Processing paper feedstocks

• US 9,683,250 B2
• Filed: 06/19/2015
• Issued: 06/20/2017
• Est. Priority Date: 02/14/2011
• Status: Expired due to Fees

• Current Assignee: Xyleco, Inc.
• Original Assignee: Xyleco, Inc.
• Inventors: Medoff, Marshall, Masterman, Thomas Craig
• Primary Examiner(s): CORDAS, EMILY ANN
• Application Number:
  US14/745,208
• Publication Number:
  US 20150284757A1
• Time in Patent Office: 732 Days
• Field of Search: None
• CPC Class Codes: C12M 21/18 Apparatus specially designed for the use of free, immobilized or carrier-bound enzymes
• CPC Class Codes: C12M 27/00 Means for mixing, agitating or circulating fluids in the vessel by introduction of gas C12M29/06, C12M29/14, mixing in general or mixers per se B01F; mixing in apparatus for chemical or physical processes B01J
• CPC Class Codes: C12M 29/06 Nozzles; Sprayers; Spargers; Diffusers per se B01F23/231, B01J19/26
• 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 2203/00 Fermentation products obtained from optionally pretreated or hydrolyzed cellulosic or lignocellulosic material as the carbon source ethanol C12P7/10
• CPC Class Codes: C12P 7/10 substrate containing cellulosic material
• CPC Class Codes: C12P 7/14 Multiple stages of fermentation; Multiple types of microorganisms or re-use of microorganisms
• CPC Class Codes: C13K 1/02 obtained by saccharification of cellulosic materials manufacture of fodder A23K10/32
• CPC Class Codes: C13K 13/002 Xylose
• 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 of processing paper feedstocks are provided, as well as intermediates and products made using such methods. Certain types of paper feedstocks, in particular highly pigmented papers, and/or highly loaded papers such as paper that has been color printed, e.g., magazines, and high basis weight coated papers, e.g., magazine stock, are utilized to produce useful intermediates and products, such as energy, fuels, foods or materials.

Claims

1. A method of saccharifying paper feedstock, the method comprising:

providing in a vessel, a slurry comprising a paper feedstock consisting essentially of polycoated paper, water, and an enzyme, the slurry having greater than 20 weight percent solids of the paper feedstock;

drawing slurry material from the vessel and jetting the slurry material into the vessel, while saccharifying at least a portion of the paper feedstock, producing a sugar; and

after saccharification, removing from the slurry material a polymer residue from the polycoated paper.

2. The method of claim 1, wherein jetting the slurry material comprises providing a jet mixer having a nozzle, and directing the slurry material through the nozzle under pressure.

3. The method of claim 2, wherein a pump generates the pressure, the nozzle being in fluid communication with the pump.

4. The method of claim 2, wherein the nozzle comprises a shroud surrounding an impeller, the impeller configured to provide jet flow through the nozzle.

5. The method of claim 1, wherein jetting the slurry material comprises directing the slurry material through a plurality of nozzles under pressure, the pressure generated by one or more pumps, each of the plurality of nozzles being in fluid communication with at least one of the one or more pumps.

6. The method of claim 1, wherein jetting the slurry material comprises drawing slurry material through an inlet to a pump, the inlet being in fluid communication with the vessel;

and

pumping the slurry material through a nozzle under pressure, the nozzle being in fluid communication with the pump.

7. The method of claim 6, wherein the pump is located outside of the vessel.

8. The method of claim 6, wherein the inlet draws slurry material from near the surface of the slurry in the vessel.

9. The method of claim 6, wherein the inlet draws slurry material from near the bottom surface of the vessel.

10. The method of claim 1, wherein the slurry material jets into the vessel through a nozzle at a velocity between 5 to 150 meters per second.

11. The method of claim 1, wherein jetting the slurry material into the vessel, causes a secondary entrained flow of aqueous slurry material in the vessel.

12. The method of claim 1, wherein jetting the slurry material into the vessel provides effective mixing in the vessel while minimizing damage to the enzyme.

13. The method of claim 1, wherein the vessel has a flat bottom surface.

14. The method of claim 1, wherein the vessel has an arcuate bottom surface.

15. The method of claim 1, wherein the vessel has a volume of at least 4,000 L.

16. The method of claim 1, wherein the vessel has a volume of at least 40,000 L.

17. The method of claim 1, wherein the initial solids concentration of the paper feedstock in the slurry is at least 20 weight percent.

18. The method of claim 1, wherein the paper feedstock comprises paper having a pigment, filler, and/or coating content of at least 20 weight percent.

19. The method of claim 1, wherein the paper feedstock comprises paper having an ash content of at least 8 weight percent.

20. The method of claim 1, wherein the paper feedstock has been exposed to irradiation, the irradiation provided by one or more of:

an ion beam and an electron beam.

21. The method of claim 20, wherein the paper feedstock has received at least at least 10 Mrad of irradiation.

22. The method of claim 20, wherein the paper feedstock has received irradiation at a dose rate of at least 1 Mrad per second.

23. The method of claim 1, wherein the paper feedstock has been subjected to a physical treatment, the physical treatment effective to reduce the bulk density of the paper feedstock and/or increase the BET surface area of the paper feedstock.

24. The method of claim 1, wherein the paper feedstock has a bulk density of less than about 0.5 grams per cubic centimeter.

25. The method of claim 1, wherein the enzyme comprises a cellulase.

26. The method of claim 1, further comprising fermenting at least a portion of the sugar with a microorganism.

27. The method of claim 26, wherein the paper feedstock comprises a toxic material and/or a solid inorganic material.

28. The method of claim 27, wherein the toxic material comprises a pigment and/or an ink.

29. The method of claim 27, wherein the solid inorganic material comprises a filler, a coating, and/or a pigment.