Continuous counter-current organosolv processing of lignocellulosic feedstocks

Abstract

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

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application is a continuation-in-part of our prior application Ser. No. 11 / 839,378 filed Aug. 15, 2007, and claims the benefit of U.S. Provisional Application No. 60 / 941,220 filed May 31, 2007.FIELD OF THE INVENTION[0002]This invention relates to fractionation of lignocellulosic feedstocks into component parts. More particularly, this invention relates to processes, systems and equipment configurations for recyclable organosolv fractionation of lignocellulosic material for continuous controllable and manipulable production and further processing of lignins, monosaccharides, oligosaccharides, polysaccharides and other products derived therefrom.BACKGROUND OF THE INVENTION[0003]Industrial processes for production of cellulose-rich pulps from harvested wood are well-known and typically involve the steps of physical disruption of wood into smaller pieces and particles followed by chemical digestion under elevated temperatures and pressur...

AI Technical Summary

Benefits of technology

[0013]According to yet another aspect, the plurality of equipment in the second module is configured to sequentially: (a) receive and reduce the viscosity of the cellulosic solids fraction discharged from the first module, then (b) progressively saccharify the cellulosic solids into suspended solids, dissolved solids, hemicelluloses, polysaccharides, oligosaccharides thereby producing a liquid stream primarily comprising monosaccharides, (c) ferment the liquid stream, (d) distill and refine the fermentation beer to separate the beer into at least a fuel-grade ethanol and / or other fuel alcohols such as butanol, and a stillage stream, (e) delignify the stillage stream, and (f) recycle the delignified stillage stream for reducing the viscosity of fresh incoming cellulosic solids fraction discharged from the first module.

[0014]According to a further aspect, the plurality of equipment in the second module may be optionally configured to sequentially: (a) receive and reduce the viscosity of the cellulosic solids fraction discharged from the first module, then (b) concurrently saccharify the cellulosic solids into monosaccharides while fermenting the monosaccharides in the same vessel, (c) distill and refine the fermentation beer to separate the beer into at least a fuel-grade ethanol and a stillage stream, (d) de-lignify the stillage stream, and (f) recycle the de-lignified stillage stream for reducing the viscosity of fresh incoming cellulosic solids fraction discharged from the first module.

[0017]According to one aspect, controllably counter-flowing the organic solvent against the incoming lignocellulosic feedstock during the cooking causes turbulence that facilitates and speeds the dissolution and disassociation of the lignins and lignin-containing components from the lignocellulosic feedstock. However, it is within the scope of this invention to alternatively provide turbulence during the cooking process with a controllable flow of organic solvent directed in the same direction as the flow of lignocellulosic feedstock, i.e., a concurrent flow, thereby controllably intermixing the solvent and lignocellulosic feedstock together. It is also within the scope of this invention to controllably partially remove the organic solvent during the cooking process and to replace it with fresh organic solvent.

[0024]According to yet another aspect, there are provided processes and systems for producing ethanol from the monosaccarides hydrolyzed from the cellulosic fibrous pulp, by fermentation of the hydrolysate solutions. It is within the scope of this invention to controllably provide inocula comprising one or more selected strains of Saccharomyces spp. to facilitate and enhance the rates of fermentation and / or fermentation efficiencies and / or fermentation yields.

[0025]According to a further aspect, there are provided processes and systems for concurrently saccharifying and fermenting the cellulosic pulps produced as disclosed herein. It is within the scope of the present invention to controllably hydrolyze the cellulosic fibrous pulps into monosaccharides by providing suitable hydrolysis means exemplified by enzymatic, microbial, chemical hydrolysis and combinations thereof, while concurrently and controllably fermenting the monosaccharide moieties produced therein. It is within the scope of this invention to controllably provide inocula comprising one or more selected strains of Saccharomyces spp. to facilitate and enhance the rates of concurrent fermentation and / or fermentation efficiencies and / or fermentation yields.

Problems solved by technology

Although it appears that biorefining using organosolv systems has considerable potential for large-scale fuel ethanol production, the currently available processes and systems are not yet economically feasible because they require expensive pretreatment steps and currently produce only low-value co-products (Pan et al., 2006, J. Agric. Food Chem.

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