Patent Application
20130116424
A. Field of Invention
The present invention is directed generally to a method of the production of value-added, biobased chemical products from a plurality of component streams from biomass. The present method further provides treatments to obtain the plurality of component streams from biomass.
B. Description of the Related Art
The world currently faces depletion of fossil fuels while demands for these fuels are ever increasing. Petrochemicals provide an energy source and a component of the majority of raw materials used in many industries. In fact, approximately 95% of all chemicals manufactured today are derived from petroleum. However, this heavy reliance upon fossil fuels is creating harm to the environment. The burning of these fossil fuels has led to the pollution of air, water and land, as well as global warming and climate changes. Through the use of fossil fuels, the environment has been harmed, perhaps irreparably, in an effort to meet the nearly insatiable demand for energy and manufactured products. Fossil fuels are a finite natural resource, with the depletion of readily available oil reserves across the globe; the supply chain has shifted to more complex and environmentally risky production technologies. A reduction in the use and conservation of fossil fuels is clearly needed. Some alternatives to fossil fuels, like solar power, wind power, geothermal power, hydropower, and nuclear power, are used to a degree. However, a more efficient use of renewable resources is always being sought.
As a stable and independent alternative to fossil fuels, biomass has emerged as a potentially inexhaustible resource for the production of energy, transportation fuels, and chemicals. The advantage in turning to domestic, renewable biomass for such purposes would be magnified during periods of an oil crisis, a price surge, or political unrest within oil producing regions of the world. Herein biomass consists essentially of plant biomass, including agricultural biomass, woody biomass, and cultivated plant biomass. Biomass can be freshly harvested, stored, recovered, or recycled. Biomass can be employed as a sustainable source of energy and is a valuable alternative to fossil fuels in the production of chemicals. More specifically, the biorefining of biomass into derivative products typically produced from petroleum could help to lessen the dependence on foreign crude oil. Biomass can become a key resource for chemical production in much of the world. Moreover, biomass, unlike petroleum, is renewable. Biomass can provide sustainable substitutes for petrochemically derived feedstocks used in existing markets.
Biomass is made up primarily of cellulose, hemicellulose, and lignin. These components, if economically separated from one another, can provide vital sources of chemicals normally derived from petrochemicals. The use of biomass can also be beneficial with plants that are sparsely used and plant wastes that currently have little or no use. Biomass can provide valuable chemicals and reduce dependence on coal, gas, and fossil fuels, in addition to boosting local and worldwide economies.
The use of biomass in the production of chemicals historically has focused mostly on bioethanol and biodiesel. Cellulosic bioethanol production requires a breakdown of the biomass into component streams with often only the cellulose component utilized. The OrganoSolv™ and Alcell® processes can be used to efficiently separate cellulose from biomass under mild conditions, namely through the use of an aqueous organic solvent, usually ethanol. These processes provide the simultaneous removal of the hemicellulose sugar and lignin in separated streams. Even though an organic solvent is used during this process, it can be recycled and used again in the process. Alternatively, separate component streams can be obtained from biomass through at least one of kraft pulping, sulfite pulping, steam explosion, ammonia fiber explosion, dilute acid hydrolysis, alkaline hydrolysis, alkaline oxidative treatment, enzymatic hydrolysis, pyrolytic processes, and enzymatic treatment. Of these, the kraft pulping of woody biomass is by far the dominant chemical pulping method practiced across the world today.
Although the cellulosic fraction of biomass has garnered attention as a feedstock for bioethanol and a few chemicals, the intrinsic value of the other components of biomass in chemical production continues to be largely overlooked. Other than fossil fuels, lignin is the most abundant source of aromatic chemicals. Lignin can be used in developing technologies that transform biomass into value-added, aromatic chemicals. In addition, the hemicellulose portion of biomass can also be converted into useful biobased chemicals.
The present invention provides methods for producing a plurality of component streams from biomass, namely cellulose, hemicellose, and lignin, and converting these component streams into value-added biobased chemicals while minimizing waste products.
Accordingly, it is an object of the present invention to provide a method for biorefining. It may include the steps of providing biomass and treating the biomass to provide a plurality of component streams. The method may further include producing derivative products from the plurality of component streams.
One object of the present invention includes biomass that consists essentially of plant biomass.
According to another object of the present invention, biomass comprises agricultural biomass, woody biomass, and cultivated plant biomass.
Yet another object of the present invention is processing biomass to provide a plurality of component streams.
Still another object of the present invention is the plurality of component streams comprises lignin, cellulose, and hemicellulose.
Another object of the present invention is treating biomass by mechanical processing and component separation processing.
According to one embodiment of the present invention, mechanical processing comprises at least one of chopping, chipping, cutting, shredding, debarking, milling, and grinding.
According to another embodiment of the present invention, mechanical processing of woody biomass comprises at least one of debarking, chopping, chipping, milling, and grinding.
According to yet another embodiment of the present invention, mechanical processing of agricultural biomass or cultivated plant biomass comprises at least one of chopping, cutting, shredding, milling, and grinding.
Yet another object of the present invention is treatment of biomass by component separation processing provides cellulose.
In another embodiment of the present invention, component separation processing provides a mixture of hemicellulose and lignin.
Still another object of the present invention is treating biomass by component separation processing provides lignin and hemicellulose as separated components.
Still yet another object of the present invention is to treat biomass by optional chemical processing.
According to one embodiment of the present invention, optional chemical processing comprises at least one of solvent treatment, acidic treatment, basic treatment, or enzymatic treatment.
According to another embodiment of the present invention, extractables are separated from the biomass by optional chemical processing.
According to yet another embodiment of the present invention, the extractables removed can be used for at least one of producing biofuels, lubricating, cleaning, disinfecting, deodorizing, scenting, and metal extracting from ores.
Another object of the present invention is the production of derivative products from the plurality of component streams.
In another embodiment of the present invention, chemicals used in optional chemical processing are recovered and recycled.
According to another embodiment of the present invention, component separation processing includes a residual chemical removal with optional pH adjustment.
Another embodiment of the present invention provides hemicellulose and lignin as part of residual chemical removal.
According to one embodiment of the invention, a chemical can be recovered and recycled from the residual chemical removal.
Yet another object of the present invention is an additional treatment comprising of at least one of heat treatment, pressure treatment, kraft pulping, sulfite pulping, pyrolysis, steam explosion, ammonia fiber explosion, dilute acid hydrolysis, alkaline hydrolysis, alkaline oxidative treatment, and enzymatic treatment.
Another embodiment of the present invention includes removing extractables from the additional treatment of the component separation processing.
Yet another embodiment of the present invention includes recovering and recycling at least one chemical from the additional treatment.
According to one embodiment of the invention, one of the component streams is selectively utilized.
According to another embodiment of the invention, at least two of the component streams are selectively utilized.
According to one embodiment of the invention, the plurality of component streams is a mixture of the plurality of component streams.
According to still yet another embodiment of the invention, an independent component stream is a mixture of the plurality of component streams.
According to still another embodiment of the invention, an independent component stream is independent and separate from the plurality of component streams.
Yet another object of the present invention is the production of one or more derivative products from an independent and separate component stream.
Another object of the present invention according to one embodiment of the invention is utilizing at least one of the component streams for producing the derivative products.
Still yet another object of the present invention is use of the residue component stream from production of at least one derivative product in the production of other biobased chemicals.
Still another object of the present invention is at least one of the derivative products comprises commodity chemicals, fine chemicals, and specialty chemicals.
Yet another object of the present invention is producing at least one derivative product comprises at least one chemical process, biological process, catalytic process, and pyrolytic process.
According to one object of the present invention, the derivative products of lignin comprise at least one of aromatic chemicals and fuels.
According to one embodiment of the present invention, the derivative products of lignin comprise at least one of aromatic carboxylic acids, aromatic esters, aromatic aldehydes, aryl alcohols, aryl ketones, styrenes, aryl ethanes, aryl propenes, aryl propanes, cresols, phenols, benzenes, and pyrolytic oils.
According to another embodiment of the present invention, the derivative products of lignin may comprise but are not limited to methyl and ethyl 4-hydroxybenzoate, methyl and ethyl vanillate, methyl and ethyl syringate, 4-hydroxybenzoic acid, (4-hydroxyphenyl)acetic acid, vanillic acid, homovanillic acid, syringic acid, homosyringic acid, 4-hydroxybenzaldehyde, vanillin, syringaldehyde, 4-hydroxybenzyl alcohol, 2-(4-hydroxyphenyl)ethanol, vanillyl alcohol, homovanillyl alcohol, syringyl alcohol, homosyringyl alcohol, 4-hydroxyacetophenone, acetoguaiacone, acetosyringone, 4-hydroxystyrene, 3-methoxy-4-hydroxystyrene, 3,5-dimethoxy-4-hydroxystyrene, (4-hydroxyphenyl)-1-propene, (4-hydroxyphenyl)-2-propene, eugenol, iso-eugenol, syringeugenol, iso-syringeugenol, ethyl phenol, ethyl guaiacol, ethyl syringol, propyl phenol, propyl guaiacol, propyl syringol, cresol, creosol, syringyl creosol, phenol, guaiacol, syringol, benzene, toluene, xylene, ethyl benzene, propyl benzene, biphenyl, and pyrolytic oils.
Another object of the present invention is the derivative products of cellulose comprise at least one of aliphatic chemicals, heterocyclic chemicals, and fuels.
According to one embodiment of the present invention, the derivative products of cellulose comprise at least one of cellulosic esters, aliphatic carboxylic acids, aliphatic esters, polyols, furans, dihydrofurans, tetrahydrofurans, lactones, and ethanol.
According to another embodiment of the present invention, the derivative products of cellulose may comprise but are not limited to cellulose acetate, cellulose propionate, cellulose benzoate, methyl and ethyl adipate, methyl and ethyl levulinate, methyl and ethyl succinate, methyl and ethyl 2,5-furandicarboxylate, adipic acid, levulinic acid, succinic acid, 2,5-furandicarboxylic acid, 3,4-dehydro-γ-valerolactone, γ-valerolactone, 2-methyltetrahydrofuran, sorbitol, hexane-1,6-diol, pentane-1,4-diol, butane-1,4-diol, 2,5-di(hydroxymethyl)furan, 2,5-di(hydroxymethyl)tetrahydrofuran, glyercol, propylene glycol, and ethanol.
Yet another object of the present invention is the derivative products of hemicellulose comprise at least one of aliphatic chemicals, heterocyclic chemicals, and fuels.
According to one embodiment of the present invention, the derivative products of hemicellulose comprise at least one of polyols, furans, dihydrofurans, tetrahydrofurans, lactones, and butenes.
According to another embodiment of the present invention, the derivative products of hemicellulose may comprise but are not limited to furfural, γ-butyrolactone, tetrahydrofuran, ribitol, arabitol, xylitol, glyercol, propylene glycol, and isoprene.
Still another object of the present invention is that the chemicals used for processing the biomass are recoverable for reuse.
Still yet another object of the present invention is that the plurality of derivative products comprises at least one of achiral, racemic, and optically pure products.
Still another object of the present invention is that at least one derivative product can be used in the production of other chemicals, materials, and products.
Yet another object of the present invention according to one embodiment of the invention is that the biomass has a weight, and a waste product of the biomass is less than 25% of the biomass weight.
Still yet another object of the present invention according to one embodiment of the invention is that the biomass has a weight, and a waste product of the biomass is less than 15% of the biomass weight.
Further, another object of the present invention is to provide a method for producing energy utilizing the waste product of the biomass.
According to another aspect, the present invention provides a method for biorefining which may comprise the steps of providing biomass, processing the biomass to provide a plurality of component streams, and using waste product from the plurality of component streams to produce energy.
According to another aspect of the present invention, the energy is heat or power.
Another object of the present invention is that it provides a method for biorefining which may comprise the steps of providing biomass, processing the biomass to provide a plurality of component streams by mechanical processing, component separation processing, optional chemical processing, residual chemical removal, and an additional treatment, providing a plurality of component streams comprising lignin, cellulose, and hemicellulose from the biomass, recovering chemicals used for chemical processing and residual chemical removal for reuse, removing extractables, reducing the waste product of the biomass, and producing at least one of aromatic carboxylic acids, aromatic esters, aromatic aldehydes, aryl alcohols, aryl ketones, styrenes, aryl ethanes, aryl propenes, aryl propanes, cresols, phenols, benzenes, and pyrolytic oils, cellulosic esters, aliphatic carboxylic acids, aliphatic esters, polyols, furans, dihydrofurans, tetrahydrofurans, lactones, ethanol, and butenes, from at least one of the component streams.
Another object of the present invention is to provide a method for biorefining that is cost effective.
Further, another object of the present invention is to provide a method for biorefining that is easy to implement and use.
Still other benefits and advantages of the present invention will become apparent to those skilled in the art to which it pertains upon a reading and understanding of the following detailed specification.
The invention may take physical form in certain parts and arrangement of parts, embodiments of which will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof, and wherein:
Referring now to the drawings wherein the showings are for purposes of illustrating embodiments of the invention only and not for purposes of limiting the same. Relative language used herein is best understood with reference to the drawings, in which like numerals are used to identify like or similar items.
Next, the biomass 10 may undergo mechanical processing 12 in order to reduce the size of the biomass 10 and prepare it for further processing. For the mechanical processing 12, the biomass can undergo chopping, chipping, cutting, shredding, debarking, milling, and grinding. In order to break down the biomass, there can be one or more mechanical processing 12 steps needed. The type of mechanical processing 12 may be dependent upon the type of biomass and its requirements for breaking it down for further treatment.
After the mechanical processing 12, the biomass 10 may be subjected to an optional chemical processing 14. This optional chemical processing 14 may serve to further break down the biomass 10 as well as remove fats, oils, resins, pitches, waxes, and other extractables. After both mechanical processing 12 and optional chemical processing 14, the biomass fractionation 16 can be formed.
Still referring to
Using the biomass fractionation 16 can provide a greener process by utilizing at least three of the component streams of biomass 10. These three component streams of biomass 10 may include cellulose 26, hemicellulose 36, and lignin 34.
After the first filtration 18 with the optional chemical processing 14, the filtered biomass fractionation 20 may be formed. Either the filtered biomass fractionation 20 from the optional chemical processing 14 or the biomass fractionation 16 from the mechanical processing 12 alone can be broken down even further by the component separation processing 22. In the component separation processing 22, a high pressure and temperature can successfully break down the biomass even further. Alternatively, the filtered biomass fractionation 20, or the biomass fractionation 16 from the mechanical processing 12 alone, can be broken down with other processes in the component separation processing 22 that may include at least one of kraft pulping, sulfite pulping, pyrolysis, steam explosion, ammonia fiber explosion, dilute acid hydrolysis, alkaline hydrolysis, alkaline oxidative treatment, and enzymatic treatment. A second filtration 24 can then be done to separate the cellulose 26 from the lignin and hemicellulose mixture 28. This lignin and hemicellulose mixture 28 can then go through both a residual chemical removal 30 and a third filtration 32 in order to separate the lignin and hemicellulose mixture 28 into lignin 34 and hemicellulose 36. Further, an optional pH adjustment 50 may take place prior to the third filtration 32 to effect a more complete separation of lignin 34 and hemicellulose 36.
With the separated component streams for cellulose 26, lignin 34, and hemicellulose 36, a production of biobased chemicals 40 can be achieved.
In
After the mechanical processing 12, the biomass 10 may be subjected to an optional chemical processing 14. Biomass 10 may undergo the optional chemical processing 14 if additional breakdown of the biomass is needed. Some biomass, like agricultural stover, may not require optional chemical processing 14 since it may be sufficiently broken down with mechanical processing 12 alone. This optional chemical processing 14 may typically be done through a solvent treatment. During the optional chemical process 14, the biomass 10 can be further broken down after the mechanical processing 12. Typically, the optional chemical processing 14 can be performed in a solvent like ethanol. Besides ethanol, other organic solvents, acids, bases, or enzymes can be used for the optional chemical processing 14. However, the use of these acids, bases, or enzymes may lead to varying degrees of hydrolysis.
This optional chemical processing 14 can also undergo an optional extractables removal 52. This optional extractables removal 52 helps to remove any extractables from the biomass 10. Some of these extractables can include fats, oils, resins, pitches, and waxes present in different forms of biomass. Depending on the biomass source, the type and amount of these extractables can vary. The extractables do not have to be taken out, but their removal may allow for a purer end product with the production of biobased chemicals 40 in
After both mechanical processing 12 and optional chemical processing 14, the biomass fractionation 16 may be formed. The biomass fractionation 16 can then filtered to form the filtered biomass fractionation 20 if it was subjected to optional chemical processing 14. In this filtration after the mechanical and chemical processing, which is referred to as the first filtration 18, the optional chemical processing 14 can be partially removed from the biomass fractionation 16. For the first filtration 18, there are a series of steps where the biomass fractionation 16 may be filtered, then washed with additional chemical which is used in the optional chemical processing 14, typically ethanol or another alcohol, and then filtered again to remove some of the chemical from the optional chemical processing 14. After this wash and first filtration 18, typically about 50% of the chemical may be removed. The filtered biomass fractionation 20 may or may not contain some of the chemical from the optional chemical processing 14 step. From this step, either the filtered biomass fractionation 20 or the biomass fractionation 16 will be subjected to component separation processing 22 as detailed in
With reference now to
After the high pressure and temperature treatment, the treated biomass fractionation 42 may then be attained. Alternatively, the biomass fractionation 16 or filtered biomass fractionation 20 can also be broken down with other processes in the component separation processing 22 that may include at least one of kraft processing, sulfite pulping, pyrolysis, steam explosion, ammonia fiber explosion, dilute acid hydrolysis, alkaline hydrolysis, alkaline oxidative treatment, and enzymatic treatment. No matter what process is used within the component separation processing 22, the biomass can be broken down to the treated biomass fractionation 42 after the component separation processing 22 is completed. During the component separation processing 22, the hemicellulose component may hydrolyze the easiest whereas cellulose may be the most difficult to hydrolyze. This hydrolyzation can help to separate the component streams of the biomass. From this hydrolysis, a physical division of the component streams may occur.
From there, a second filtration 24 can be done on the treated biomass fractionation 42 in order to separate the cellulose 26 from the lignin and hemicellulose mixture 28. This second filtration 24 serves to remove the insoluble cellulose from the soluble lignin and hemicellulose mixture 28. Optionally, the insoluble cellulose can be washed with water or a chemical like aqueous ethanol and separated from the wash in the second filtration 24. The filtration leaves an aqueous mixture of hemicellulose sugars and solubilized lignin. The residual chemical(s) can be removed from this filtrate through concentration or distillation by applying a low to modest temperature and a minimal vacuum which may be sufficient to evaporate the chemical in the residual chemical removal 30 of
The flow diagrams depicted herein are provided merely as an example to clearly and concisely describe embodiments of a method within the scope of the present invention. Some steps may be skipped or modified, new steps may be added, existing steps may be deleted, or the order of steps may be altered from that shown in the flow diagram without departing from the scope of the present invention. It will be apparent to those skilled in the art that the above methods and apparatuses may incorporate changes and modifications without departing from the general scope of this invention. It is intended to include all such modifications and alterations in so far as they come within the scope of the appended claims or the equivalents thereof.
