METHOD OF MAKING A REACTION PRODUCT USING CARBON DIOXIDE PRODUCED IN A BIOPROCESSING PLANT, AND PLANT

Abstract

Systems and methods for making a reaction product using carbon dioxide produced at a bioprocessing facility. The bioprocessing facility involves fermenting a fermentable composition to generate at least one target biochemical and carbon dioxide. At least a portion of the carbon dioxide is reacted with at least one reactant to form at least one reaction product.

Description

1 / 34 “METHOD OF MAKING A REACTION PRODUCT USING CARBON DIOXIDE PRODUCED IN A BIOPROCESSING PLANT AND FACILITY” CROSS-REFERENCE ON RELATED REQUEST

[001] This application claims the benefit of the Non-Provisional Patent Application for Serial number US 18 / 124,972, filed on March 22, 2023, in which said non-provisional patent application is incorporated herein by reference in its entirety. BACKGROUND

[002] The present development relates to the use of carbon dioxide from fermentation in a bioprocessing facility.

[003] The bioprocessing of raw materials for the production of various bioproducts is an increasingly important source of products, including animal feed, food, fuels, pharmaceuticals, and other chemicals. There is a continuing need to utilize various outputs from a bioprocessing facility and / or reduce the carbon intensity of bioprocessing facilities. SUMMARY

[004] The present disclosure involves systems and methods for making a reaction product using carbon dioxide produced in a bioprocessing facility. The bioprocessing facility involves fermenting a fermentable composition to generate at least one target biochemical product and carbon dioxide. At least a portion of the carbon dioxide reacts with at least one reagent to form at least one reaction product.

[005] The present disclosure includes embodiments of a method for making a reaction product using carbon dioxide produced in a bioprocessing facility, wherein the method includes: to ferment a fermentable composition in a bioprocessing facility, in which the fermentation generates at least one biochemical target and Petition 870250078543, dated 03 / 09 / 2025, pp. 108 / 155 2 / 34 carbon dioxide; react at least one reactant and carbon dioxide to form at least one reaction product through an exothermic reaction, in which at least part of the carbon dioxide comes from fermentation; and use at least part of the thermal energy from the exothermic reaction in the bioprocessing facility.

[006] The present disclosure also includes modalities of an installation that includes: a bioprocessing facility that includes: a fermentation system configured to ferment a fermentable composition and generate at least one target biochemical product and carbon dioxide gas; and one or more systems configured to utilize thermal energy for one or more processes in the bioprocessing facility; A chemical production system that is co-located with a bioprocessing facility, wherein the chemical production system is in fluid communication with at least one power generation system to receive at least a portion of the carbon dioxide gas, wherein the chemical production system includes: a source of at least one reagent that can react with carbon dioxide gas through an exothermic reaction to produce at least one reaction product; and a reaction vessel configured to react at least one reagent and carbon dioxide to form at least one reaction product through an exothermic reaction, wherein the chemical production system is configured to transport thermal energy from the exothermic reaction, wherein the facility is configured to use at least a portion of the thermal energy to generate electricity for the bioprocessing facility and / or wherein the facility is configured to use at least Petition 870250078543, dated 03 / 09 / 2025, pages 109 / 155 3 / 34 a portion of the thermal energy in one or more systems in the bioprocessing facility, wherein the one or more systems are chosen from an evaporation system, a distillation system, a drying system, a power generation system, and combinations thereof. BRIEF DESCRIPTION OF THE DRAWINGS

[007] Several examples of the present disclosure will be discussed with reference to the accompanying drawings. These drawings represent only illustrative examples of the disclosure and should not be considered limiting of its scope: Figure 1A is a schematic showing an illustrative example of a facility and process for making a reaction product in a bioprocessing facility using green carbon dioxide and at least one reactant via an exothermic reaction and using at least a portion of the thermal energy from the exothermic reaction in the bioprocessing facility; Figure 1B is a diagram showing an illustrative example of oxygen supply from the electrolysis system to one or more combustion processes / systems shown in Figure 1A; Figure 2A is a diagram showing an illustrative example of a facility and process for producing ethanol in a corn ethanol bioprocessing plant; Figure 2B is a schematic showing an illustrative example of a facility and process for integrating the corn ethanol bioprocessing facility of Figure 2A with a chemical production system for the production of methane using green carbon dioxide and green hydrogen through an exothermic reaction and utilizing at least a portion of the thermal energy from the exothermic reaction in the corn ethanol bioprocessing facility; and Figure 2C is a diagram showing an illustrative example of oxygen supply from the electrolysis system to the combustion processes / systems shown in Figure 2B. DETAILED DESCRIPTION Petition 870250078543, dated 03 / 09 / 2025, pages 110 / 155 4 / 34

[008] The present disclosure relates to bioprocessing facilities. As used in this document, a bioprocessing facility refers to a facility that can produce one or more bioproducts by converting biomass feedstock through one or more physical processes, one or more chemical processes, one or more bioprocesses, and combinations thereof. Non-limiting examples of bioprocessing facilities include dry mills, wet mills, biofuel production facilities, pharmaceutical production facilities, soybean processing facilities, breweries, bakeries, and the like.

[009] A bioproduct refers to a product derived from a renewable biological resource. For example, a bioproduct may be a biomass feedstock component that is released from the biomass feedstock (e.g., corn oil from corn kernels) and / or may include a chemical (“biochemical” or “target biochemical”) that is produced by a biocatalyst (e.g., microorganism and / or enzyme), such as, for example, alcohol produced by yeast fermenting sugar. Non-limiting examples of bioproducts produced in a bioprocessing facility include one or more of the following: fuels, feed, food, pharmaceuticals, beverages, and precursor chemicals.In some embodiments, a bioproduct includes, among others, one or more monomeric sugars, one or more enzymes, one or more oils, one or more alcohols (e.g., ethanol, butanol and the like), fungal biomass, amino acids and one or more organic acids (e.g., lactic acid) and combinations thereof.

[010] In some embodiments, one or more bioprocesses are carried out in a bioprocessing facility that utilizes living cells (one or more microorganisms) and / or their components (e.g., enzymes produced by a microorganism) to obtain a desired bioproduct. Non-limiting examples of bioprocesses include one or more of hydrolysis (e.g., enzymatic hydrolysis), aerobic fermentation, or anaerobic fermentation. In some embodiments, a bioprocess includes saccharification and fermentation of a plant feedstock in a Petition 870250078543, dated 03 / 09 / 2025, p. 111 / 155 5 / 34 biofuel through enzymatic hydrolysis and yeast-based fermentation of the hydrolysate (e.g., a grain-to-ethanol biofuel plant).

[011] According to one aspect of the present disclosure, methods and systems are described for making a reaction product in a bioprocessing facility using green carbon dioxide and at least one reagent. Green carbon dioxide refers to carbon dioxide that is produced through, for example, fermentation using feedstocks that absorb carbon from the atmosphere, so that the green carbon dioxide contains recycled carbon, for example, from a gas in the air to carbon-based chemicals in plants and back to a gas as a product of the fermentation of plant material. Examples of bioprocessing facilities that produce green carbon dioxide include facilities that treat waste and facilities that produce fermented foods and beverages, animal feed, pharmaceuticals, enzymes, and biofuels using, for example, microorganisms such as bacteria and fungi.

[012] According to another aspect of the present disclosure, at least one reagent reacts with carbon dioxide produced in a bioprocessing facility to form at least one reaction product via an exothermic reaction, and at least a portion of the thermal energy of the exothermic reaction is used by the bioprocessing facility. A non-limiting embodiment of a facility and process for making a reaction product in a bioprocessing facility using green carbon dioxide and at least one reagent via an exothermic reaction and using at least a portion of the thermal energy of the exothermic reaction for the bioprocessing facility will be illustrated with reference to Figure 1A.

[013] As shown in Figure 1, the facility 100 includes a bioprocessing facility 105 with a primary system 110 that receives at least one raw material 112 and produces one or more bioproducts 114.

[014] The primary system 110 includes at least one fermentation system that is configured to ferment a fermentable composition (also called Petition 870250078543, dated 03 / 09 / 2025, page 112 / 155 6 / 34 as a fermentable wort) and generate at least one target biochemical product and carbon dioxide.

[015] Non-limiting examples of a material source to provide a fermentable composition include one or more of the following microorganisms, enzymes, carbon sources (e.g., feedstock), aqueous compositions (e.g., freshwater, backset, etc.), nutrient sources (e.g., feedstock), etc. In some embodiments, a feedstock may function as a carbon source and / or a nutrient source and may be used to form a fermentable composition. A feedstock may include one or more components that are used by a microorganism to produce one or more bioproducts through a bioprocess. Non-limiting examples of feedstocks may be derived from biomass (e.g., plant) and may include, for example, monosaccharides such as glucose and fructose, disaccharides such as sucrose and lactose, and more complex polysaccharides such as starch, cellulose, hemicellulose, and pectin.These biomass-derived raw materials can come from seeds, sap, stems, and leaves of plants. A wide variety of plant raw materials can be used according to the present disclosure, such as sugar beet, sugarcane, grains, legumes, crop residues (e.g., husks, stems, corn remains, sugarcane bagasse, wheat straw), grasses, and woody plants. In some embodiments, the raw material may be derived from corn, sorghum, wheat, rice, barley, soybeans, rapeseed, oats, millet, rye, corn straw, straw, bagasse, and the like. In some embodiments, a raw material may include ground whole grains (e.g., corn flour) formed through a dry milling process, for example. In some embodiments, a biomass feedstock may include one or more cellulosic polysaccharides (e.g., corn grain fiber, crop residues, wood, municipal waste, etc.), and combinations thereof.

[016] In some embodiments, a primary system 110 may include one or more feedstock systems for processing feedstock in a manner to Petition 870250078543, dated 03 / 09 / 2025, pp. 113 / 155 7 / 34 another before fermentation. For example, a feedstock system may include one or more size reduction devices to reduce the size of the feedstock, such as grains, and / or to further reduce the size of milled grain that has been previously reduced in size. Methods for reducing the size of the feedstock, for example, corn and / or previously milled corn, into fine particles before fermentation include dry methods, such as passing corn through one or more hammer mills, ball mills and / or roller mills, or wet methods, such as passing a fluid paste of milled grains through one or more mills, such as a disc mill, roller mill, colloid mill, ball mill or other type of grinding device.

[017] In some embodiments, a ground raw material may be mixed with an appropriate amount of water (e.g., in a fluid paste tank) to form at least a portion of a fermentable composition (sometimes called wort). In some embodiments, whole ground corn may be mixed with liquid at about 20 to about 50% by weight or about 25 to about 45% by weight of dry whole ground corn based on the total weight of the fluid paste. Whole ground corn may include starch, fiber, protein, oil, endogenous enzymes, amino acids, etc.

[018] One or more exogenous microorganisms may be present in the fermentable composition of a fermentation system for producing beer that includes at least one or more biochemical byproducts. Secondary fermentation by a microorganism may produce biomass (e.g., single-cell protein (SCP)), extracellular metabolites (e.g., alcohol such as ethanol), intracellular metabolites (e.g., enzymes), and combinations thereof. Non-limiting examples of such microorganisms include one or more ethanologens, butanologens, and the like. Exemplary microorganisms include one or more yeasts, algae, or bacteria. For example, yeast can be used to convert sugars into an alcohol, such as ethanol. Suitable yeast includes any commercially available yeast variety, such as commercial strains of Petition 870250078543, dated 03 / 09 / 2025, pages 114 / 155 8 / 34 Saccharomyces cerevisiae.

[019] Optionally, one or more additional exogenous materials may be used in a fermentable composition. Non-limiting examples of such materials include one or more of the following enzymes, phosphate, citric acid, ionic additives and the like.

[020] A fermentation system may include one or more vessels that are adapted to expose a fermentable composition to conditions suitable for converting sugars, such as glucose, into one or more bioproducts. As used herein, a “vessel” refers to any container that allows a bioproduct to be formed from a microorganism through fermentation. In some embodiments, a vessel may refer to a bioreactor adapted or configured to expose a fermentable composition to fermentation conditions. Non-limiting examples of vessels that may expose a fermentable composition to fermentation conditions include fermenters, brewing wells, and the like. Two or more vessels may be arranged in any desired configuration, such as parallel or in series.

[021] A fermentation system is set up to expose the fermentable composition to fermentation conditions so that one or more microorganisms can convert one or more components in the fermentable composition, such as sugars, into a beer that includes one or more target byproducts. Fermentation conditions include one or more conditions such as pH, time, temperature, aeration, agitation, and the like.

[022] The pH of a fermentable composition may be at a pH that helps a microorganism produce one or more target bioproducts in a desired quantity. In some embodiments, the pH is greater than 3.5, for example, from 3.5 to 7, from 3.5 to 5.5, or even from 3.5 to 4.5. Techniques for adjusting and maintaining the pH include, for example, adding one or more acidic materials and / or adding one or more basic materials.

[023] With regard to temperature and time, the content of a Petition 870250078543, dated 03 / 09 / 2025, pp. 115 / 155 9 / 34 A fermentable composition can be maintained at a temperature for a period of time that helps a microorganism produce one or more target bioproducts in a desired quantity. In some embodiments, the temperature of a fermentable composition may be in a range of 20 °C to 45 °F, 25 °C to 40 °C, or even 30 °C to 40 °C. In some embodiments, primary fermentation may occur over a period of up to 72 hours, for example, from 1 hour to 48 hours, from 2 hours to 48 hours, or even from 10 hours to 30 hours.

[024] Fermentation can be carried out under anaerobic and / or aerobic conditions. For example, fermentation can be carried out under aerobic conditions during at least a portion of the fermentation and carried out under anaerobic conditions for another portion of the fermentation. Alternatively, the entire fermentation can be carried out under anaerobic or aerobic conditions. Anaerobic or aerobic conditions are selected based on the microorganism and the “target” biochemical(s) chosen to be produced by a microorganism, even though there may be minimal amounts of “non-target” biochemicals that are also produced by the microorganism. Anaerobic conditions mean that the fermentation process is conducted without any intentional introduction of oxygen-containing gases, such as equipment like blowers, compressors, etc., that could operate to create a suitable aerobic environment for aerobic fermentation.It is observed that, although simply stirring a fermentable composition to maintain the reactor contents homogeneous may or may not introduce a minimal amount of an oxygen-containing gas, such as air, in some embodiments, stirring alone may not create conditions that would be considered aerobic conditions, as used in this document. However, if desired, the contents of a fermenter can be mixed using appropriate equipment so that sufficient oxygen is introduced throughout the fermentable composition to create a suitable aerobic environment for aerobic fermentation (see below).

[025] Aerobic conditions means that fermentation is carried out with Petition 870250078543, dated 03 / 09 / 2025, pages 116 / 155 10 / 34 Intentional introduction of one or more oxygen-containing gases (“aeration”) to create a suitable aerobic environment for aerobic fermentation, so that oxygen can be consumed by one or more microorganisms and, for example, in the case of yeasts, selectively favor the production of enzymes via an aerobic metabolic pathway compared to an anaerobic pathway that favors the production of biochemical products (e.g., alcohol, organic acids, and the like). A fermentation system may incorporate aeration including one or more blowers, sprayers, gas compressors, mixing devices, and the like, which are in fluid communication with one or more fermentation vessels and which may introduce an oxygen-containing gas (e.g., air) into a fermentable composition during at least a portion of the fermentation.For example, a gas containing oxygen can be sprayed into a fermentable composition so that the gas bubbles through the fermentable composition and oxygen is transferred to the fermentable composition. As another example, a gas containing oxygen can be introduced into the empty space of a fermenter so that the gas diffuses into the fermentable composition.

[026] Optionally, in addition to aeration, a fermentable composition can be agitated or mixed to facilitate the transfer of oxygen into and through the fermentable composition, so as to achieve an aerobic environment. For example, a continuous stirred tank reactor (CSTR) can be used to agitate or mix the fermentable composition. The speed of the agitation mechanism (rpms) can be adjusted based on a variety of factors, such as tank size, fluid paste viscosity, and the like. As mentioned above, in addition to mixing the contents of a composition, the mixing can be selected, if desired, to intentionally incorporate oxygen into a fermentable composition to facilitate aerobic fermentation.

[027] A fermentation system can be operated according to batch fermentation, fed-batch fermentation or continuous fermentation (continuous feeding and discharge from a vessel, such as a fermenter). Petition 870250078543, dated 03 / 09 / 2025, pages 117 / 155 11 / 34

[028] Furthermore, a fermentation system according to the present disclosure may conduct sequential or simultaneous fermentation in relation to a polysaccharide hydrolysis / saccharification process (e.g., jet cooking and / or enzymatic hydrolysis). Saccharification and fermentation may occur simultaneously in accordance with what is known as “simultaneous saccharification and fermentation” (“SSF”). Sequential hydrolysis and fermentation may also be referred to as separate hydrolysis and fermentation (SHF).

[029] An example of an SSF process involves the formation of a fluid paste that includes a starch-containing grain, such as corn. The fluid paste can be combined with a microorganism to form a fermentable composition such that at least a portion of the starch in the fermentable composition is hydrolyzed by one or more enzymes to produce monosaccharides. As the monosaccharides are produced, they can be metabolized by a microorganism into a target biochemical product. For example, the sugar (glucose, xylose, mannose, arabinose, etc.) that is generated from saccharification can be fermented into one or more biochemical products (e.g., butanol, ethanol, and the like).

[030] Alternatively, an SHF process may include a dedicated saccharification process that is separate from a fermentation process (in the same vessel or in a separate vessel). For example, after forming an aqueous fluid slurry that includes the biomass feedstock (e.g., corn material from a milling system), the aqueous fluid slurry may be subjected to saccharification in one or more fluid slurry tanks to break down (hydrolyze) at least a portion of the polysaccharides, e.g., starch, cellulose, hemicellulose, etc., into oligosaccharides and / or monosaccharides (e.g., glucose, xylose, mannose, arabinose, etc.) that can be used by microorganisms (e.g., yeast) in a subsequent fermentation process.

[031] Saccharification can be carried out by various mechanisms. For example, heat and / or one or more enzymes can be used to form one or more Petition 870250078543, dated 03 / 09 / 2025, pages 118 / 155 12 / 34 monosaccharides by saccharification of one or more oligosaccharides and / or one or more polysaccharides that are present in a polysaccharide such as starch. In some embodiments, a relatively low temperature saccharification process (whether used in SSF or SHF) involves enzymatically hydrolyzing at least a portion of starch into an aqueous fluid paste at a temperature below the starch gelatinization temperatures, so that saccharification occurs directly from the raw native insoluble starch to soluble glucose, bypassing the conventional starch gelatinization conditions, which are typically in the range of 57 °C to 93 °C, depending on the starch source and polysaccharide type.In some embodiments, saccharification involves the use of one or more enzymes (e.g., alpha-amylases and / or glucoamylases) to enzymatically hydrolyze at least a portion of the starch in the aqueous fluid paste at a temperature of 40 °C or less to produce a fluid paste that includes glucose. In some embodiments, enzymatic hydrolysis occurs at a temperature in the range of 25 °C to 35 °C to produce a fluid paste that includes glucose. Non-limiting examples of conversion of raw starch to glucose are described in Patents Serial Numbers 7,842,484 (Lewis), 7,919,289 (Lewis), 7,919,291 (Lewis et al.), 8,409,639 (Lewis et al.). 8,409,640 (Lewis et al.), 8,497,082 (Lewis), 8,597,919 (Lewis), 8,748,141 (Lewis et al.), 2014-0283226 (Lewis et al.) and 2018-0235167 (Lewis et al.), wherein the entirety of each patent document is incorporated herein by reference.

[032] The primary system 110 may also include one or more systems downstream of fermentation. For example, after fermentation, one or more byproducts may be separated from the beer to form at least one target byproduct stream (e.g., ethanol) and one or more byproduct streams (e.g., whole vinasse). A byproduct stream may encompass any vinasse composition downstream of fermentation. As used in this document, a vinasse composition may include whole vinasse, at least one vinasse composition derived from whole vinasse, and combinations thereof. Non-limiting examples of Petition 870250078543, dated 03 / 09 / 2025, pages 119 / 155 13 / 34 A composition of vinasse derived from whole vinasse includes fine vinasse, concentrated fine vinasse (syrup), defatted syrup, defatted emulsion, clarified fine vinasse, distiller's oil, distiller's grain, distillery yeast and the like. Non-limiting examples of defatted vinasse compositions include one or more defatted streams derived from fine vinasse, such as defatted syrup, defatted emulsion and the like.

[033] A separation system can separate a byproduct from beer using one or more of the following: distillation, evaporation, separation based on particle size (e.g., filtration) or separation based on density (e.g., centrifugation).In some embodiments, a separation system may include one or more centrifuges (e.g., two-phase vertical disc stack centrifuge, three-phase vertical disc stack centrifuge, filtration centrifuge), one or more decanters (e.g., filtration decanters), one or more filters (e.g., fiber filter, rotary vacuum drum filter, filter device with one or more membrane filters), one or more screens (e.g., a DSM screen, which refers to a Dutch State Mines screen or folded sieve screen, and is a type of bar, wedge, concave, and curved stationary screen; a pressure screen;Various separation systems can be used together and arranged in a parallel and / or series configuration.

[034] Depending on the separation system selected, one or more process inlet streams can be separated into two or more outlet streams to produce an outlet stream with a higher amount of solids compared to other outlet streams. If desired, a separation system may include one or more evaporators and / or one or more dryers to further concentrate an outlet stream from any of the devices. Petition 870250078543, dated 03 / 09 / 2025, pages 120 / 155 14 / 34 mentioned.

[035] As shown in Figure 1A, a power system 130 is represented in the bioprocessing facility 105. The power system 130 represents the various power generation systems within the bioprocessing facility 105. As explained below, a power generation system may be part of a larger system in the primary system 110 or may be a stand-alone power generation system within the bioprocessing facility 105.

[036] In more detail, in some embodiments, one or more power generating systems of the power system 130 may be physically integrated and dedicated to a system within the primary system 110. For example, a drying system of the primary system 110 may be configured to generate thermal energy using a combustion system as a power generating system within the drying system to form a hot gas to be used in the drying system. As another example, a regenerative thermal oxidizer of the primary system 110 may be configured to generate thermal energy using a combustion system as a power generating system within the regenerative thermal oxidizer to form a hot gas to be used in the regenerative thermal oxidizer.

[037] In some embodiments, one or more power generating systems of the energy system 130 may be integrated with one or more systems of the primary system 110 within the bioprocessing facility 105, but are physically separated from one or more systems of the primary system 110 as a distinct power generating system. For example, a steam boiler system may be configured to generate steam using a combustion system as a power generating system, where the steam boiler system is physically separated from an evaporator system and / or distillation system. The steam may be transported to an evaporation system and / or distillation system via a piping system within the bioprocessing facility 105.

[038] One or more power generating systems of the energy system 130 Petition 870250078543, dated 03 / 09 / 2025, pages 121 / 155 15 / 34 can operate independently of other power generating systems of energy system 130 or can be integrated with other power generating systems of energy system 130 to control the total energy generated by energy system 130.

[039] In some embodiments, the energy system 130 can generate electricity (electrical energy) using a power generation system such as a power generation system. A power generation system can generate electricity using one or more wind, solar, hydroelectric, steam, and combinations thereof.

[040] Steam-generated energy can generate electrical energy using a steam turbine system that receives steam from a steam boiler system. In some embodiments, a steam boiler system can create steam at a temperature and pressure suitable for a steam turbine system through combustion of one or more fuels 132 and one or more oxidizers 133, which produces thermal energy and a gaseous exhaust (exhaust gas) 134 (the combustion processes in the energy system 130 are discussed further below). Non-limiting examples of suitable inlet pressures and temperatures for generating electricity in a steam turbine system are described below in connection with a steam boiler system.

[041] Non-limiting examples of steam turbine systems include condensing turbine systems, non-condensing turbine systems, reheat turbine systems, extraction turbine systems and combinations thereof.

[042] In addition to producing electricity, in some embodiments, the energy system 130 may also include at least one thermal power generation system to generate heat for use in one or more process streams and / or one or more systems in the primary system 110. The heat generated may be present in a liquid or gaseous medium and be used to heat one or more process streams in the bioprocessing facility 150. A thermal power generation system may Petition 870250078543, dated 03 / 09 / 2025, pages 122 / 155 16 / 34 generate heat via solar heat or heat from combustion. For example, a thermal power generation system may produce thermal energy by combustion of one or more fuels 132 and one or more oxidants 133, which produces thermal energy (heat) 136 and a gaseous exhaust (combustion gas) 134.

[043] Fuels may include solid fuel, liquid fuel, gaseous fuel, and combinations thereof. Non-limiting examples of solid fuel include coal, renewable fuel, and combinations thereof. Non-limiting examples of renewable solid fuel include biomass material such as wood, agricultural residues (e.g., corn straw), and combinations thereof. Liquid fuel may include fossil fuel, renewable fuel, and combinations thereof. Non-limiting examples of liquid fuel include gasoline, oil, ethanol, butanol, and the like. Gaseous fuel may include fossil fuel, renewable fuel, and combinations thereof. Non-limiting examples of gaseous fuel include natural gas, propane, methane, and the like.

[044] Oxidizers have a relatively high oxidation potential. Non-limiting examples of gaseous oxidants include atmospheric oxygen, concentrated oxygen, and combinations thereof. Atmospheric oxygen is a component of atmospheric air, which includes about 78% nitrogen, 21% oxygen, and about 1% argon. Concentrated oxygen can be supplied from a variety of sources that have a variety of oxygen concentrations, an example of which is discussed below in relation to Figures 1B and 2C.

[045] Combustion can produce a flue gas with a composition that depends on the fuel, the oxidant, and the combustion conditions (e.g., temperature and amount of oxidant). For example, the fuel-to-oxidant ratio can be selected to facilitate complete combustion. When a hydrocarbon such as methane burns in oxygen, the reaction will primarily produce carbon dioxide gas and water. Trace elements that may be present can also react to form common oxides, such as carbon dioxide. Petition 870250078543, dated 03 / 09 / 2025, pages 123 / 155 17 / 34 Sulfur, iron(III) oxide and similar substances. If atmospheric air is used as the source for the oxidizing oxygen, nitrogen is generally not considered a combustible substance.

[046] As mentioned above, in some embodiments, one or more power generating systems of the power system 130 may be physically integrated and dedicated to a system within the primary system 110. Non-limiting examples of such thermal power generation systems configured to generate thermal energy include at least one drying system, at least one regenerative thermal oxidizer, and combinations thereof. In more detail, for example, a drying system (e.g., a ring drying system) may use combustion to form a hot combustion gas that comes into direct contact with and heats a distillery residue stream to remove moisture from suspended solids (e.g., fiber and / or protein) to make, for example, dried distillers grains with solubles (DDGS) and / or a high-protein product.

[047] As mentioned above, in some embodiments, one or more power generating systems of the energy system 130 may be integrated with one or more systems of the primary system 110 within the bioprocessing facility 105, but are physically separated from one or more systems as distinct power generating systems. Non-limiting examples of such systems in the primary system 110 that may receive and use thermal energy from one or more power generating systems in the energy system 130 include an evaporator system, a distillation system, and combinations thereof. For example, a steam boiler system may be configured to generate steam that is transported to an evaporation system and / or a distillation system via piping within the bioprocessing facility 105.For illustrative purposes, in the context of a corn ethanol bioprocessing plant, a distillation system (not shown) might use steam to indirectly heat the fermenting beer in a heat exchanger and distill ethanol from the fermenting beer. As another example, an evaporator system (not shown) might use steam in a heat exchanger to... Petition 870250078543, dated 03 / 09 / 2025, pages 124 / 155 18 / 34 Indirectly heat a final vinasse stream (e.g., fine vinasse or a composition derived from fine vinasse) to remove water and concentrate the vinasse stream.

[048] For illustrative purposes, additional non-limiting examples of process flows and systems in a corn grain ethanol plant that can be heated (e.g., indirectly or directly via a heated gas or liquid) using thermal energy 112 from the power generating system 105 include input flows, such as a fluid paste. For example, a fluid interface paste can be exposed to a high-temperature cooking process for starch.

[049] As mentioned above, a steam boiler system is an example of a thermal power generation system that can create heat through combustion so that the heat can be used to form steam, which can be used to generate electricity and / or process heat streams. A steam boiler system heats water to generate pressurized steam that can be transported through a piping system to one or more points of use in the bioprocessing facility 105. In some embodiments, a steam boiler system generates steam suitable for generating electricity using a steam turbine system (discussed above). Non-limiting examples of a steam inlet pressure suitable for generating electrical power 111 in a steam turbine system include a pressure in the range of 200 pounds per square inch (psig) to 2000 psig, 250 psig to 1000 psig, or even 300 psig to 600 psig.Non-limiting examples of a suitable steam inlet temperature for generating electrical energy 111 in a steam turbine system include a temperature in the range of 200 °C to 300 °C, or even 215 °C to 255 °C.

[050] In some embodiments, a steam boiler system generates steam suitable for process steam (e.g., in an evaporation system and / or distillation system). Non-limiting examples of a steam inlet pressure suitable for generating electricity in a steam turbine system include a Petition 870250078543, dated 03 / 09 / 2025, pages 125 / 155 19 / 34 pressure in the range of 50 psig to 200 psig, or even 100 psig to 125 psig. Non-limiting examples of a suitable steam inlet temperature for generating electrical energy 111 in a steam turbine system include a temperature in the range of 200 °C to 300 °C, or even 215 °C to 255 °C. In some embodiments, the steam escaping from a steam turbine system (e.g., non-condensing turbine system) is controlled by a regulating valve so that the steam is at a temperature and pressure that allows the steam escaping from the steam turbine system to be used as “process” steam for, for example, an evaporator system and / or a distillation system.

[051] As shown in Figure 1A, stream 116 of the gaseous composition produced by fermentation in the bioprocessing plant 105 can be transferred to the reaction system 155 in the chemical production system / plant 150, where the carbon dioxide in the gaseous composition can be used as a reagent (discussed below). Fermentation in the primary system 110 can produce a gaseous composition with a relatively high concentration of carbon dioxide. Advantageously, in some embodiments, a relatively concentrated carbon dioxide gaseous composition can be supplied directly to a reaction system 155 in the chemical production system 150 with little or no purification required. In some embodiments, the gaseous composition produced by fermentation has a carbon dioxide concentration of at least 90% by weight on a dry basis, at least 95% by weight on a dry basis, at least 99% by weight on a dry basis, or even at least 99.9% by weight on a dry basis.

[052] Optionally, in some embodiments, it may be desirable to remove one or more non-carbon dioxide components from the gas composition produced by fermentation before using it as a reagent in the chemical production system 150. Non-limiting examples of such non-carbon dioxide related components include sulfur, oxygen, nitrogen, alcohol (e.g., ethanol), acetaldehyde, solid particles, oil, and combinations thereof. One or more non-carbon dioxide related components may be removed from the gas composition in Petition 870250078543, dated 03 / 09 / 2025, pages 126 / 155 20 / 34 flow 116 through an amine purification system, a pressure swing adsorption system, a cryogenic distillation system, a membrane separation system, filtration, fixed bed adsorption (e.g. using activated carbon) and combinations thereof.

[053] As mentioned above, according to one aspect of the present disclosure, at least one reagent can react with carbon dioxide to produce at least one reaction product via an exothermic reaction, and at least a portion of the thermal energy 161 from the exothermic reaction can be used in the bioprocessing facility 150. In some embodiments, at least a portion of the thermal energy 161 can offset at least a portion of the thermal energy generated using fuel in a thermal energy generation system of the energy system 130.

[054] In some embodiments, as shown in Figure 1A, the chemical production system 150 is located in the physical vicinity of the bioprocessing facility 150 (on-site). Colocalization of the chemical production system 150 with the bioprocessing facility 105 allows the chemical production system 150 and the bioprocessing facility 105 to be integrated with each other, so that one or more process streams can be readily shared between the chemical production system 150 and the bioprocessing facility 105. For example, materials produced in the chemical production system 150 (e.g., oxygen, steam, and the like) can be readily transported to (e.g., via insulated piping) and shared with the bioprocessing facility 105.Similarly, materials produced in the bioprocessing facility 105 (e.g., carbon dioxide and similar substances) can be readily transported to (e.g., via piping) and shared with the chemical production system 150.

[055] Chemical production system 150 includes a reaction system 155 configured to react at least one reactant and carbon dioxide to form at least one reaction product via an exothermic reaction. The system of Petition 870250078543, dated 03 / 09 / 2025, pages 127 / 155 21 / 34 reaction 155 includes one or more reaction vessels in fluid communication with one or more fermentation systems in the primary system 110 of the bioprocessing facility 150 to receive at least a portion of the carbon dioxide 116 produced in the fermentation. One or more reaction vessels in the reaction system 155 are also in fluid communication with a stream 157 that includes at least one reactant that can react with carbon dioxide via an exothermic reaction to produce a product stream 159 that includes at least one reaction product.

[056] A wide variety of chemical production processes can be included in a chemical production system 150 that is colocated with the bioprocessing facility 105 to directly or indirectly use the carbon dioxide gas produced by fermentation for chemical synthesis. Non-limiting examples of chemicals that can be synthesized in the chemical production system 150 using carbon dioxide as a reagent include methane, methanol, formate, formic acid, ethanol, ethylene, propylene, sustainable aviation fuel (SAF), and combinations thereof. The reagent 157 can be selected to react with carbon dioxide and produce the desired reaction product 159 via an exothermic reaction. The physical state of the reagent 157 can also be selected as desired. For example, the reagent can be solid, liquid, or gaseous. Non-limiting examples of reagents 157 include hydrogen gas.

[057] The reactants can be exposed to reaction conditions suitable for chemical synthesis in reaction system 155. The reaction conditions may depend on the reaction scheme selected. For example, carbon dioxide and hydrogen can be mixed and then exposed to reaction conditions to form methane (e.g., via the Sabatier reaction). In some embodiments, carbon dioxide and hydrogen can be exposed to one or more catalysts at a temperature in the range of 200 °C to 550 °C and a pressure of 1 to 100 bar. The catalyst can be disposed of in a variety of reactors, such as an adiabatic bed reactor, a fluidized bed reactor, a fixed bed reactor, and the like. Examples Petition 870250078543, dated 03 / 09 / 2025, pages 128 / 155 22 / 34 non-limiting suitable catalysts can be based on Ni, Ru, Rh, CO as active phases.

[058] In some embodiments, one or more of the reaction products 159 mentioned above may be chemical intermediates for the production of other end-product chemicals in the facility 100, for example, in subsequent reactions and / or processes in the facility 100 (for example, in the bioprocessing facility 105 and / or chemical production system 150). In some embodiments, the reaction product 159 may be produced by means of a series of reactions in the chemical production system 150. A non-limiting example of such a reaction product is sustainable aviation fuel (SAF), which may be produced from a chain of several unit operations, including reverse water-gas exchange (RWGS), Fischer-Tropsch (FT), hydrotreating, hydrocracking, and fractionation.

[059] In some embodiments, one or more of the reaction products 159 mentioned above may be end products produced at facility 100 and may, for example, be transported from facility 100 (off-site). For example, the end products may be transported via a pipeline and / or transferred to one or more storage containers for transport by truck, railcar, etc.

[060] According to one aspect of the present disclosure, in some embodiments, at least a portion of the energy 161 from one or more exothermic reactions in the chemical production system 150 can be used to supply heat and / or energy (electricity) to one or more systems or processes in the bioprocessing facility 105. The chemical production system 150 is configured to transport at least a portion of the thermal energy 161 from the exothermic reaction in the reaction system 155 to the bioprocessing facility 105.

[061] Furthermore, if desired, at least part of the energy 161 from one or more exothermic reactions in the chemical production system 150 may be used to supply heat and / or energy to one or more systems or processes in the installation 100 Petition 870250078543, dated 03 / 09 / 2025, pages 129 / 155 23 / 34 that are not part of the bioprocessing facility 105, such as the chemical production system 150. For example, at least part of the energy 161 from one or more exothermic reactions in the chemical production system 150 can be used to heat liquid water which can be used to form steam for a solid oxide electrolyzer which can be used in the electrolysis system 170 (discussed below).

[062] As mentioned, at least part of the energy from an exothermic reaction in reaction system 155 can be used in a power generation system to generate electricity. For illustrative purposes, a non-limiting example of using energy from an exothermic reaction to produce energy for the bioprocessing facility 105 includes the formation of steam and then using that steam to generate electricity in a steam turbine system. The steam turbine system may be one that is already present in the bioprocessing facility 105 and as part of the power system 130, and / or the steam turbine system may be part of another area of ​​the facility 100, such as the chemical production system 150.

[063] In some embodiments, reaction system 155 may include one or more reaction vessels that function as a heat exchanger to transfer heat from the exothermic reaction to a heat transfer fluid that is isolated from reactants and reaction product or products. Non-limiting examples of a heat exchanger that may be used as a reaction vessel in reaction system 155 include a shell-and-tube heat exchanger.

[064] A shell-and-tube heat exchanger has a shell-and-tube arrangement, where a plurality of tubes are arranged within the shell. The tubes (also called tube side) may be packed with catalyst to facilitate the reaction between carbon dioxide and at least one reactant. The shell may have an internal space around the tubes (also known as shell side), where the internal space may be filled with heat transfer fluid to extract heat from the exothermic reaction within the tubes and transfer the heat to the bioprocessing facility 105. The shell may have an inlet and outlet to receive heat transfer fluid and discharge heat transfer fluid. Petition 870250078543, dated 03 / 09 / 2025, pages 130 / 155 24 / 34 which absorbed the energy from the exothermic reaction. In some embodiments, the heat transfer fluid may include water. For example, liquid water may be introduced into the shell side of a shell-and-tube reaction vessel at a temperature and pressure to facilitate heat transfer from the tube side to the shell-side water and form steam that can be transferred for use in the bioprocessing facility 105. In some embodiments, liquid water may be introduced into a reaction vessel at a pressure of 10 pounds per square inch (psig) to 1,000 psig and a temperature in the range of 38 °C to 285 °C. The exothermic reaction on the tube side may generate thermal energy that is transferred to the liquid water so that the liquid water changes phase to vapor.The steam produced may be at a suitable temperature and pressure to generate electricity by means of a steam turbine (discussed above) and / or as process steam, for example, for an evaporator system and / or a distillation system (discussed above). In some embodiments, the steam from reaction system 155 may be at a pressure in the range of 10 psig to 1,000 psig and a temperature in the range of 115 °C to 285 °C. If desired, the temperature and / or pressure of the steam may be regulated depending on how it will be used.

[065] As also mentioned, at least a portion of the energy from an exothermic reaction in reaction system 155 can be used to heat one or more process streams in one or more systems of the bioprocessing facility 105, in addition to or instead of generating electricity. For illustrative purposes, a non-limiting example of using energy from an exothermic reaction to heat one or more process streams in the bioprocessing facility 105 includes the formation of steam and then using that steam to heat a particular process stream, for example, via indirect heating. One or more process streams in the bioprocessing facility 105 can be heated by means of one or more systems in the bioprocessing facility 105, but using at least a portion of the thermal energy from reaction system 155 instead of receiving all the thermal energy from a thermal power generation system in power system 130. Petition 870250078543, dated 03 / 09 / 2025, pages 131 / 155 25 / 34 Non-limiting examples of systems in the primary system 110 that may receive thermal energy from the reaction system 155 (instead of or in addition to the energy system 130 of the bioprocessing facility 105) include an evaporator system, a distillation system, a drying system, and combinations thereof.

[066] Steam can be formed in reaction system 155 by means of a heat exchanger, as discussed above. The steam can be supplied at a temperature and pressure to facilitate the heating of a process stream. In some embodiments, the steam can be supplied under the same or similar conditions to the boiler steam discussed above in connection with a thermal power generation system in energy system 130. As mentioned above, in some embodiments, the steam generated in reaction system 155 can replace part or all of the boiler steam generated by one or more thermal power generation systems in energy system 130 of the bioprocessing facility 105. In some embodiments, the steam from reaction system 155 can be supplied to these systems at a temperature and pressure discussed above.

[067] In some embodiments, the reaction system 155 can produce relatively high pressure steam, which can be used by a steam turbine system to generate electricity for the bioprocessing facility 105. The steam pressure can drop after being used to drive the turbines in a steam turbine system, which can be a low pressure steam equal to or similar to the pressure of the boiler steam used as process steam.

[068] A chemical production system according to the present disclosure may obtain one or more reagents from a variety of sources. For example, one or more reagents may be obtained from a commercial supplier and may be transported to the chemical production system 150. As another example, one or more reagents may be produced on-site by the chemical production system 150. A non-limiting example of the production of a reagent in a chemical production system is illustrated in Figure 1A. As shown in Figure 1A, a stream 157 of hydrogen may be produced by means of an electrolysis system 170. The system Petition 870250078543, dated 03 / 09 / 2025, pages 132 / 155 Electrolysis 26 / 34 at 170°C is configured to form hydrogen and oxygen from water.

[069] Water electrolysis (also known as water splitting) is a process using electricity to decompose liquid water into oxygen gas and hydrogen gas. The process uses an electrical power source that is applied to an electrolyzer that includes an anode and a cathode separated by an electrolytic material. Hydrogen gas is formed at the cathode and oxygen gas at the anode. Non-limiting examples of suitable electrolyzers include polymer electrolyte membrane (PEM) electrolyzers, alkaline electrolyzers, and solid oxide electrolyzers.

[070] In a PEM electrolyzer, the electrolyte includes a solid plastic material. Liquid water is introduced into the PEM electrolyzer, where the water reacts at the anode to form oxygen and positively charged hydrogen ions. Hydrogen ions flow selectively through the PEM membrane to the cathode, and electrons flow through an external circuit. Hydrogen ions combine with electrons at the cathode to form hydrogen gas. PEM electrolysis systems can operate at temperatures in the range of 50 °C–90 °C (122 °F–194 °F) and at pressures up to 435 psig.

[071] In an alkaline electrolyzer, hydroxide ions pass through the electrolyte from the cathode to the anode, while hydrogen gas is produced at the cathode. The electrolyte can be a solid or liquid material. An example of a liquid material includes an alkaline solution of metal hydroxide, such as sodium hydroxide or potassium hydroxide.

[072] In a solid oxide electrolyzer, the electrolyte is a solid ceramic material and selectively conducts oxygen ions at an elevated temperature. Liquid water is used to form steam. The steam present at the cathode combines with electrons to form hydrogen gas and negatively charged oxygen ions that pass through the solid ceramic electrolyte and react at the anode to form oxygen gas.

[073] As shown in Figure 1A, a supply 174 of liquid water is provided to the electrolysis system 170 for conversion of liquid water into gas. Petition 870250078543, dated 03 / 09 / 2025, pages 133 / 155 27 / 34 hydrogen and oxygen gas. A variety of water sources can be used as a supply 174. Depending on the water source, the water can be filtered and / or deionized to remove particles, minerals and the like, for example, to meet an ASTM Type II water specification with a conductivity of less than 1 μS / cm, or an ASTM Type I water specification with a conductivity of less than 0.056 μS / cm.

[074] As described above, an electrolyzer is configured to produce a hydrogen gas stream separate from the oxygen gas stream. With reference to Figure 1A, the electrolysis system 170 is in fluid communication with a reaction vessel in the reaction system 155 to transport a hydrogen gas stream 157 to the reaction vessel to react with the carbon dioxide gas supplied by stream 116 and form at least one reaction product via the exothermic reaction. The gas composition in stream 157 may be relatively concentrated in hydrogen. In some embodiments, the gas composition discharged from the electrolysis system via stream 157 has a hydrogen concentration of at least 95% by weight on a dry basis, at least 99% by weight on a dry basis, at least 99.9% by weight on a dry basis, at least 99.99% by weight on a dry basis, or even at least 99.999% by weight on a dry basis.The gas composition comprising oxygen can be discharged from the electrolysis system 170 via stream 176. The gas composition in stream 176 can be relatively concentrated in oxygen. In some embodiments, the gas composition discharged from the electrolysis system has an oxygen concentration of at least 90% by weight on a dry basis, at least 95% by weight on a dry basis, or even at least 99% by weight on a dry basis. The concentrated oxygen gas stream 176 can be used as desired. In some embodiments, it can be used as an oxygen source for combustion (see Figure 1B discussion below).

[075] In some embodiments, for example, depending on the electrolyzer used, the oxygen and / or hydrogen produced in the electrolysis system 170 can be further processed (e.g., purified, heated, compressed and / or Petition 870250078543, dated 03 / 09 / 2025, pages 134 / 155 28 / 34 similar), if desired. For example, hydrogen can be treated to remove any residual oxygen, for example, by means of a deoxo process which is a catalytic purification process. In some embodiments, oxygen can be supplied directly to a combustion process and / or hydrogen can be supplied directly to the reaction system.

[076] With reference to Figure 1A, one or more energy sources 172 are supplied to the electrolysis system, for example, to supply energy to one or more electrolyzers described above. In some embodiments, at least a portion of the electricity 172 is generated using renewable energy. A reagent such as hydrogen that is produced from renewable energy may be called a “green” reagent. With the increasing availability of green hydrogen, it may be desirable to combine green hydrogen and green carbon dioxide (CO2) that is produced by fermentation in the bioprocessing facility 105, as discussed above. This would be synergistic in part because 1) it would provide a value-added use for CO2 close to the production source in a bioprocessing facility and 2) some chemical production processes are exothermic, resulting in a significant amount of energy that may be useful in a bioprocessing facility 105.

[077] Non-limiting examples of renewable energy sources include wind power, solar power, hydropower, biomass combustion, and combinations thereof. Non-limiting examples of biomass that can be burned in a power generation system include wood, agricultural residues (e.g., corn straw), and combinations thereof.

[078] According to another aspect of the present disclosure, the oxygen produced in an electrolysis system, as described herein, can be used as at least a partial source of oxygen for one or more combustion processes associated with the installation 100 (e.g., bioprocessing installation 105) to produce an exhaust gas (combustion) relatively more concentrated in carbon dioxide, which in turn can be used as an additional source of carbon dioxide for the reaction system 155. Advantageously, Petition 870250078543, dated 03 / 09 / 2025, pages 135 / 155 29 / 34 By combining one or more outputs from the bioprocessing plant 105 with the chemical production system 150, and vice versa, the amount of recoverable exothermic energy from the reaction of the reaction system 155 for use in the bioprocessing plant 105 can be increased. If desired, this increase in the amount of thermal energy recovered from the reaction system 155 can be used to offset other energy inputs (e.g., based on fossil fuels) in the energy system 130 for the bioprocessing plant 105.

[079] In contrast, when ambient air is used in a combustion process, a combustion gas is produced with carbon dioxide that is diluted by the nitrogen content of the ambient air. For example, the concentration of carbon dioxide in a combustion gas produced with ambient air is approximately 16% by mass. As the oxygen concentration increases and the amount of nitrogen gas decreases in the gas supplied to combustion, the carbon dioxide gas in the combustion gas becomes more concentrated (and the nitrogen gas concentration decreases). Advantageously, a gas composition produced directly from the electrolysis of water can have a relatively much higher concentration of oxygen compared to ambient air.

[080] A non-limiting example of an installation and process for using oxygen produced in an electrolysis system as at least a partial source of oxygen for one or more combustion processes associated with the installation 100 is illustrated with reference to Figure 1B. Reference characters in Figure 1B that are described in connection with Figure 1A may or may not be repeated in connection with Figure 1B. As shown in Figure 1B, the oxygen flow 176 produced in the electrolysis system 170 is in fluid communication with at least one thermal power generation system in the power system 130 to supply oxygen via flow 178 to a combustion process. Optionally, if desired, any remaining oxygen 180 that may not be required for combustion in a thermal power generation system may be diverted to one or more other destinations. A non-limiting example of another destination includes the aeration of one or more compositions of Petition 870250078543, dated 03 / 09 / 2025, pages 136 / 155 30 / 34 process in the bioprocessing facility 105, as a propagation system for the growth of a population of microorganisms used in fermentation. Another non-limiting example of another destination includes the transport (e.g., via pipeline, railcar, containers and the like) of oxygen as a co-product off the site of the facility 100.

[081] In some forms, the oxygen produced in the electrolysis system 170 may be at a concentration and pressure such that it can be supplied directly to a combustion process in the energy system 130 without any purification or pressurization. In some embodiments, the gas composition in the stream 178 has an oxygen concentration of at least 90% by weight on a dry basis, at least 95% by weight on a dry basis, at least 99% by weight on a dry basis, or even at least 99.9% by weight on a dry basis.

[082] As discussed in Figure 1A above, the generation of thermal energy in the energy system 130 for the bioprocessing facility 105 by means of a combustion process produces a combustion gas. In Figure 1B, the combustion gas is relatively much more concentrated in carbon dioxide because a relatively concentrated source of oxygen is provided by electrolysis via stream 178 instead of ambient air. In some embodiments, the combustion gas in stream 134 directly from combustion in the energy system 130 has a carbon dioxide concentration of at least 85% by weight on a dry basis, at least 90% by weight on a dry basis, at least 95% by weight on a dry basis, at least 99% by weight on a dry basis, or even at least 99.9% by weight on a dry basis.

[083] Optionally, as shown in Figure 1B, the flue gas stream 134 may be cleaned by means of one or more separation systems 140 to separate one or more non-carbon dioxide gases from the carbon dioxide gas, so that a relatively more concentrated stream 145 of carbon dioxide may be carried as a reactant to the reaction system 155. Non-limiting examples of separation systems 140 include one or more amine scrubbing systems, a pressure swing adsorption system, a system Petition 870250078543, dated 03 / 09 / 2025, pages 137 / 155 31 / 34 cryogenic distillation and a membrane separation system. EXAMPLE

[084] A prophetic example comparing theoretical energy calculations between three scenarios using a corn ethanol bioprocessing plant as a baseline will be described using Figures 2A-2C. Reference characters in Figures 2A-2C that are described in connection with Figures 1A and 1B may or may not be repeated in connection with Figures 2A-2C. A major difference between Figures 1A and 2B is that Figure 2B shows theoretical flow rate calculations for certain process streams and / or energy generation for a corn ethanol bioprocessing plant integrated with a methane production system and a water electrolysis system. Similarly, a major difference between Figures 1B and 2C is that Figure 2C shows theoretical flow rate calculations for certain process and / or energy generation streams for a corn ethanol bioprocessing plant that is even more integrated with a methane production system and a water electrolysis system.

[085] Figure 2A shows a non-limiting embodiment of a bioprocessing facility 105 as a corn ethanol bioprocessing facility. As shown in Figure 2A, a corn ethanol bioprocessing facility 105 includes a primary system 110 that receives raw material from corn grains 112. The primary system 110 includes one or more fermentation vessels that produce ethanol as a byproduct 114 along with a gas composition 116 concentrated in carbon dioxide gas.

[086] As shown in Figure 2A, energy calculations are provided for a steam boiler system, a drying system, and a regenerative thermal oxidizer as thermal energy generation systems in energy system 130. As shown in Figure 2A, the combined energy generated by the steam boiler system, the drying system, and the regenerative thermal oxidizer is 257.1 MMbtu / h, of which 128.6 MMbtu / h are attributed to the steam boiler system. The calculations are based on the use of natural gas as fuel 132 and ambient air. Petition 870250078543, dated 03 / 09 / 2025, pages 138 / 155 32 / 34 as a source of combustion oxygen 133. As can be seen, using ambient air to supply oxygen to these combustion processes produces a combined combustion gas that contains carbon dioxide significantly diluted by the nitrogen content of the ambient air. Carbon dioxide is present at approximately 16% by mass.

[087] Figure 2B shows a non-limiting embodiment of a facility and process for the production of methane in a corn ethanol bioprocessing facility using green carbon dioxide and green hydrogen via an exothermic reaction and utilizing at least a portion of the thermal energy of the exothermic reaction in the corn ethanol bioprocessing facility 105. Figure 2B is similar to Figure 2A, but Figure 2B integrates the corn ethanol bioprocessing facility 105 with a chemical production facility 150 to produce the water vapor stream 256 and the methane stream 258 using carbon dioxide 116 from the corn ethanol bioprocessing facility 105. As can be seen, the thermal energy 161 of the exothermic reaction can be used in the corn ethanol bioprocessing facility 105.As the theoretical calculations in Figure 2B show, the combined flue gas stream 134 has a slightly lower mass rate than the baseline corn ethanol bioprocessing plant 105 shown in Figure 2A because the amount of energy recovered 161 from the methanation process in the chemical production system 150 and the energy system 130 has a corresponding reduction in natural gas input. As shown in Figure 2B, the combined energy generated by the steam boiler system, the drying system, and the regenerative thermal oxidant is 161 MMbtu / h, of which 32 MMbtu / h are attributed to the steam boiler system. As can also be seen, the carbon dioxide content of the combined flue gas stream 134 is approximately 16% by mass, which is the same as that shown in Figure 2A and to be expected.If desired, the carbon dioxide in the combined flue gas stream 134 of Figure 2B could be recovered and used as an additional input for the methanation process of the production system. Petition 870250078543, dated 03 / 09 / 2025, pages 139 / 155 33 / 34 chemical 150 to produce additional methane 258. Purifying the pure carbon dioxide that is present in the combined flue gas stream 134 of Figure 2B for use as feedstock in the methanation process could be carried out with one or more additional unit operations such as amine scrubbing, pressure swing adsorption, cryogenic distillation or membrane separation, which may or may not be worth the investment.

[088] Figure 2C shows a non-limiting embodiment of a plant and process for the production of methane in a corn ethanol bioprocessing plant using green carbon dioxide and green hydrogen via an exothermic reaction and utilizing at least a portion of the thermal energy of the exothermic reaction in the corn ethanol bioprocessing plant 105. Figure 2C is similar to Figure 2B, but Figure 2C integrates the oxygen produced in the electrolysis system 170 with the combustion processes associated with the thermal generation systems in the energy system 130 to produce flue gas 134 which is relatively much more concentrated in carbon dioxide compared to Figures 2A and 2B.This results in an exhaust gas stream 134 that is essentially pure carbon dioxide gas on a dry basis and is much easier to capture and use as feedstock or sequester underground in permanent geological storage than the carbon dioxide in a typical combustion exhaust gas stream shown in Figures 2A and 2B. As shown in Figure 2C, recovering this additional carbon dioxide as feedstock for the methanation process increases methane production and also the amount of excess energy that can be recycled from the methanation process back to the corn ethanol bioprocessing facility 105. This, in turn, reduces the amount of natural gas input energy required for the ethanol plant's power system 130 and the amount of combined combustion gas relative to Figures 2B and 2C.As shown in Figure 2C, the combined energy generated by the steam boiler system, the drying system, and the regenerative thermal oxidizer is 135 MMbtu / h, of which 6.9 MMbtu / h are... Petition 870250078543, dated 03 / 09 / 2025, pages 140 / 155 34 / 34 assigned to the steam boiler system. In the example shown in Figure 2C, only minimal processing, if any, would be required to clean the combined flue gas before the carbon dioxide could be used by the methanation process.

[089] In Figure 2B, the methanation process produces half (98 gpm) of the water required (196 gpm) for electrolysis. In Figure 2C, the methanation process produces half (124 gpm) of the water required (247 gpm) for electrolysis.

[090] In some embodiments, there may be a water cleaning process to recycle the water produced in the methanation process back to the electrolyzer in the electrolysis system.

[091] The calculations in Figures 2B and 2C are for the catalytic reaction of carbon dioxide with hydrogen by electrolysis to produce methane. These estimates do not include any energy consumption in the methanation synthesis area (such as heating the CO2, separating the products, etc.), therefore the actual amount of energy that could be returned to the bioethanol plant is less than indicated.

[092] For methanation in Figure 2B, the percentage of energy input (874 The percentage of energy input (1100 MMbtu / h) in electrolysis system 170 that is converted into energy content (521 MMbtu / h) of the final methane produced by reaction system 155 is 59.6% ((521 MMbtu / h / 874 MMbtu / h) * 100). For methanation in Figure 2C, the percentage of energy input (1100 MMbtu / h) in electrolysis system 170 that is converted into energy content (657 MMbtu / h) of the final methane produced by reaction system 155 is 59.7% ((657 MMbtu / h / 1100 MMbtu / h) * 100). Petition 870250078543, dated 03 / 09 / 2025, pp. 141 / 155

Claims

1 / 6 CLAIMS 1. A method of making a reaction product using carbon dioxide produced in a bioprocessing facility, wherein the method is characterized by comprising: fermenting a fermentable composition in a bioprocessing facility, wherein the fermentation generates at least one biochemical target and carbon dioxide; reacting at least one reactant and carbon dioxide to form at least one reaction product by means of an exothermic reaction, wherein at least a portion of the carbon dioxide is derived from the fermentation; and using at least a portion of the thermal energy of the exothermic reaction in the bioprocessing facility.

2. A method according to claim 1, characterized in that at least a portion of the thermal energy is used to generate electricity for at least the bioprocessing facility.

3. A method according to claim 1, characterized in that at least a portion of the thermal energy is used in at least one or more systems in the bioprocessing plant, wherein the one or more systems are chosen from an evaporator system, a distillation system, a drying system, a power generation system, and combinations thereof.

4. Method according to claim 1, characterized in that at least one reagent is produced by a chemical production system that is colocated with the bioprocessing facility.

5. Method, according to claim 4, characterized in that at least a portion of the thermal energy is used in a power generation system to generate electricity for at least the bioprocessing facility and / or the chemical production system.

6. Method according to claim 1, characterized in that at least one reagent comprises hydrogen. Petition 870250078543, dated 03 / 09 / 2025, pp. 142 / 155 2 / 6 7. Method according to claim 6, characterized in that at least part of the hydrogen is produced by electrolysis of water.

8. A method according to claim 7, characterized in that electricity is used for the electrolysis of water and in which at least part of the electricity is generated using renewable energy.

9. A method according to claim 8, characterized in that at least part of the electricity is generated by means of one or more renewable energy sources chosen from wind energy, solar energy, hydroelectric energy, biomass combustion, and combinations thereof.

10. A method according to claim 1, characterized in that at least one reaction product is chosen from methane, methanol, formate, formic acid, ethanol, ethylene, propylene, carbon monoxide, and combinations thereof.

11. A method according to claim 7, characterized in that the electrolysis of water produces hydrogen and oxygen and further comprises: generating energy for the bioprocessing plant by means of at least one combustion process that produces a combustion gas composed of carbon dioxide; and supplying oxygen from the electrolysis of water for at least a portion of the oxygen used in at least one combustion process.

12. A method according to claim 11, characterized in that at least one combustion process uses at least one fuel chosen from at least one biomass material, at least one gaseous fuel, at least one liquid fuel, and combinations thereof.

13. Method according to claim 11, characterized by further comprising providing at least a portion of the combustion gas as at least a portion of the carbon dioxide in the reagent of at least one reagent and carbon dioxide.

14. Method according to claim 1, characterized in that at least one reagent is produced by a chemical production system that is co-located with the bioprocessing facility, wherein the at least one reagent comprises hydrogen that is produced by electrolysis of water, wherein the electrolysis of water produces hydrogen and oxygen, and wherein at least a portion of the thermal energy of the exothermic reaction is used in one or more systems in the bioprocessing facility, and further comprises: generating thermal energy for the bioprocessing facility through at least one combustion process that produces a combustion gas composed of carbon dioxide, wherein at least a portion of the thermal energy of the at least one combustion process is used in one or more systems of the bioprocessing facility;and to supply oxygen from the electrolysis of water for at least part of the oxygen used in at least one combustion process; and to supply at least part of the combustion gas as at least part of the carbon dioxide for the reaction between at least one reactant and carbon dioxide.

15. A method according to claim 14, characterized in that at least a portion of the thermal energy from the exothermic reaction and at least a portion of the thermal energy from at least one combustion process are used in one or more systems in the bioprocessing plant and / or chemical production system, wherein the one or more systems are chosen from an evaporator system, a distillation system, a drying system, a power generation system, a regenerative thermal oxidant system, and combinations thereof.

16. Method, according to claim 14, characterized by a gaseous composition with a carbon dioxide concentration of at least 90% by mass on a dry basis being obtained directly from fermentation, wherein a gaseous composition with an oxygen concentration of at least 90% by mass on a dry basis is obtained directly from electrolysis, and / or wherein the combustion gas has a carbon dioxide concentration of at least 85% by mass on a dry basis and is obtained directly from at least one combustion process.

17. Method according to claim 1, characterized by further comprising the use of at least a portion of the reaction product as a reagent to form a derivative thereof and / or the transfer of at least a portion of the reaction product to one or more storage containers.

18. Method according to claim 17, characterized in that the derivative comprises sustainable aviation fuel (SAF).

19. A method according to claim 1, characterized in that the fermentable composition comprises one or more sugars derived from at least one grain starch, at least one cellulosic polysaccharide, and combinations thereof, wherein at least one target biochemical comprises at least one alcohol.

20. A method according to claim 1, characterized in that the fermentable composition comprises one or more sugars derived from corn starch, and wherein at least one target biochemical comprises ethanol.

21. Installation characterized by comprising: a bioprocessing installation comprising: a fermentation system configured to ferment a fermentable composition and generate at least one target biochemical product and carbon dioxide gas; and one or more systems configured to utilize thermal energy for one or more processes in the bioprocessing installation; a chemical production system that is colocated with the bioprocessing installation, wherein the chemical production system is in fluid communication with the fermentation system to receive at least a portion of the carbon dioxide gas, wherein the chemical production system comprises: a source of at least one reagent that can react with carbon dioxide gas. Petition 870250078543, dated 03 / 09 / 2025, page 1.145 / 155 5 / 6 of carbon through an exothermic reaction to produce at least one reaction product; and a reaction vessel configured to react at least one reactant and carbon dioxide to form at least one reaction product through an exothermic reaction, wherein the chemical production system is configured to transport thermal energy from the exothermic reaction, wherein the facility is configured to use at least a portion of the thermal energy to generate electricity for the bioprocessing facility and / or wherein the facility is configured to use at least a portion of the thermal energy in one or more systems in the bioprocessing facility, wherein the one or more systems are chosen from an evaporation system, a distillation system, a drying system, a power generation system and combinations thereof.

22. Installation according to claim 21, wherein the installation is further characterized by comprising: at least one thermal power generation system configured to generate thermal energy for the bioprocessing installation and to produce a combustion gas composed of carbon dioxide by means of a combustion process, wherein the bioprocessing installation is configured to use at least a portion of the thermal energy in one or more systems in the bioprocessing installation, and wherein the at least one thermal power generation system is in fluid communication with the reaction vessel to supply at least a portion of the combustion gas to the reaction vessel, such that the carbon dioxide can react with at least one reactant to form at least one reaction product by means of the exothermic reaction;and wherein the chemical production system further comprises: an electrolysis system configured to form hydrogen and oxygen from water, wherein the electrolysis system is in fluid communication with the reaction vessel to supply hydrogen to the reaction vessel to react with carbon dioxide and form at least one reaction product by means of an exothermic reaction, and wherein the electrolysis system is in fluid communication with at least one thermal power generation system to supply oxygen to at least one thermal power generation system for the combustion process.

23. Installation according to claim 22, characterized in that at least one thermal power generation system is chosen from at least one steam boiler system, at least one drying system, at least one power generation system, at least one regenerative thermal oxidizer, and combinations thereof. Petition 870250078543, dated 03 / 09 / 2025, pp. 147 / 155

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