Processing biomass

• US 9,586,341 B2
• Filed: 03/01/2016
• Issued: 03/07/2017
• Est. Priority Date: 11/17/2008
• Status: Active Grant

• Current Assignee: Xyleco, Inc.
• Original Assignee: Xyleco, Inc.
• Inventors: Medoff, Marshall
• Primary Examiner(s): Claytor, Renee
• Assistant Examiner(s): FERNANDEZ, SUSAN EMILY
• Application Number:
  US15/058,033
• Publication Number:
  US 20160177358A1
• Time in Patent Office: 371 Days
• US Class Current: 1/1
• CPC Class Codes: B01J 19/085 Electron beams only
• CPC Class Codes: B01J 2219/0879 Solid
• CPC Class Codes: B01J 2219/12 Processes employing electromagnetic waves
• CPC Class Codes: B29B 9/12 characterised by structure or composition
• CPC Class Codes: B29B 9/16 Auxiliary treatment of granules
• CPC Class Codes: B29K 2001/00 Use of cellulose, modified cellulose or cellulose derivatives, e.g. viscose, as moulding material
• CPC Class Codes: B29L 2031/00 Other particular articles
• CPC Class Codes: C08B 1/00 Preparatory treatment of cellulose for making derivatives thereof , e.g. pre-treatment, pre-soaking, activation
• CPC Class Codes: C08H 8/00 Macromolecular compounds derived from lignocellulosic materials pretreatment thereof B27N
• CPC Class Codes: C10L 5/44 on vegetable substances
• CPC Class Codes: C12P 19/02 Monosaccharides 2-ketogulonic acid C12P7/60
• 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 2201/00 Pretreatment of cellulosic or lignocellulosic material for subsequent enzymatic treatment or hydrolysis
• CPC Class Codes: C12P 7/08 produced as by-product or from waste or cellulosic material substrate
• CPC Class Codes: C12P 7/10 substrate containing cellulosic material
• CPC Class Codes: C12Y 302/01004 Cellulase (3.2.1.4), i.e. endo-1,4-beta-glucanase
• 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

Methods are provided for reducing one or more dimensions of individual pieces of biomass; treating biomass, such as size-reduced biomass; changing a molecular structure of a biomass material; and, optionally, subjecting the biomass to a primary process to form a product. The methods include processing biomass materials using a screw extrusion process, and treating the biomass material with a screw extrusion process in size-reduction and treating steps.

Claims

1. A method of producing sugars using a screw extrusion process, the method comprising:

hydrolyzing one or more lignocellulosic materials with cellulase while conveying the one or more lignocellulosic materials through a screw extrusion process, the one or more lignocellulosic materials having been exposed to ionizing radiation; and

discharging an extrudate from the screw extrusion process, the extrudate comprising one or more fermentable sugars released from cellulolytic hydrolysis of the one or more lignocellulosic materials;

wherein the screw extrusion process utilizes a co-extruder having a first barrel and a second barrel; and

conveying comprises conveying a first lignocellulosic material through the first barrel and conveying a second lignocellulosic material through the second barrel; and

hydrolyzing comprises exposing the first lignocellulosic material to a first hydrolysis process and exposing the second lignocellulosic material to a second hydrolysis process.

2. The method of claim 1, wherein the one or more lignocellulosic materials have been subjected to a size-reduction process.

3. The method of claim 2, wherein the size-reduction process is performed during the screw extrusion process.

4. The method of claim 3, wherein the size-reduction process comprises compression and shear forces applied via a plurality of interpenetrate helicoidal surfaces within a screw extruder, the forces effective to reduce one or more dimensions of individual pieces of lignocellulosic material.

5. The method of claim 1, wherein the exposure to ionizing radiation occurs during the screw extrusion process.

6. The method of claim 5, wherein the exposure to ionizing radiation comprises exposing the one or more lignocellulosic materials to an ion beam while conveying the one or more lignocellulosic materials through a screw extruder, the ion beam effecting a desired dose of ionizing radiation.

7. The method of claim 6, wherein the dose of ionizing radiation received by the one or more lignocellulosic materials depends, at least in part, on the speed of the screw extruder.

8. The method of claim 5, further comprising exposing the one or more lignocellulosic materials to a reactive gas during at least part of the exposure to ionizing radiation.

9. The method of claim 8, wherein the reactive gas comprises ozone.

10. The method of claim 5, wherein the ionizing radiation comprises an electron beam.

11. The method of claim 1, wherein the degree of cellulolytic hydrolysis performed on the one or more lignocellulosic materials depends, at least in part, on the speed of a screw extruder in the screw extrusion process.

12. The method of claim 1, wherein conveying comprises selectively advancing the one or more lignocellulosic materials through a plurality of apertures after a desired effect of the screw extrusion process has been attained.

13. The method of claim 12, wherein the desired effect comprises a change in one or more of:

level of recalcitrance, average molecular weight, average crystallinity, surface area, average fiber length, average length-to-diameter ratio, average BET surface area, bulk density, degree of polymerization, porosity, degree of branching, degree of grafting, domain size of the lignocellulosic material, and molecular make-up of the lignocellulosic material.

14. The method of claim 1, wherein the screw extrusion process comprises controlling the temperature of the lignocellulosic material within one or more zones by means of controlled heating or cooling.

15. The method of claim 1, wherein the screw extrusion process utilizes one or more of the following elements:

a mixing element, a pulverizing element, and a kneading element; and

the one or more elements are effective to provide a homogeneous extrudate.

16. The method of claim 1, wherein the first lignocellulosic material differs from the second lignocellulosic material prior to introduction to the co-extruder.

17. The method of claim 16, wherein the first lignocellulosic material differs from the second lignocellulosic material in respect of one or more of the following characteristics:

source of lignocellulosic material, type of lignocellulosic material, level of recalcitrance, average molecular weight, average crystallinity, surface area, average fiber length, average length-to-diameter ratio, average BET surface area, bulk density, degree of polymerization, porosity, degree of branching, degree of grafting, domain size of the lignocellulosic material, and molecular make-up of the lignocellulosic material.

18. The method of claim 16, wherein the individual pieces of the first lignocellulosic material have one or more dimensions which, on average, exceed the corresponding one or more dimensions of the individual pieces of the second lignocellulosic material.

19. The method of claim 16, wherein the first lignocellulosic material has received a first dose of ionizing radiation and the second lignocellulosic material has received a second dose of ionizing radiation, the first dose of ionizing radiation being greater than the second dose of ionizing radiation.

20. The method of claim 19, wherein the first dose of ionizing radiation is applied at a first dose rate and the second dose of ionizing radiation is applied at a second dose rate, the first dose rate differing from the second dose rate.

21. The method of claim 20, wherein the first dose rate is greater than the second dose rate.

22. The method of claim 1, wherein hydrolyzing the first lignocellulosic material yields a first hydrolyzed material, and hydrolyzing the second lignocellulosic material yields a second hydrolyzed material, the first hydrolyzed material differing from the second hydrolyzed material in respect of the concentration of the one or more fermentable sugars.

23. The method of claim 22, wherein the one or more fermentable sugars comprise glucose, xylose, arabinose, mannose, galactose, oligosaccharides, polysaccharides, or mixtures of these.