CONTINUOUS COUNTER-CURRENT ORGANOSOLV PROCESSING OF LIGNOCELLULOSIC FEEDSTOCKS

• US 20120289685A1
• Filed: 07/23/2012
• Published: 11/15/2012
• Est. Priority Date: 05/31/2007
• Status: Active Grant

• Current Assignee: Suzano Canada Inc. (Suzano S.A.)
• Original Assignee: Lignol Innovations Ltd (Suzano S.A.)
• Inventors: HALLBERG, Christer, O'CONNOR, Donald, RUSHTON, Michael, PYE, Edward Kendall, GJENNESTAD, Gordon, BERLIN, Alex, MACLACHLAN, John Ross
• Granted Patent: US 8,528,463 B2
• Time in Patent Office: Days
• US Class Current: 530/500
• CPC Class Codes: B01D 11/0226 with the general transport direction of the solids parallel to the rotation axis of the conveyor, e.g. worm
• CPC Class Codes: B01D 11/0288 Applications, solvents
• CPC Class Codes: B01D 3/002 by continuous methods
• CPC Class Codes: B01D 3/14 Fractional distillation or use of a fractionation or rectification column
• CPC Class Codes: C02F 11/04 Anaerobic treatment; Production of methane by such processes
• CPC Class Codes: C02F 3/34 characterised by the microorganisms used
• CPC Class Codes: C07H 19/00 Compounds containing a hetero ring sharing one ring hetero atom with a saccharide radical; Nucleosides; Mononucleotides; Anhydro-derivatives thereof
• CPC Class Codes: C08H 6/00 Macromolecular compounds derived from lignin, e.g. tannins, humic acids
• CPC Class Codes: C08H 8/00 Macromolecular compounds derived from lignocellulosic materials pretreatment thereof B27N
• CPC Class Codes: C08L 3/02 Starch; Degradation products thereof, e.g. dextrin
• CPC Class Codes: C08L 5/04 Alginic acid; Derivatives thereof
• CPC Class Codes: C12M 21/04 for producing gas, e.g. biogas digesters for manure with production of biogas A01C3/028, biological treatment of water, waste water or sewage C02F3/00, C02F11/02, preparation of natural gas or syngas C10L3/06, C10L3/10
• 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 45/02 by mechanical forces; Stirring; Trituration; Comminuting crushing, pulverizing, disintegrating in general B02C
• CPC Class Codes: C12M 45/04 Phase separators; Separation of non fermentable material; Fractionation
• CPC Class Codes: C12M 45/06 by chemical means or hydrolysis
• CPC Class Codes: C12M 45/09 by enzymatic treatment
• 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 5/023 Methane
• CPC Class Codes: C12P 7/00 Preparation of oxygen-containing organic compounds
• 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: C12P 7/40 : containing a carboxyl group including Peroxycarboxylic acids
• CPC Class Codes: C12P 7/54 : Acetic acid vinegar C12J
• CPC Class Codes: C13K 1/02 : obtained by saccharification of cellulosic materials manufacture of fodder A23K10/32
• CPC Class Codes: D21H 17/00 : Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
• 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
• CPC Class Codes: Y02W 10/20 : Sludge processing

Abstract

A modular process for organosolv fractionation of lignocellulosic feedstocks into component parts and further processing of said component parts into at least fuel-grade ethanol and four classes of lignin derivatives. The modular process comprises a first processing module configured for physico-chemically digesting lignocellulosic feedstocks with an organic solvent thereby producing a cellulosic solids fraction and a liquid fraction, a second processing module configured for producing at least a fuel-grade ethanol and a first class of novel lignin derivatives from the cellulosic solids fraction, a third processing module configured for separating a second class and a third class of lignin derivatives from the liquid fraction and further processing the liquid fraction to produce a distillate and a stillage, a fourth processing module configured for separating a fourth class of lignin derivatives from the stillage and further processing the stillage to produce a sugar syrup.

Claims

1. A modular system for organosolv fractionation of lignocellulosic feedstock into component parts and further processing of said component parts;

the modular process comprising;

a first processing module configured for receiving, physically processing, and physico-chemically digesting a lignocellulose feedstock with a separately supplied organic solvent thereby extracting component parts therefrom said feedstock, and separating said component parts into a cellulosic solids fraction and a first liquid fraction;

a second processing module configured for receiving therein said cellulosic solids fraction and for separating therefrom at least ethanol, a first class of lignin derivatives, and a de-lignified stillage;

a third processing module configured for separating the first liquid fraction into a second class of lignin derivatives, a third class of lignin derivatives and a filtrate, for optionally separating furfurals from said filtrate, and for recovering a portion of the organic solvent from the filtrate by distillation thereby producing a first stillage; and

a fourth processing module configured for separating the first stillage into one or more of an acetic acid-containing liquid fraction, a fourth class of lignin derivatives, a sugar syrup, and a semi-solid waste material.

2. A modular system according to claim 1, additionally provided with a fifth processing module configured for anaerobic digestion and processing of the semi-solid waste material separated by the fourth processing module, into at least a collectable biogas and an liquid effluent.

3. A modular system according to claim 1, wherein the first processing module comprises a plurality of equipment selected and configured for controllable and manipulable communication and cooperation for:

receiving therein a lignocellulosic feedstock;

processing the lignocellulosic feedstock by physically separating non-lignocellulosic materials therefrom;

physico-chemically digesting the processed lignocellulosic feedstock by commingling said feedstock with a separately supplied organic solvent while controllably manipulating at least the temperature and pressure therein and thereabout, thereby producing the cellulosic solids fraction and the first liquid fraction; and

separately and controllably discharging the cellulosic solids fraction and the first liquid fraction.

4. A modular system according to claim 1, wherein the first processing module is configured to continuously receive, physically process, and physico-chemically digest a lignocellulosic feedstock thereby continuously producing the cellulosic solids fraction and the first liquid fraction.

5. A modular system according to claim 1, wherein the first processing module is configured to receive, physically process, and physico-chemically digest a batch of lignocellulosic feedstock thereby producing the cellulosic solids fraction and the first liquid fraction.

6. A modular system according to claim 1, wherein the first processing module is provided with a temperature-controllable and pressure-controllable digestion vessel configured to:

receive therein the processed lignocellulosic feed stock at about a first end and to convey said feedstock therethrough to about a second end;

receive therein an organic solvent at about the second end, and to flow said organic solvent therethrough to about the first end;

discharge the cellulosic solids fraction through an outlet provided therefor approximate the second end; and

discharge the first liquid fraction through an outlet provided therefor approximate the first end.

7. A modular system according to claim 6, wherein the temperature-controllable and pressure-controllable digestion vessel is configured to:

receive therein the processed lignocellulosic feed stock at about a first end and to convey said feedstock therethrough to about a second end;

receive therein an organic solvent at about the first end, and to circulate said organic solvent therethrough and thereabout;

discharge the cellulosic solids fraction through an outlet provided therefor approximate the second end; and

discharge the first liquid fraction through an outlet provided therefor approximate the second end.

8. A modular system according to claim 6, wherein the temperature-controllable and pressure-controllable digestion vessel is configured to:

receive therein the processed lignocellulosic feed stock at about a first end and to convey said feedstock therethrough to about a second end;

receive therein an organic solvent interposed the first end and second end, and to circulate said organic solvent therethrough and thereabout;

discharge the cellulosic solids fraction through an outlet provided therefor approximate the second end; and

discharge the first liquid fraction through an outlet provided therefor approximate the first end.

9. A modular system according to claim 1, wherein the first processing module is additionally provided with equipment configured to sequentially saturate and de-saturate the processed lignocellulosic feedstock prior to physico-chemically digesting said processed lignocellulosic feedstock.

10. A modular system according to claim 1, wherein the second processing module comprises a plurality of equipment selected and configured for controllable and manipulable communication and cooperation for:

receiving therein the cellulosic solids fraction discharged from the first processing module;

reducing the viscosity of the cellulosic solids fraction;

enzymatic digestion of the reduced-viscosity cellulosic fraction thereby producing a second liquid fraction;

fermentation of the second liquid fraction thereby producing a beer therefrom;

distillation of the beer thereby producing a fuel-grade ethanol and a second stillage therefrom; and

separating a first class of lignin derivatives from said second stillage.

11. A modular system according to claim 1, wherein the de-lignified second stillage is recyclable for reducing the viscosity of the cellulosic solids fraction.

12. A modular system according to claim 1, wherein the second processing module is provided with a vessel for containing therein concurrent enzymatic digestion of the reduced-viscosity cellulosic solids fraction and fermentation of the second liquid fraction produced therefrom.

13. A modular system according to claim 1, wherein the anaerobic digestion module is provided with a plurality of equipment configured for:

receiving and biologically hydrolyzing therein the solid waste material separated by the fourth processing module thereby producing a third liquid fraction;

receiving and biologically acidifying therein the third liquid fraction thereby producing a biologically acidified liquid fraction;

receiving and biologically acetifying therein the biologically acidified liquid fraction thereby producing at least acetic acid; and

receiving the at least acetic acid and biologically producing at least a biogas and a liquid effluent therefrom.

14. A modular system according to claim 13, wherein the anaerobic digestion module is additionally configured for controllably receiving and commingling a portion of said sugar syrup separated in the fourth processing module with the a third liquid fraction.

15. A modular system according to claim 1, additionally provided with a sixth processing module configured for receiving, fermenting and distilling therein said sugar syrup, and for separating therefrom a distillate and a stillage.

16. A modular system according to claim 15, wherein said distillate comprises at least 1,3 propanediol.

17. A modular system according to claim 15, wherein said distillate comprises at least lactic acid.

18. A modular system according to claim 1, wherein a portion of the sugar syrup separated in the fourth processing module is controllably delivered into the second module for production therein of ethanol therefrom.

19. A modular system according to claim 1, wherein the ethanol is a fuel-grade ethanol.

20. A modular system for fractionation of lignocellulosic feedstocks into component parts and further processing of said component parts to recover ethanol therefrom, the modular process comprising:

a first processing module configured for fractionating a lignocellulose feedstock into component parts with an organic solvent separately provided thereto and separating said component parts into a first liquid fraction and a cellulosic solids fraction;

a second processing module configured for receiving therein said cellulosic solids fraction and for producing therefrom ethanol and a first stillage;

a third processing module configured for receiving therein the first liquid fraction and separating therefrom at least said organic solvent and a second stillage; and

a fourth processing module configured for separating the second stillage into at least a sugar syrup and a semi-solid waste material, wherein a portion of the sugar syrup separated in the fourth processing module is controllably delivered into the second module for production therein of ethanol therefrom.

21. A modular system according to claim 20, wherein the ethanol is a fuel-grade ethanol.

22. A first class of lignin derivatives recoverable from a lignocellulosic feedstock, said first class of lignin derivatives recoverable by a process comprising steps of:

separating the lignocellulosic feedstock into a cellulosics solids fraction and a liquid fraction, and recovering therefrom the cellulosic solids fraction;

hydrolizing the cellulosic solids fraction thereby producing a liquid stream containing at least solubilized sugars;

fermenting said liquid stream thereby producing a fermentation beer;

distilling said beer to produce ethanol and a stillage therefrom; and

precipitating said first class of lignin derivatives from said stillage; and

recovering said precipitated first class of lignin derivatives.

23. A second class of lignin derivatives recoverable from a lignocellulosic feedstock, said second class of lignin derivatives recoverable by a process comprising steps of:

fractionating the lignocellulosic feedstock into a cellulosics solids fraction comprising a first class of lignin derivatives and a pressurized liquids fraction, and recovering therefrom the pressurized liquids fraction;

depressurizing and cooling the liquids fraction thereby precipitating therefrom a second class of lignin derivatives; and

separating and recovering said precipitated second class of lignin derivatives from said de-pressurized and cooled liquids fraction.

24. A third class of lignin derivatives recoverable from a lignocellulosic feedstock, said third class of lignin derivatives recoverable by a process comprising steps of:

fractionating the lignocellulosic feedstock into a cellulosics solids fraction comprising a first class of lignin derivatives and a pressurized liquids fraction, and recovering therefrom the pressurized liquids fraction;

depressurizing and cooling the liquids fraction thereby precipitating therefrom a second class of lignin derivatives;

separating the precipitated second class of lignin derivatives from said de-pressurized and cooled liquids fraction thereby producing a partially delignified liquids fraction;

precipitating a third class of lignin derivatives from said partially delignified liquids fraction; and

recovering the third class of lignin derivatives.