, wherein the fermentation is conducted under anaerobic conditions.

34. A system according to claim 33, wherein the microorganism is a Clostridium strain.

35. A system according to claim 34, wherein the Clostridium strain is derived from a species selected from Clostridium saccharobutylicum, Clostridium saccharoperbutylacetonicum, Clostridium acetobutylicum, Clostridium beijerinckii, Clostridium puniceum, Clostridium aurantibutyricum, Clostridium tetanomorphum, Clostridium thermosaccharolyticum, Clostridium butyricum, Clostridium cellulolyticum, Clostridium phytofermentans, Clostridium thermohydrosulfuricum, Clostridium thermobutyricum, Clostridium thermocellum, and Clostridium pasteurianum.

36. A system according to claim 34, wherein the Clostridium strain is an environmental isolate or is derived from an environmental isolate.

37. A system according to claim 1, wherein the support on which the microorganism is immobilized on a support material selected from bone char, polypropylene, steel, diatomaceous earth, zeolite, ceramic, engineered thermal plastic, clay brick, concrete, lava rock, wood chips, polyester fiber, glass beads, Teflon, polyetheretherketone, and polyethylene.

38. A system according to claim 1, wherein the immobilized microorganism comprises a biofilm.

39. A system according to claim 1, wherein the bioreactor comprises a packed bed, an expanded bed, or a fluidized bed.

40. A system according to claim 1, wherein the bioreactor operates under pressure to compress gas in the bioreactor.

41. A system according to claim 1, wherein said hydrolysis of the feedstock comprises enzymatic hydrolysis.

42. A system according to claim 1, wherein said hydrolysis of the feedstock comprises autohydrolysis with acetic acid released by the feedstock.

43. A system according to claim 1, wherein the bioproduct comprises a biofuel selected from butanol, acetone, ethanol, or a combination thereof.

44. A system according to claim 43, wherein the biofuel comprises butanol.

45. A system according to claim 44, further comprising a recovery unit for recovery of butanol from the fermentation medium, wherein said recovery comprises distillation to separate the butanol from other components of the fermentation medium.

46. A system according to claim 45, wherein butyric acid is recovered in said distillation, and wherein said butyric acid is added to the fermentation medium in said bioreactor, wherein said microorganism converts said butyric acid to butanol.

47. A system according to claim 45, wherein flash steam is generated during hydrolysis of the feedstock and said flash steam provides energy for said distillation.

48. A system according to claim 1, further comprising a recovery unit for recovery of the bioproduct from the fermentation medium.

49. A system according to claim 48, wherein the recovery unit is in fluid communication with and downstream from the bioreactor, wherein the recovery process operates continuously for the duration of the fermentation.

50. A system according to claim 48, wherein the recovery unit comprises a concentration module for concentration of the bioproduct.

51. A system according to claim 50, wherein the recovery unit comprises a distillation module to separate the bioproduct from other components of the fermentation medium, wherein the distillation module is in fluid communication with and downstream from the concentration module.

52. A system according to claim 48, wherein bioproduct-containing effluent is continuously withdrawn from the bioreactor, and wherein the byproduct is recovered from the effluent in the recovery unit.