Biomass conversion to alcohol using ultrasonic energy

• US 7,504,245 B2
• Filed: 09/30/2004
• Issued: 03/17/2009
• Est. Priority Date: 10/03/2003
• Status: Expired due to Fees

• Current Assignee: FCStone Carbon LLC (StoneX Group, Inc.)
• Original Assignee: FCStone Carbon LLC (StoneX Group, Inc.)
• Inventors: Krohn, Bradley, Kinley, Michael T.
• Primary Examiner(s): Saucier; Sandra
• Assistant Examiner(s): Singh; Satyendra K
• Application Number:
  US10/954,657
• Publication Number:
  US 20050136520A1
• Time in Patent Office: 1,629 Days
• Field of Search: None
• US Class Current: 435/161
• 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 35/04 Mechanical means, e.g. sonic waves, stretching forces, pressure or shear stimuli
• CPC Class Codes: C12M 45/02 by mechanical forces; Stirring; Trituration; Comminuting crushing, pulverizing, disintegrating in general B02C
• CPC Class Codes: C12M 45/06 by chemical means or hydrolysis
• CPC Class Codes: C12M 45/20 Heating; Cooling heating or cooling apparatus for laboratory uses B01L7/00
• CPC Class Codes: C12P 7/06 Ethanol, i.e. non-beverage
• CPC Class Codes: Y02E 50/10 Biofuels, e.g. bio-diesel

Abstract

A method comprising applying ultrasonic energy to a biomass to alcohol production process is provided. In one embodiment the alcohol production process is an ethanol production process. In one embodiment, the biomass to alcohol process employs ultrasonic energy as the only means of pretreatment. In one embodiment, the biomass to alcohol process additionally employs a concentrated acid hydrolysis pretreatment. In one embodiment, the biomass to alcohol process additionally employs any conventional pretreatment, such as a hydrothermal or chemical pretreatment, followed by an enzymatic hydrolysis step or a simultaneous enzymatic hydrolysis and saccharification step. In one embodiment, the conventional pretreatment is selected from the group consisting of dilute acid hydrolysis, high pressure hot water-based methods, i.e., hydrothermal treatments such as steam explosion and aqueous hot water extraction, reactor systems (e.g., batch, continuous flow, counter-flow, flow-through, and the like), ammonia explosion, ammonia recycled percolation (ARP), lime treatment and a pH-based process.

Claims

1. A method comprising:

applying ultrasonic energy to a liquid medium processing stream in a cellulose-to-ethanol production process, wherein the liquid medium processing stream contains switch grass comprised of cellulose surrounded by a protective sheath of hemicellulose and lignin, wherein the ultrasonic energy is applied at one or more locations prior to fermentation, or before and after fermentation, with one or more high-powered transducers, each generating at least 3 kW of power and operating at a frequency of at least 17 kHz, wherein the power and frequency of the ultrasonic energy are sufficient to produce cavitational forces in the processing stream at an intensity and duration which causes at least a portion of the lignin to be loosened or removed from the cellulose, allowing an increased amount of cellulose to be hydrolyzed into one or more individual component sugars, wherein conversion of the one or more individual component sugars to one or more fermented individual component sugars during fermentation is increased; and

distilling and dehydrating the one or more fermented individual component sugars to produce ethanol and residuals, wherein ethanol yield is increased by applying the ultrasonic energy.

2. The method of claim 1 further comprising pretreating the liquid medium processing stream with a high pressure hot water-based pretreatment, a reactor system pretreatment, ammonia explosion pretreatment, ammonia recycled percolation (ARP) pretreatment, lime pretreatment, pH-based pretreatment, or combinations thereof.

3. The method of claim 2 wherein at least one of the one or more locations is upstream of the pretreatment step, at the pretreatment step or immediately following the pretreatment step.

4. The method of claim 3 further comprising applying ultrasonic energy to the liquid medium processing stream downstream of the pretreatment step with one or more additional transducers, wherein the one or more additional transducers are high-powered transducers, transducers operating at less than high power, or a combination thereof, further wherein at least one of the one or more additional transducers operate at a level which is not sufficient to produce cavitational forces.

5. The method of claim 1 wherein the hemicellulose is predominantly xylose.

6. The method of claim 3 wherein there is also an increased conversion of hemicellulose into one or more individual component sugars.

7. The method of claim 3 wherein the cellulose is hydrolyzed and saccharified with acid and the process further comprises:

separating the individual component sugars and the acid to produce one or more separated individual component sugars;

neutralizing the one or more individual component sugars to produce one or more neutralized individual component sugars which are fermented with yeast to produce the one or more fermented individual component sugars.

8. The method of claim 1 further comprising centrifuging the residuals to produce thin stillage.

9. The method of claim 8 further comprising applying sonication to the thin stillage to kill fermentative recombinant microorganisms.

10. The method of claim 3 wherein the cellulose is hydrolyzed and saccharified with acid and the process further comprises:

separating the individual component sugars and the acid to produce one or more separated individual component sugars;

neutralizing the one or more individual component sugars to produce one or more neutralized individual component sugars which are fermented with bacteria to produce the one or more fermented individual component sugar.

11. The method of claim 8 further comprising applying sonication to the thin stillage to cause any transgenic nucleic acids present to be altered by degradation, depolymerization, denaturation or any combination thereof.

12. The method of claim 1 further comprising pretreating the liquid medium processing stream with a dilute acid hydrolysis pretreatment.