Roller mill for converting cellulosic material into sugar

Abstract

The present application discloses a device for converting cellulose into sugar. The device includes a reactor chamber with multiple control components, and a control assembly. The control assembly is operatively connected to the reactor chamber, the drive assembly and the control assembly to transmit and receive interoperability signals. The device has a feed hopper with a detector, a crusher, a discharge hopper, a sensor assembly, a steam inlet and a carbon dioxide inlet. The feed hopper is configured to receive and analyze the proportion data of substances in a mixture of raw materials and catalysts via the detector. The crusher receives and grinds the mixture from the feed hopper to induce a chemical reaction to produce sugar. The discharge hopper is configured to determine the proportion data of substances in the ground mixture. The control assembly is configured to determine the adjustments that need to be made to the components and the drive assembly to optimize sugar production.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This utility model patent application claims priority to U.S. Provisional Patent Application Serial No. 62 / 617,900, filed on January 16, 2018, entitled Apparatus for Converting Cellulosic Materials into Sugars and Systems and Methods Using the Apparatus, the entire contents of which are incorporated herein by reference for all purposes.

[0003] STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0004] not applicable Technical Field

[0005] The present invention relates generally to the hydrolysis of cellulosic materials and more particularly to certain new and useful improvements in apparatus for inducing hydrolysis to cleave the glycosidic bonds of cellulose to produce monosaccharides in maximum yield over time while minimizing the formation of substitute products or loss of monosaccharides; and with reference to the accompanying drawings which form a part hereof. Background Art

[0006] Cellulose is a kind of 6 H 10 O 5 ) n An organic compound, it is a polysaccharide composed of hundreds to thousands of straight chains of D-glucose units linked by β(1→4) bonds to form essentially linear long molecular chains. These bonds give cellulose a high degree of crystallinity and therefore a low accessibility to enzymes or acid catalysts. This phenomenon is known as recalcitrance.

[0007] Cellulose is an important structural component of the primary cell walls of green plants, many forms of algae, and oomycetes. It is close to hemicellulose and lignin, which together form the main components of plant fiber cells. In addition, some species of bacteria secrete it to form biofilms. Cellulose is naturally formed by plants and it is the most abundant organic polymer on Earth.

[0008] Enzymes do hydrolysis. Enzymes are specific types of catalysts, such as liquid or solid acids. Cellulose can be made into many products in many ways, including nanocellulose, microcrystalline cellulose, glucose, many things you can make from glucose including ethanol, and many things you can make from ethanol as a chemical commodity.

[0009] Hydrolysis means water splitting reaction, and it is the reaction that uses water to make the bond fracture in molecule.The hydrolysis of cellulose produces the mixture of simple reducing sugars, mainly the mixture of glucose.These hydrolysates can be converted into the ethanol used as liquid fuel to replace oil, and cause more thorough, cleaner combustion, and they can also be used as fuel or the intermediate of the approach leading to the preparation of other fuels.In addition, hydrolysate also can be used for making the various organic chemicals produced by oil at present.With regard to available energy, the combustion heat of cellulose or the glucose product that can obtain from cellulose in theory is expressed as: one pound of cellulose is approximately equal to 0.35 pound of gasoline or other fuel.

[0010] It is estimated that on Earth, approximately 6.45 × 10 11 Tons of carbon, wherein half exists in the form of cellulose. In addition, it is estimated that the biomass generated on cultivated land and grassland at present approximately has 3 / 4 to help waste generation. Expect to utilize this waste material to develop alternative sources of fuel, chemicals and other useful products for a long time. However, mainly due to the crystalline structure of cellulose and the presence of lignin wherein, the attempt of hydrolyzed cellulose has not yet successfully provided an economically feasible method for producing sugar. The huge scale of this potential source has determined the necessity of improving cellulose utilization method and system.

[0011] Furthermore, in the known processes and methods, especially when processing extremely viscous, highly substituted products, the chemical or thermal stresses on the macromolecules are so intense that during the conversion, the macromolecules may decompose in the form of chain scissions, which is noticeable, in particular, by a more or less significant reduction in viscosity compared to the starting product. Moreover, the surface of the product treated by the preliminary embrittlement or drying step becomes rough. Furthermore, it is a common feature of the known processes that, after preliminary drying, embrittlement or compacting, a large amount of energy is expended on the conversion of the cellulose derivative.

[0012]

[0006] Therefore, there is a need for an improved apparatus, system, and method for converting cellulosic materials to sugars that is cost-effective and provides maximum sugar yield over time, as will be described in greater detail herein. Summary of the invention

[0013] The following content of the present invention is provided to ensure a basic understanding of certain aspects and features of the present invention. This content is not a broad overview of the present invention, and therefore it is not intended to particularly identify key or important elements of the present invention or to describe the scope of the present invention. Its sole purpose is to present some concepts of the present invention in a simplified form as a preface to the more detailed description presented below.

[0014] In order to achieve the above and other aspects and to meet the purpose of the present invention, a device for converting cellulose in a material containing cellulose into sugars, and a system and method using the device are proposed.

[0015] The present invention relates to a system, apparatus and method for converting cellulose to sugars using solid-solid reactions, the system, apparatus and method using at least one set of rollers to obtain an optimized sugar yield from a feedstock containing a cellulosic material. The system, apparatus and method use an atmospheric balance sensor, a cellulosic feedstock and a solid acid to optimize internal conditions to maximize sugar yield while reducing wasted energy.

[0016] The present invention utilizes mixing in general, but micro-mixing in particular, to maximize the reaction sites in the cellulose while ensuring that the time the raw materials are available for reaction is increased. Micro-mixing improves the interaction of the reaction sites and the catalyst and optimizes the energy performance. The rollers can be set up so that they are fully adjustable to control the mechanical, temperature, atmospheric and chemical reaction parameters. This is to ensure ideal conditions for achieving reaction speed and process efficiency.

[0017] It is therefore an object of the present invention to provide an efficient and economical process for producing sugars from cellulosic materials.

[0018] Another object of the present invention is to provide a new and improved apparatus which can produce monosaccharides in high yields in a short period of time.

[0019] Another object of the present invention is to provide a new and improved apparatus which also reduces the formation of substitute products and the loss of monosaccharides.

[0020] More particularly, it is an object of the present invention to provide a new and improved apparatus which is simple and cost-effective in construction and which occupies less floor space and is more portable than similar apparatus which can be used in the cellulosic sugar process.

[0021] In an exemplary embodiment, an apparatus for converting cellulose to sugar and a system and method for using the apparatus are provided. The apparatus is in the form of a mill and, more specifically, is designed for use in a cellulose sugar process.

[0022] According to the present invention, a device / mill for converting cellulose into sugar is proposed, the device comprising: a reactor chamber including a plurality of control components; a control assembly operatively connected to the reactor chamber and each of the control components, the control components being configured to transmit and receive interoperability signals, wherein the plurality of control components comprises a crusher assembly for receiving a mixture of a cellulose feedstock and a solid acid catalyst, wherein the crusher assembly is configured to grind the mixture under pressure to induce a solid-solid chemical reaction between the cellulose feedstock and the solid acid catalyst to produce sugar; and a discharge hopper having a detector configured to determine a proportion of material in the ground mixture delivered by the crusher assembly, wherein the control assembly is configured to determine whether the ground mixture needs to be reprocessed, and if so, to adjust the control components to optimize sugar production.

[0023] In one embodiment, a plurality of control assemblies comprise a feed hopper, a crusher assembly, a discharge hopper, a sensor assembly, a steam inlet and a carbon dioxide inlet. In one embodiment, the feed hopper further comprises a detector. In one embodiment, the feed hopper is configured to receive and analyze the ratio of elements or substances in the mixture of raw materials and catalysts. The substance may comprise a cellulose substance of protein, cellulose, starch, monosaccharide, lignin, dust, water or oil or any other form. The solid acid may be any type of solid acid known now or in the future. In one embodiment, the detector is a NIR detector, but may also be any other detector capable of passive or active detection observation to determine the properties and composition of the material.

[0024] In one embodiment, the crusher assembly receives a mixture of raw materials and catalyst from the feed hopper. The crusher assembly is configured to grind or thereby apply extremely high pressure to the mixture to induce a chemical reaction for producing sugar. In one embodiment, the crusher assembly includes at least one pair of rollers with different surface conditions. In another embodiment, the crusher assembly includes at least one pair of mutually meshing or interconnected roller assemblies with gear teeth (e.g., gear teeth). In some embodiments, the crusher assembly includes multiple groups of mutually meshing gears or roller assemblies with approximately smooth grinding surfaces.

[0025] The discharge hopper includes a detector. In one embodiment, the discharge hopper is configured to determine the extent of the reaction and send a signal to the control system to further adjust the conditions of the crusher assembly, grinding the mixture delivered by the crusher assembly. In this way, the control assembly is configured to determine whether the ground mixture needs to be reprocessed.

[0026] The sensor assembly is configured to transmit one or more phenomena of the reactor chamber to the control assembly, the phenomena including but not limited to pH data, temperature data, oxygen data, moisture data and pressure data. The sensor assembly includes but is not limited to pH sensors, temperature sensors, oxygen sensors, humidity sensors and pressure sensors.

[0027] The steam inlet is configured to regulate the flow of steam in the reactor chamber, and the carbon dioxide inlet is configured to regulate the flow of carbon dioxide in the reactor chamber. Carbon dioxide can be used to replace any other substances such as nitrogen and argon to prevent oxidation, or to add any gas that enhances the reaction by having certain properties or a certain composition.

[0028] The apparatus further includes a mixing device and a feed line. The mixing device communicates with a control assembly configured to mix the feedstock and the catalyst. The feed line connecting the mixing device and the feed hopper feeds the mixture of the feedstock and the catalyst into the reactor chamber.

[0029] The apparatus further includes an atmosphere adjustment module or balancer such as a vacuum pump and a heater and a pressure valve or pressure pump for a semi-closed system. The pump is configured to generate a positive pressure or a negative pressure in the reactor chamber. The heater is configured to heat the reactor chamber. The radiator or cooling device is configured to cool the reactor chamber. The apparatus further includes a return feed line connected to the discharge hopper and the feed hopper, configured to feed the ground mixture into the reactor chamber for further processing. The apparatus further includes a collection device configured to receive the ground mixture from the discharge hopper.

[0030] In one embodiment, a method for converting cellulose into sugars includes mixing a feedstock and a catalyst in a mixing device, and inputting the mixture of the feedstock and the catalyst into a feed hopper of a reactor chamber. In another step, receiving and analyzing data on the proportion of substances in the mixture of the feedstock and the catalyst via at least one detector. In another step, receiving the mixture of the feedstock and the catalyst from the feed hopper and entering the crusher assembly, thereby grinding the mixture to induce a chemical reaction to produce sugars. In another step, determining data on the recovered substances in the ground mixture transmitted by the crusher assembly. In another step, determining the reprocessing of the ground mixture by a control system that communicates with the reactor chamber, and reprocessing if necessary. In another step, feeding the ground mixture to the reactor chamber via a feed line for reprocessing. In a further step, receiving the sugars produced after reprocessing from the discharge hopper by a collection device.

[0031] Other features, advantages and aspects of the present invention will become more apparent and more readily understood from the following detailed description, which should be read in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1is a perspective front view showing an embodiment of an apparatus that can be used in a cellulosic sugar production process, namely a mill according to one embodiment of the present invention.

[0033] Figure 2 is a perspective front view of a crusher assembly for use in a rolling mill according to one embodiment of the present invention.

[0034] Figure 3 is a front view of a rolling mill including three sets of gears according to one embodiment of the present invention.

[0035] Figure 4 is a front view of a rolling mill including three sets of rolls according to one embodiment of the present invention.

[0036] Figure 5 is a flow chart showing an embodiment of a system and method for preparing monosaccharides by inducing hydrolysis using a mill in a cellulose sugar production process to cleave glycosidic bonds of cellulose according to an embodiment of the present invention. DETAILED DESCRIPTION

[0037] The invention will be best understood by reference to the detailed drawings and description set forth herein.

[0038] Embodiments of the present invention are discussed below with reference to the accompanying drawings. However, it will be readily appreciated by those skilled in the art that, since the present invention extends beyond these limited embodiments, the detailed description given herein for these drawings is for illustrative purposes. For example, it will be appreciated that, according to the teachings of the present invention, based on the needs of specific applications, those skilled in the art will recognize a variety of alternatives and suitable methods to implement the functions of any given details described herein, and in the embodiments described below, selections other than specific implementations are shown. That is, many modifications and variations of the present invention are too many to list, but all of them are within the scope of the present invention. Moreover, where appropriate, singular words should be interpreted as plural, and vice versa, and masculine words should be interpreted as feminine, and vice versa, and alternative embodiments do not necessarily mean that the two are mutually exclusive.

[0039] It should be further understood that the present invention is not limited to the specific methods, compounds, materials, manufacturing techniques, uses and applications described herein, because these can vary. It should also be understood that the terms used herein are only for the purpose of describing specific embodiments, and are not intended to limit the scope of the present invention. It must be noted that, as used herein and in the appended claims, unless the context otherwise clearly indicates, the singular forms "one", "an" and "the" include plural references. Therefore, for example, a reference to "an element" is a reference to one or more elements, and includes equivalents known to those skilled in the art. Similarly, for another example, a reference to "a step" or "a mode" is a reference to one or more steps or modes, and may include sub-steps and sub-modes. All conjunctions used should be understood as far as possible in the broadest sense. Therefore, unless the context otherwise clearly stipulates, the word "or" should be understood to have a definition of logical "or", rather than a definition of logical "exclusive or". The structure described herein should also be understood to refer to the functional equivalent of such a structure. Unless otherwise clearly stipulated in the context, it should be interpreted as a language that can be understood to express approximation.

[0040] As used herein, "feed" refers to the material introduced into the mill as part of the cellulosic sugar production process, as well as the material exiting the mill after the process is completed.

[0041] "Interaction" refers to the interaction between the raw material and the solid acid to produce a chemical reaction to form sugars.

[0042] Unless otherwise limited, all technical and scientific terms used herein have the same meanings as those of ordinary skill in the art to which the present invention belongs. Although any method, technology, device or material similar or equivalent to those described herein can be used in the practice or testing of the present invention, preferred methods, technologies, devices or materials are still described. The structures described herein should also be understood to refer to the functional equivalents of such structures. The present invention will now be described in detail with reference to embodiments of the present invention as shown in the accompanying drawings.

[0043] Reference Figure 1 , generally indicated by reference numeral 100, is a perspective front view of an embodiment showing an apparatus, i.e., a rolling mill, that can be used in a cellulosic sugar production process according to an embodiment of the present invention. The embodiment 100 shows the functional components of a rolling mill according to an embodiment of the present invention. Figures 1 to 3The various components of the mill / apparatus 100 and their roles in the cellulosic sugar production process are further described. The mill / apparatus 100 includes a reactor chamber 102 having a plurality of control components. In one embodiment, the plurality of control components include a feed hopper 120, a crusher assembly 128, a discharge hopper 122, a sensor assembly, a steam inlet 118, and a carbon dioxide inlet 124.

[0044] Continue to refer to Figure 1 , the control system / assembly 132 is coupled to the drive assembly 130, and both are coupled to the reactor chamber 102. In one embodiment, the drive assembly 130 includes a motor. In one embodiment, the motor 130 is powered via a power supply. By being coupled to the reactor chamber 102, the control assembly 132 is able to communicate with the various sensors 104 to 112, the vacuum pump 116, the heater 126, the crusher assembly 128, the steam inlet 118, the carbon dioxide (CO 2 ) inlet 124 communicates with detectors 114A to 114B and receives information therefrom. Through its interconnectivity, control assembly 132 will allow real-time monitoring, analysis and adjustment to ensure that the process is optimized. The above content is further discussed in this article when describing other components of the device.

[0045] In the present disclosure, the crusher assembly 128 is configured to induce a solid phase chemical reaction between a raw material and a catalyst (e.g., clay). In one embodiment, the crusher assembly 128 can be a single set of approximately smooth rollers (e.g., circular), but any shape of roller can be used as long as it induces appropriate pressure. In another embodiment, the crusher assembly 128 can be a roller group that meshes with each other in the form of high hardness gears. In some embodiments, the crusher assembly 128 can be any mechanism that compresses solids under very high pressure. The crusher assembly 128 is configured to compress or squeeze solids together under very high pressure and a predetermined temperature, which helps the solid-solid molecular reaction between the raw material and the hydrated clay to produce or synthesize sugars using the raw material. In one embodiment, the solid includes but is not limited to lignocellulosic biomass and solid acid. In one embodiment, the ratio of biomass to solid acid can be but is not limited to 1kg:0.1kg to 1kg:10kg. In one embodiment, the solid acid can be but is not limited to kaolin, bentonite and montmorillonite or any solid acid that exists now or in the future.

[0046] Continue to refer to Figure 1, the drive assembly 130 and control assembly 132 are also connected to a mixing device 134 that mixes the raw materials and catalyst; once mixed, the material is sent to the feed hopper 120 via the feed line 138. Once entering the feed hopper 120, the detector 114A, together with any other necessary sensors or detectors, analyzes the material and calculates information that will be useful in the process, such as protein content, cellulose, starch and monomeric sugars, water, lignin, dust, oil and mechanical properties. In one embodiment, the detectors (114A and 114B) are NIR detectors, but can be any detector or sensor that analyzes the compounds and materials in the mixture. This information will be used to analyze the material to ensure that the process is performed at an optimal level, thereby ensuring consistency and optimal yield. In one embodiment, the control assembly 132 can use the readings of the detector 114A to adjust the speed of the crusher assembly 128 to ensure that the process is optimized. Once the material is analyzed inside the feed hopper 120, the feed valve 144 will be used to open the feed hopper 120 so that the material can pass from the feed hopper 120 downwardly into the feed guide 140, which guides the material downwardly between the crusher assembly 128 located inside the reactor chamber 102. As previously discussed, the crusher assembly 128 is powered via the drive assembly 130 and the control assembly 132 coupled to the reactor chamber 102. In one embodiment, the crusher assembly 128 and the drive assembly 130 are connected via a drive shaft. Once the process is completed, the material exits the reactor chamber 102 via the discharge hopper 122. Once in the discharge hopper 122, the detectors 114A and 114B, along with any other necessary sensors or detectors, analyze the material to determine whether it must be passed through the mill again. If it is determined that the material must be passed through again, the material will be sent back to the feed hopper 120 via the return feed line 142, where the detector 114A will analyze the material again and determine the adjustments that must be made to the device in order to process the material again. Once the process is completed and the material no longer needs to pass through the crusher assembly 128, the material is sent to the end collection device via the discharge line 140. In one embodiment, an outlet valve can be provided at the feed guide or line 140 to control the flow of material. In one embodiment, a tight seal is provided to the feed lines 140 and 142 to prevent material leakage. It is important to note that more than one crusher assembly 128 can be used in the chamber 102.

[0047] Continue to refer to Figure 1, a feed hopper 120 and a discharge hopper 122 are connected to the reactor chamber 102 and are used to introduce the material into the collection device 102 and discharge the material from the collection device 102, respectively. In order to open and close the feed hopper 120 so that the material can enter the reactor chamber 102, a feed valve 144 is used. In this embodiment, the feed hopper 120 and the discharge hopper 122 are operated based on an atmosphere control system, which regulates the pressure in the reactor chamber 102 to enhance the transportation of materials in the system. In other embodiments, the feed hopper 120 and the discharge hopper 122 can be controlled via an electronic system and connected to the control assembly 132.

[0048] Continue to refer to Figure 1 , the control assembly 132 is coupled to the drive assembly 130, which is further coupled to the crusher assembly 128, which is further coupled to the reactor chamber 102. The drive assembly 130 must provide sufficient power and torque required to rotate the crusher assembly 128 at a predetermined or optimal revolutions per minute, and can change the speed and power output over time. In an embodiment, each of the rollers of the crusher assembly 128 can rotate at a different RPM (revolutions per minute) to optimize the reaction. In one embodiment, the control assembly 132 is a processor that reads the sensors 104 to 112 and automatically responds to predefined parameters. Real-time measurements will allow real-time adjustments to ensure that the crusher assembly 128 operates in an optimal manner. As an example, the drive assembly 130 and the control assembly 132 can change the revolutions per minute as needed to adjust the torque and power of the crusher assembly 128 based on the response of sugar production and parameter monitoring. In another example, if the temperature sensor 106 sends a reading to the control assembly 132 that the temperature is outside of a predetermined range, the control assembly 132 will send a corresponding signal to the heater 126 to heat the reactor chamber 102 .

[0049] Continue to refer to Figure 1, the mill 100 further includes a sensor assembly. In one embodiment, the sensor assembly includes various sensors 104 to 112 connected to the interior of the reactor mill 102, including a pH sensor 104, a temperature sensor 106, an oxygen sensor 108, a humidity sensor 110, and a pressure sensor 112, all of which will be further described herein. In order to communicate with other systems and devices that can be connected to the reactor chamber 102, all sensors 104 to 112 will also be connected to the control assembly 132 to ensure that the yield of cellulose is at an optimal level, all of which will be further described herein. The pH sensor 104 is connected to the reactor chamber 102 and helps to measure the effective acidity of the reaction environment. The pH sensor is configured to measure the hydrogen ion concentration of the solution, which helps to establish the actual acidity of each site and the number of acid sites. Because hydrolysis is catalyzed by acid sites on the catalyst, lower pH values ​​indicate more acid sites, thereby increasing the variation in hydrolysis. In addition, monitoring the pH level and ensuring that a certain level is met will also affect the fermentation and / or conversion of the materials loaded into the reactor chamber 102 process. A temperature sensor 106 may be coupled to the reactor chamber 102 and used to monitor the frictional heat temperature within the reactor chamber 102 to ensure that a sufficiently high temperature is reached to activate the hydrolysis reaction occurring between water and cellulose to produce sugars; at the same time, the temperature must also be low enough to avoid reactions that result in sugar degradation.

[0050] Continue to refer to Figure 1 , an oxygen sensor 108 may be coupled to the reactor chamber 102 and used to monitor the oxygen level inside the reactor chamber 102. Because oxygen causes oxidation of the sugar products, oxygen must be removed from the reactor chamber 102 before the cellulosic sugar production process can be completed. To accomplish this, the oxygen sensor 108 works in conjunction with a vacuum pump 116 that is also coupled to the reactor chamber, such that if the oxygen sensor 108 detects any oxygen in the reactor chamber 102, the oxygen sensor 108 will communicate with the vacuum pump 116 via a control assembly 132 coupled to the oxygen sensor 108 and the vacuum pump 116 to release the oxygen from the reactor chamber 102. These sensors / devices may be referred to herein as atmospheric balance sensors / devices that work in conjunction with other sensors to optimize conditions in the mill 100.

[0051] Continue to refer to Figure 1 , oxygen sensor 108 also with CO 2 Inlet 124 works in conjunction with the CO 2The inlet is also coupled to the reactor chamber 102 and the control assembly 132. Thus, if the oxygen sensor 108 detects oxygen in the reactor chamber 102 and communicates with the vacuum outlet 116 to release the oxygen via the control assembly 132, the carbon dioxide inlet 124 will automatically add protective inert carbon dioxide gas to the reactor chamber 102 to maintain a positive CO2 atmosphere inside the reactor chamber 102. 2 pressure.

[0052] Continue to refer to Figure 1 , a humidity sensor 110 is coupled to the reactor chamber 102 and is used to monitor the moisture content inside the reactor chamber 102. In one embodiment of the present invention, moisture is used as a reactant in the cellulose sugar production process to produce sugars and is consumed by the reaction. As sugars are produced, the humidity level in the reactor chamber 102 decreases and moisture is localized to hydrate more of the produced hygroscopic monosaccharides. Therefore, in this embodiment, the humidity sensor 110 is important for ensuring that the humidity level in the reactor chamber 102 is maintained at an optimal level to achieve optimal reaction. In this embodiment, the humidity level can be greater than 0.00% but less than 50% by mass. In order to ensure that the above-mentioned humidity levels are maintained, a steam inlet 118 is also coupled to the reactor chamber 102 and is used to disperse additional steam into the reactor chamber 102, so that the humidity sensor 110 can communicate with the steam inlet 118 via the control assembly 132 to disperse additional steam into the reactor chamber 102.

[0053] Continue to refer to Figure 1 , spectral detectors 114A to 114B, along with any other necessary sensors or detectors, are respectively connected to the feed hopper 120 and the discharge hopper 122 and can be used to analyze their composition as they pass through the feed port. Detectors 114A to 114B, along with any other necessary sensors or detectors, will provide data on protein content, cellulose, starch, water, monosaccharides, lignin, dust, and oil. In future embodiments, algorithms can be used to automate the response through the control assembly 134. In one embodiment, the detector 114B connected to the discharge hopper 122 will determine whether the material must be passed through the device again; if the spectral detector 114B determines that it must pass again, the material is returned to the feed hopper 120 via the return feed line 142. In one embodiment, a feed pump can be set at the feed line 142 to return the material to the feed hopper 120.

[0054] Continue to refer to Figure 1The pressure sensor 112 may be coupled to the reactor chamber 102 and used to monitor the pressure within the reactor chamber 102. The pressure required to induce hydrolysis is generated by the crusher assembly 128 within the reactor chamber 102, but because the pressure may increase or decrease with changes in temperature, the pressure in the reactor chamber 102 must be monitored, and therefore needs to be monitored via CO. 2 Inlet 124 will CO 2 is added to the reactor chamber 102 to maintain an optimal pressure for the reaction.

[0055] Continue to refer to Figure 1 , heater 126 is coupled to the base of the reactor chamber 102. Although the heat required for the cellulosic sugar process comes primarily from the friction generated within the reactor chamber 102 during the process, the heater 126 will still be used to perform the initial heating of the reactor chamber 102. In other optional embodiments, the cooling process can be performed using fans and radiators coupled to the reactor chamber or the gears or rollers themselves 102 and controlled via the control assembly 132. The crusher assembly itself can also be temperature controlled by internal heating or cooling elements or external heating and cooling elements.

[0056] Reference Figure 2 , a perspective front view of a crusher assembly 128 used in a rolling mill is generally indicated by reference numeral 200. The crusher assembly 128 includes two separate smooth rollers 202A-202B that are pressed together using springs 204, but any device capable of generating high pressure may be used, such as hydraulic pistons, screws, and any other mechanism to induce pressure, but other pressure applying mechanisms capable of generating the force required for the reaction may be used herein. As referred to herein Figure 1 As discussed, the crusher assembly 128 is rotated at a certain rate by the drive assembly 130, which uses the readings from all of the various sensors 104 to 112 to determine the optimal rate. The smooth roller is made of a material with excellent wear resistance to withstand long operating times under high pressures, and in an embodiment, is made using various materials with different hardnesses.

[0057] Each of the rollers 202A and 202B can be formed of materials having respective hardnesses (i.e., layers formed of different materials). In an exemplary embodiment, the rollers 202A and 202B have three layers 206A and 206B, 208A and 208B, and 210A and 210B. The outer layers 206A and 206B have the relatively highest hardness. The inner layers 210A and 210B have the lowest hardness, and the middle layers 208A and 208B have a hardness that falls between the hardness ranges of the inner layers and the layers. In operation, because the rollers 202A and 202B increase the micro-reaction of the material, the rollers 202A and 202B are formed of different hardnesses to optimize the reaction. Since the pressure of the outer layer is too high, and in order to prevent compression of the roller material, the outer layers 206A and 206B with high hardness ensure that a higher pressure is maintained on the material, and the middle layers with different hardnesses (or softer hardnesses) ensure that energy is not lost. By varying the roller pressure across the depth, we can adjust the surface and thus the reaction space and energy efficiency. The number, thickness, aspect ratio, length, diameter and material type of layers can be optimized based on the raw material and influence the properties of hardness, toughness, compressive strength and wear resistance.

[0058] In one embodiment, because the roller has a hard surface and induces favorable compressive residual stress, thereby effectively reducing the load stress, the roller can be made of gear teeth. In other embodiments, the roller can be made of strong metals and alloys, tungsten carbide, diamond, plastic, ceramic and composite materials. In an embodiment, the wheel shaft rotated by power can be supplied by a sufficiently cold, clean and dry lubricant, which has sufficient viscosity, and the high-pressure viscosity coefficient can be used to prevent pitting, that is, fatigue phenomenon that occurs when fatigue cracks are generated at a shallow depth on the surface or below the surface of the gear. In one embodiment, the bearing can be but is not limited to a ball bearing. The gear teeth on each gear 202A to 202B must also be designed to have the most effective wear resistance and reaction efficiency of contact area and pressure. Although only two sets of rollers are shown, there may be countless rollers in series. The rollers and gears are composed of surfaces for reaction purposes and are in contact with the feed mixture, but the surfaces supported by the rollers or gears can be composed of surfaces that reduce friction and enhance wear resistance, and the transmission surface will be strengthened to use pulleys, belts, sprockets, chains, couplings and direct drive accessories.

[0059] Reference Figure 3, the front view of the crusher assembly 128 includes three sets of gear rollers 302. In another embodiment, the set of gears of the crusher assembly 128 is used to efficiently compress or squeeze the solids together at very high pressures and required temperatures, which facilitates the molecular reaction between the raw materials and the hydrated clay to produce or synthesize sugars from the raw materials. The three sets of gear rollers 302 can be controlled via the control assembly 132. In another embodiment, as Figure 4 As shown, the crusher assembly 128 further includes three sets of smooth rollers 146. The mixture of raw material and clay is grabbed by the rollers 146 and pressed together with great force. The three sets of rollers 146 can be controlled via the control assembly 132. Of course, additional sets of smooth rollers or gear rollers can also be used depending on the raw material.

[0060] Reference Figure 5 , generally indicated at 500, is a flow chart showing a system and method for preparing monosaccharides by inducing hydrolysis using a mill in a cellulose sugar production process to cleave glycosidic bonds of cellulose according to an embodiment of the present invention. The method begins by adding a cellulose-containing material 306 and a catalyst 302 to a mixing device 130. The cellulose-containing material 306 generally includes cell walls of green plants, various forms of algae and oomycetes, and any plant-derived material. In addition to plant-based materials, the cellulose-containing material 306 can also be obtained from plant bark, wood, or leaves.

[0061] Continue to refer to Figure 5 Once the materials contained in the mixing device 130 are mixed, they are introduced into the reactor chamber 102 via the feed hopper 120. The detector 114A is coupled to the feed hopper 120 and monitors the composition of the material as it passes through the feed hopper 120. The information collected by the detector 114A is communicated with the control assembly 132 to analyze the material in real time. The control assembly 132 automatically reads the sensors 104 to 112 coupled to the reactor chamber 102 to make any adjustments to the system to ensure optimal sugar production. For example, the control assembly 132 can heat the reactor chamber to a temperature exceeding a predetermined range, or add steam when the humidity is low or when the gear is accelerated or reduced.

[0062] Continue to refer to Figure 5At the end of the cellulose sugar production process, the material leaves the reactor chamber 102 via the discharge hopper 122. The detector 114B connected to the discharge hopper 122 monitors the composition of the material as it leaves the reactor chamber 102. If the detector 114B determines that the material must be further processed, the material is sent back to the feed hopper 120 for further processing. The information collected by the detectors 114A to 114B will be sent back to the control assembly 132 so that the information can be analyzed and the system can be adjusted to obtain optimal performance. Once the material is deemed complete, the material is passed to the end collection device 136 and the process is completed. The material includes protein, cellulose, water, starch, monosaccharides, lignin, dust and oil.

[0063] In one embodiment, a method for converting cellulose into sugars includes mixing a raw material and a catalyst in a mixing device in one step. In another step, the mixture of raw material and catalyst is fed into a feed hopper of a reactor chamber. In another step, the ratio data of substances in the mixture of raw material and catalyst are received and analyzed via a detector. In another step, the mixture of raw material and catalyst is received from the feed hopper and enters the crusher assembly, thereby grinding the mixture to induce a chemical reaction to produce sugar. In another step, the ratio data of substances in the ground mixture transmitted by the crusher assembly is determined. In another step, the reprocessing of the ground mixture is determined by a control system that communicates with the reactor chamber, and reprocessing is required. In another step, the ground mixture is fed to the reactor chamber via a feed line for reprocessing. In a further step, the sugar produced after reprocessing is received from the discharge hopper by a collection device.

[0064] The specific configuration and arrangement of the present invention discussed above with reference to the accompanying drawings are for illustrative purposes only. Without departing from the spirit and scope of the present invention, other configurations and arrangements within the capabilities of those skilled in the art may be prepared, used or sold. For example, reference to "element" refers to reference to one or more elements, and includes equivalents known to those skilled in the art. All conjunctions used should be understood in the broadest sense as much as possible. Therefore, unless the context clearly stipulates otherwise, the word "or" should be understood to have a definition of a logical "or", rather than a definition of a logical "exclusive or". The structure described herein should also be understood to refer to the functional equivalent of such a structure.

[0065] Although the present invention has been described in conjunction with what are currently considered to be the most practical and preferred embodiments, it should be understood that the present invention is not limited to the embodiments disclosed herein. On the contrary, the present invention is intended to include various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

[0066] Although the specific features of various embodiments of the present invention can be shown in some drawings rather than in other drawings, this is only for convenience. According to the principles of the present invention, (multiple) features of an accompanying drawing can be merged with any or all features in any other accompanying drawings. The words "comprising", "including", "having" and "with" as used herein will be interpreted broadly and comprehensively, and are not limited to any physical interconnection. In addition, any embodiment disclosed herein should not be interpreted as the only possible embodiment. On the contrary, modifications and other embodiments are intended to be included in the scope of the appended claims.

Claims

1. A device for converting cellulose into sugars, comprising: a reactor chamber, including a plurality of control assemblies; a control assembly operatively connected to the reactor chamber and each of the control assemblies, the control assemblies being configured to transmit and receive interoperability signals; a pulverizer assembly configured to receive a mixture of a cellulosic feedstock and a solid acid catalyst, wherein the pulverizer assembly is configured to grind the mixture under pressure to induce solid-to-solid interactions between the cellulosic feedstock and the solid acid catalyst to produce sugars; a discharge hopper having a detector configured to determine a proportion of a substance in a ground mixture delivered by the crusher assembly, wherein the control assembly is configured to determine whether the ground mixture needs to be reprocessed and, if so, to adjust the control assembly to optimize sugar yield; a sensor assembly configured to transmit one or more conditions of the reactor chamber to the control assembly, the conditions including pH data, temperature data, oxygen data, humidity data, and pressure data; a steam inlet configured to regulate the flow of steam in the reactor chamber; a carbon dioxide inlet configured to regulate a flow of carbon dioxide in the reactor chamber; a feed hopper having a detector configured to receive and analyze data on the ratio of substances in the mixture of feedstock and catalyst; a mixing device in communication with the control assembly, the mixing device being configured to mix the feedstock and the catalyst; a feed line connecting a mixing device and a feed hopper to feed a mixture of feedstock and catalyst into the reactor chamber; a drive assembly in communication with the control assembly, the reactor chamber, and a mixing device; a pump configured to generate positive or negative pressure in the reactor chamber; a heater configured to heat the reactor chamber; a heat sink or cooling device configured to cool the reactor chamber; a return feed line connected to the discharge hopper and the feed hopper and configured to feed the ground mixture into the reactor chamber for reprocessing; as well as a collection device configured to receive the ground mixture from the discharge hopper; The crusher assembly includes a roller, the roller includes a roller pair, the roller includes a plurality of layers from an inner core to an outer core, each of the plurality of layers is formed of a different material, each of the materials has a different hardness, the plurality of layers includes an outer layer having a relatively highest hardness, an inner layer having a relatively lowest hardness, and an intermediate layer having a relative hardness between the hardness of the outer layer and the hardness of the inner layer.

2. The apparatus of claim 1, wherein the crusher assembly comprises at least one pair of roller assemblies.

3. The apparatus of claim 1, wherein the crusher assembly comprises a pair of intermeshing gear assemblies or roller assemblies.

4. The apparatus of claim 1 , wherein the control assembly is configured to receive data from the control components and drive assembly of the reactor chamber to determine adjustments that need to be made to the components and the drive assembly to optimize sugar yield from feedstock.

5. The device of claim 1, wherein the sensor assembly comprises a pH sensor, a temperature sensor, an oxygen sensor, a humidity sensor, and a pressure sensor.

6. The device of claim 1, wherein the substances include proteins, cellulose, starch, simple sugars, water, lignin, dust, and oil.

7. The apparatus according to claim 1, wherein the ratio of biomass to the solid acid is 1 kg:0.1 kg to 1 kg:10 kg; and wherein the solid acid comprises kaolin, bentonite and montmorillonite.

8. A method for converting cellulose into sugars, comprising the steps of: The cellulose raw material and the solid acid catalyst are mixed in a mixing device. feeding a mixture of feedstock and catalyst into a feed hopper of a reactor chamber, the feed hopper comprising a detector, wherein the reactor chamber comprises a plurality of control assemblies, wherein the control assemblies comprise the feed hopper, a crusher assembly, a discharge hopper, a sensor assembly, a steam inlet, and a carbon dioxide inlet; receiving and analyzing the ratio data of substances in the mixture of the raw material and the catalyst through a detector; receiving a mixture of the feedstock and the catalyst from the feed hopper; grinding the mixture under pressure to induce a solid-to-solid chemical reaction between the cellulosic feedstock and the solid acid catalyst to produce sugars, wherein the crusher assembly is driven by a drive assembly; wherein the shredder assembly is configured to grind the mixture under pressure to induce a solid-to-solid chemical reaction between the cellulosic feedstock and the solid acid catalyst to produce sugars; determining data for a ratio of a substance in a ground mixture passed through the crusher assembly; determining, at a control assembly in communication with the reactor chamber, whether the ground mixture needs to be reprocessed, wherein the control assembly is configured to receive data from the control components and the drive assembly of the reactor chamber to determine whether adjustments need to be made to the components and the drive assembly to optimize sugar production; According to the reprocessing requirements, the ground mixture is fed into the reactor chamber via a feed line for reprocessing, and The sugar produced after the reprocessing is received from the discharge hopper by a collecting device, The crusher assembly comprises a roller pair, wherein the roller comprises a single entity or a plurality of layers from an inner core to an outer core, each of the plurality of layers being formed of a different material, each of the materials having a different hardness.

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