Pressure valve machining

Abstract

A valve assembly in which the internal wall of the valve body includes at least one opening for the entry of liquid under pressure after the slurry or liquid has been output from a tube or pipe. The valve assembly is particularly suitable for maintaining a semi-continuous or continuous pressurised flow of biomass from an extruder and extending the reaction zone downstream from the extruder. The advantage of having an extended reaction zone allows for the complete treatment of the material without further attrition of the extruder and also allows for manipulation of the upstream treatment of the material in the tube or pipe.

Description

[0001] Cross-referencing

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 087,077, filed October 2, 2020; U.S. Provisional Application No. 63 / 146,608, filed February 6, 2021; and U.S. Provisional Application No. 63 / 153,740, filed February 25, 2021, each of which is incorporated herein by reference in its entirety. Background Technology

[0003] In many industrial processes, valves are used to control the flow of materials. A pressure-reducing valve contains a plug that, when the valve is pressurized, blocks or reduces the output of the material source. When the pressure behind the plug is released, the plug is pushed back by the force of the output pressure. This allows the valve to open until the pressure behind the plug equals or exceeds the output force. Precise, continuous movement is possible if the valve is coupled to an actuator that operates in response to the output, not just with manually operated or spring-loaded valves.

[0004] When materials are moved under pressure, controlling the pressure within the container transporting the material is challenging. This is particularly true for continuous or semi-continuous flow of slurries of material moving in one direction under critical operating conditions caused by media handling. To maintain constant pressure and velocity of the moving material, a valve must be designed to keep the pressure in the pipe or tank constant while allowing a certain velocity. This is especially true for particulate matter (e.g., biomass) moving in a liquid under high pressure, where the valve is involved in further processing and the material flow is rapid and turbulent. Such harsh operating conditions can induce premature failure and leakage of valve assemblies, leading to bursting and extreme wear. Furthermore, slurry particles may become trapped in the valve seal loop, causing performance degradation of the valve assembly. Typically, pressure-reducing valves are not designed for handling such operations. Summary of the Invention

[0005] In one aspect, this document provides a system for pretreating biomass, comprising: an extruder including one or more screws, wherein an inner plug of biomass is formed by the action of the one or more screws, thereby forming an upstream end of a pressurized reaction zone for pretreating the biomass; and a valve assembly attached to an output end of the extruder, wherein the valve assembly forms a downstream end of the reaction zone and adds liquid to the reaction zone.

[0006] On the other hand, this document provides a system for pretreating biomass comprising: an extruder including one or more screws, wherein an inner plug of biomass is formed by the action of the one or more screws, thereby forming an upstream end of a pressurized reaction zone for pretreating the biomass; and a valve assembly attached to an output end of the extruder, wherein the valve assembly includes: a valve body including a large circular portion, an intermediate conical portion, and a small circular collar, the small circular collar containing one or more nozzles for liquid input, the valve body having a chamber formed therein connecting an input end and an output end of the valve body, wherein the inner diameter of the small circular collar is smaller than the inner diameter of the large circular portion; a valve needle axially movable within the chamber of the valve body; and a housing attached to the output end of the valve body, and the housing closing the valve needle when the valve needle is disengaged from the valve body.

[0007] In some embodiments, biomass is selected from: silage, agricultural residues, corn stalks, sugarcane bagasse, sorghum, nuts, nut shells, coconut shells, distillers dried sorghum solubles, distillers dried grains, concentrated distillers dried sorghum solubles, wet distillers dried grains, distillers dried grains with sorghum solubles, wood materials, sawdust, wood chips, wood balls, wood waste, factory waste, municipal waste, waste paper, recycled toilet paper, yard cuts and energy crops such as poplar, willow, switchgrass, alfalfa and prairie bluestem, non-woody plant matter, cellulose materials, lignocellulose materials, hemicellulose materials, carbohydrates, corn, sugarcane, grass, high biomass sorghum, bamboo, corn cobs, and fruit peels and kernels. In some embodiments, the biomass is processed in the reaction zone for less than 60, 55, 50, 45, 40, 35, 30, 25, 20, 19, 18, 17, 16, 15, 14, 13, 12, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 second. In some embodiments, the temperature in the reaction zone is increased to 50-500°C, 75-400°C, 100-350°C, 150-300°C, 200-250°C, or 150-300°C, and the pressure in the reaction zone is increased to 50-1000 PSI, 100-750 PSI, 200-600 PSI, 300-500 PSI, or 350-450 PSI. In some embodiments, the system further includes means for supplying steam and one or more chemicals to the reaction zone. In some embodiments, the one or more chemicals include acids. In some embodiments, the acid is sulfuric acid.

[0008] In some embodiments, the valve assembly includes: a valve body including a large circular portion, an intermediate conical portion, and a small circular collar containing one or more nozzles for liquid inlet; the valve body having a chamber formed therein connecting an inlet and a outlet end of the valve body, wherein the inner diameter of the small circular collar is smaller than the inner diameter of the large circular portion; a valve needle axially movable within the chamber of the valve body; and a housing attached to the outlet end of the valve body and closing the valve needle when it is disengaged from the valve body. In some embodiments, the housing includes a removable outlet ring. In some embodiments, the outlet ring is conical. In some embodiments, the valve body includes an annular ring. In some embodiments, the annular ring is removable. In some embodiments, when the valve needle is closed on the valve body, an annular space is formed in the chamber between the valve body and the valve needle. In some embodiments, the nozzles for liquid inlet deliver water into the chamber. In some embodiments, the nozzles for liquid inlet deliver a liquid other than water into the chamber. In some embodiments, the liquid is selected from: acids, bases, alcohols, ketones, aldehydes, solvents, or combinations thereof. In some embodiments, the inner diameter of the housing at the end adjacent to the valve body is at least 7% larger than the inner diameter of the valve body at its discharge end. In some embodiments, the inner diameter of the housing at the end adjacent to the valve body is approximately 7% larger than the inner diameter of the valve body at its discharge end. In some embodiments, the valve needle has a cone with a wide end opposite its conical tip. In some embodiments, the cone angle is in the range of 45 degrees to 75 degrees. In some embodiments, the cone has a cone angle of approximately 45 degrees. In some embodiments, the diameter of the valve needle at its wide end is at least 4% larger than the inner diameter of the valve body at its discharge end. In some embodiments, the diameter of the valve needle at its wide end is approximately 4% larger than the inner diameter of the valve body at its discharge end. In some embodiments, the extruder is a twin-screw extruder. In some embodiments, the extruder has a port for adding steam and / or acid.

[0009] On the other hand, this paper provides a method for pretreating biomass using the system disclosed herein.

[0010] On the other hand, this article provides a method for pretreating biomass, the method comprising: conveying biomass from a feed zone of an extruder to a reaction zone of the extruder via an extruder, wherein the feed zone and the reaction zone are separated by biomass plugs formed downstream of the feed zone and upstream of the reaction zone; adding steam and / or chemicals to the biomass in the reaction zone to partially treat the biomass; conveying the partially treated biomass to a valve assembly attached to an output end of the extruder and treating the partially treated biomass in the valve assembly to produce pretreated biomass; and discharging the pretreated biomass through the valve assembly.

[0011] In some embodiments of the method, the biomass is fed through the extruder at the same speed as the partially processed biomass is fed through the valve assembly. In some embodiments, the temperature in the reaction zone is increased to 50-500°C, 75-400°C, 100-350°C, 150-300°C, 200-250°C, or 150-300°C, and the pressure in the reaction zone is increased to 50-1000 PSI, 100-750 PSI, 200-600 PSI, 300-500 PSI, or 350-450 PSI. In some embodiments, biomass is selected from: silage, agricultural residues, corn stalks, bagasse, sorghum, nuts, nut shells, coconut shells, dried distillers' grains solubles, dried distillers' grains, concentrated distillers' grains solubles, wet distillers' grains, dried distillers' grains and their solubles, wood materials, sawdust, wood chips, wood balls, wood waste, factory waste, municipal waste, waste paper, recycled toilet paper, yard cuts and energy crops such as poplar, willow, switchgrass, alfalfa and steppe bluegrass, non-woody plant matter, cellulose materials, lignocellulose materials, hemicellulose materials, carbohydrates, corn, sugarcane, grass, high biomass sorghum, bamboo, corn cobs, and fruit peels and kernels. In some embodiments, the biomass is processed in the reaction zone for less than 60, 55, 50, 45, 40, 35, 30, 25, 20, 19, 18, 17, 16, 15, 14, 13, 12, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 second. In some embodiments, the chemicals are selected from acids, bases, alcohols, ketones, aldehydes, solvents, or combinations thereof. In some embodiments, the extruder includes one or more screws. In some embodiments, the extruder includes two screws.

[0012] On the other hand, this article provides a method for pretreating biomass, the method comprising: conveying biomass from a feed zone of an extruder to a reaction zone of the extruder via an extruder, wherein the feed zone and the reaction zone are separated by biomass plugs formed downstream of the feed zone and upstream of the reaction zone; adding steam and / or chemicals to the biomass in the reaction zone to partially treat the biomass; conveying the partially treated biomass to an extension compartment attached to the output end of the extruder; and treating the partially treated biomass in the extension compartment to produce pretreated biomass.

[0013] In some embodiments, the method further includes adding acid at a downstream end of the extruder as the biomass exits the extruder. In some embodiments, the extension chamber is formed of a pipe. In some embodiments, the extension chamber is formed of a container. In some embodiments, the extension chamber is formed of a valve assembly. In some embodiments, the extension chamber is capable of continuously discharging pretreated biomass. In some embodiments, the extension chamber is capable of semi-continuously discharging pretreated biomass. In some embodiments, the extension chamber is capable of batch discharging pretreated biomass. The biomass is conveyed through the extruder at the same speed as the partially treated biomass is conveyed through the extension chamber. In some embodiments, the extension chamber is pressurized. In some embodiments, the extension chamber is equipped with one or more nozzles for liquid input. In some embodiments, the nozzles for liquid input deliver water into the chamber. In some embodiments, the nozzles for liquid input deliver a liquid other than water into the chamber. In some embodiments, the liquid is selected from: acids, bases, alcohols, ketones, aldehydes, solvents, or combinations thereof. In some embodiments, the temperature in the reaction zone is increased to 50-500°C, 75-400°C, 100-350°C, 150-300°C, 200-250°C, or 150-300°C, and the pressure in the reaction zone is increased to 50-1000 PSI, 100-750 PSI, 200-600 PSI, 300-500 PSI, or 350-450 PSI. In some embodiments, biomass is selected from: silage, agricultural residues, corn stalks, bagasse, sorghum, nuts, nut shells, coconut shells, dried distillers' grains solubles, dried distillers' grains, concentrated distillers' grains solubles, wet distillers' grains, dried distillers' grains and their solubles, wood materials, sawdust, wood chips, wood balls, wood waste, factory waste, municipal waste, waste paper, recycled toilet paper, yard cuts and energy crops such as poplar, willow, switchgrass, alfalfa and steppe bluegrass, non-woody plant matter, cellulose materials, lignocellulose materials, hemicellulose materials, carbohydrates, corn, sugarcane, grass, high biomass sorghum, bamboo, corn cobs, and fruit peels and kernels. In some embodiments, the biomass is processed in the reaction zone for less than 60, 55, 50, 45, 40, 35, 30, 25, 20, 19, 18, 17, 16, 15, 14, 13, 12, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 second. In some embodiments, the chemicals are selected from acids, bases, alcohols, ketones, aldehydes, solvents, or combinations thereof. In some embodiments, the extruder includes one or more screws. In some embodiments, the extruder includes two screws.

[0014] In one aspect, a system for processing biomass via an extruder and a valve assembly is provided, comprising: an extruder including one or more screws, wherein an inner plug of biomass is formed by the action of the screws, thereby forming one end of a pressurized reaction zone; a method for supplying steam and one or more chemicals to the reaction zone; a valve assembly attached to the output end of the extruder, the valve assembly forming a downstream end of the reaction zone and adding liquid to the reaction zone; and the valve assembly being capable of rapidly discharging pressurized, processed biomass into a non-pressurized discharge zone.

[0015] In some embodiments, biomass is selected from: silage, agricultural residues, corn stalks, bagasse, sorghum, nuts, nut shells, coconut shells, dried distillers' grains solubles, dried distillers' grains, concentrated distillers' grains solubles, wet distillers' grains, dried distillers' grains and their solubles, wood materials, sawdust, wood chips, wood balls, wood waste, factory waste, municipal waste, waste paper, recycled toilet paper, yard cuts and energy crops such as poplar, willow, switchgrass, alfalfa and steppe bluegrass, non-woody plant matter, cellulose materials, lignocellulose materials, hemicellulose materials, carbohydrates, corn, sugarcane, grass, high biomass sorghum, bamboo, corn cobs, and fruit peels and kernels. In a further aspect, the biomass is processed in the reaction zone for less than 60, 55, 50, 45, 40, 35, 30, 25, 20, 19, 18, 17, 16, 15, 14, 13, 12, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 second. In another embodiment, the temperature in the reaction zone is increased to 50-500°C, 75-400°C, 100-350°C, 150-300°C, 200-250°C, or 150-300°C, and the pressure is increased by steam to 50-1000 PSI, 100-750 PSI, 200-600 PSI, 300-500 PSI, or 350-450 PSI. In another aspect, the chemical is an acid. In another aspect, the acid is sulfuric acid. In a further embodiment, the valve assembly includes: a housing; a valve body including: a large circular portion; an intermediate conical portion; a smaller circular collar containing one or more nozzles for liquid input; and a valve needle.

[0016] In another embodiment, there is a space between the valve body and the valve needle when the valve needle is in place. In one aspect, a nozzle for liquid inlet delivers water into the space between the valve body and the valve needle. In another aspect, a nozzle for liquid inlet delivers a liquid other than water into the space between the valve body and the valve needle. In one embodiment, the liquid is selected from acids, bases, alcohols, ketones, aldehydes, solvents, or combinations thereof.

[0017] In one aspect, there is a method for treating a slurry or liquid in a pipe or tank attached to a valve assembly, the method comprising: the pipe or tank having a plug forming one end of a reaction zone; conveying the liquid or slurry through the pipe or tank; attaching the valve assembly to the output end of the pipe or tank forming the downstream end of the reaction zone while maintaining pressure in the reaction zone by introducing steam; adding material to the upstream end of the valve assembly as the liquid or slurry enters the valve assembly; and discharging the treated liquid or slurry into a non-pressurized area using the valve assembly. In one aspect, the liquid or slurry comprises biomass. On the other hand, biomass is selected from: silage, agricultural residues, corn stalks, sugarcane bagasse, sorghum, nuts, nut shells, coconut shells, dried distillers' grains solubles, dried distillers' grains, concentrated distillers' grains solubles, wet distillers' grains, dried distillers' grains and their solubles, wood materials, sawdust, wood chips, wood balls, wood waste, factory waste, municipal waste, waste paper, recycled toilet paper, yard cuts and energy crops such as poplar, willow, switchgrass, alfalfa and steppe bluegrass, non-woody plant matter, cellulose materials, lignocellulose materials, hemicellulose materials, carbohydrates, corn, sugarcane, grass, high biomass sorghum, bamboo, corn cobs, and fruit peels and kernels. On the other hand, biomass is processed in the reaction zone for less than 60, 55, 50, 45, 40, 35, 30, 25, 20, 19, 18, 17, 16, 15, 14, 13, 12, 10, 9, 8, 7, 6, 5, 4, 3, 2 or 1 second.

[0018] In one embodiment, the temperature in the reaction zone is raised to 50-500°C, 75-400°C, 100-350°C, 150-300°C, 200-250°C, or 150-300°C, and the pressure is raised by steam to 50-1000 PSI, 100-750 PSI, 200-600 PSI, 300-500 PSI, or 350-450 PSI. In another embodiment, the substance is an acid. In a further embodiment, the acid is sulfuric acid.

[0019] In one aspect, a system is provided for extending a reaction zone downstream of an extruder, comprising: an extruder including a reaction zone portion, wherein the extruder reaction zone portion is attached to a downstream valve assembly including an adjacent internal space; wherein the reaction zone portion in the extruder is coupled to the adjacent internal space of the valve assembly to extend the reaction zone downstream of the extruder. In another aspect, the speed at which material moves through the reaction zone portion of the extruder is consistent with the speed at which material moves through the valve assembly.

[0020] In one embodiment, the valve assembly has an annular ring that is part of the valve body. In another embodiment, the annular ring is replaceable. In one embodiment, the valve body includes a nozzle for introducing liquid. In one embodiment, when closed in the valve body, the valve needle is positioned at the discharge ring. In a further aspect, the valve needle is attached to an actuator. In one embodiment, the actuator maintains a pressure on the valve needle that is maintained at more than 1,800 lbf. In another embodiment, the actuator maintains a pressure on the valve needle between 50,000 and 500,000 lbf.

[0021] In one embodiment, the extruder is a twin-screw extruder. In another embodiment, the extruder has a port for adding steam and / or acid.

[0022] In one aspect, a method for extending a downstream reaction zone of an extruder is provided, the method comprising processing biomass in the reaction zone, wherein the reaction zone extends from the extruder to an attached downstream valve assembly. In one embodiment, the valve assembly includes: a housing; a valve body further comprising a large circular portion, an intermediate conical portion, a smaller circular collar receiving one or more nozzles for liquid input; and a valve needle.

[0023] In one embodiment, the housing includes a removable discharge ring. In another embodiment, the discharge ring is conical. In a further embodiment, the valve body includes an annular ring. In a further embodiment, the annular ring is removable. In one aspect, there is a space between the valve body and the valve needle when the valve needle is in place. In another aspect, a nozzle for liquid inlet delivers water into the space between the valve body and the valve needle. In a further aspect, a nozzle for liquid inlet delivers a liquid other than water into the space between the valve body and the valve needle. In another embodiment, the liquid in the nozzle is selected from: acids, bases, alcohols, ketones, aldehydes, solvents, or combinations thereof. In another embodiment, the liquid is an acid. In a further embodiment, the acid is sulfuric acid. In another embodiment, steam or one or more chemicals are added to the reaction zone of the extruder. In a further embodiment, the temperature in the reaction zone is raised to 50-500°C, 75-400°C, 100-350°C, 150-300°C, 200-250°C, or 150-300°C. The pressure is increased by steam to 50-1000 PSI, 100-750 PSI, 200-600 PSI, 300-500 PSI, or 350-450 PSI. In another embodiment, the rate remains constant throughout the reaction zone.

[0024] In one aspect, a method for processing biomass is provided, comprising: conveying biomass through an extruder, wherein the extruder is divided into two zones, an input zone and a reaction zone, separated by biomass plugs formed downstream of an input zone and upstream of a reaction zone; adding steam and / or chemicals to the biomass in the reaction zone to partially treat the biomass; conveying the partially treated biomass to an attached valve assembly for a period of time for continued processing; and discharging the biomass through the valve assembly. In another aspect, the rate of biomass conveyed is the same in both the extruder and the valve assembly. In one embodiment, the temperature in the reaction zone is increased to 50-500°C, 75-400°C, 100-350°C, 150-300°C, 200-250°C, or 150-300°C. The pressure is increased by steam to 50-1000 PSI, 100-750 PSI, 200-600 PSI, 300-500 PSI, or 350-450 PSI. In a further embodiment, the biomass is selected from: silage, agricultural residues, corn stalks, sugarcane bagasse, sorghum, nuts, nut shells, coconut shells, dried distillers' grains solubles, dried distillers' grains, concentrated distillers' grains solubles, wet distillers' grains, dried distillers' grains and their solubles, wood materials, sawdust, wood chips, wood balls, wood waste, factory waste, municipal waste, waste paper, recycled toilet paper, yard cuts and energy crops such as poplar, willow, switchgrass, alfalfa and steppe bluegrass, non-woody plant matter, cellulose materials, lignocellulose materials, hemicellulose materials, carbohydrates, corn, sugarcane, grass, high biomass sorghum, bamboo, corn cobs, and fruit peels and kernels. In one aspect, the biomass is processed in the reaction zone for less than 60, 55, 50, 45, 40, 35, 30, 25, 20, 19, 18, 17, 16, 15, 14, 13, 12, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 second. In another aspect, the chemicals are selected from: acids, bases, alcohols, ketones, aldehydes, solvents, or combinations thereof.

[0025] Incorporation

[0026] All publications, patents and patent applications mentioned in this specification are incorporated herein by reference to the extent that each individual publication, patent or patent application is specifically and individually cited and incorporated herein by reference.

[0027] Brief description of the attached figures

[0028] The novel features of this disclosure are set forth in detail in the appended claims. A better understanding of the features and advantages of this disclosure will be obtained by referring to the following detailed description and accompanying drawings, which illustrate illustrative embodiments in which the principles of this disclosure are utilized, in which:

[0029] Figure 1 This is a schematic diagram depicting a modified pressure valve assembly.

[0030] Figure 2 This is a schematic diagram showing a longitudinal view of the valve and its housing.

[0031] Figure 3A and Figure 3B This is a schematic diagram depicting a longitudinal view of the valve assembly from the top (3A) and the side (3B).

[0032] Figure 4 This is a top-down longitudinal view of the valve assembly.

[0033] Figure 5 yes Figure 4 The larger portion of part A seen in the image.

[0034] Figure 6 This is a cross-sectional view of the valve body without the valve needle.

[0035] Figures 7A-7D The cross-section of the valve at the annulus is depicted: closed position (7A); 0.5 mm stroke (7B); 1.0 mm stroke (7C); and 1.5 mm stroke (7D). Detailed Implementation

[0036] Unless the context clearly specifies otherwise, the singular forms “a,” “an,” and “the” used in the specification and appended claims include the plural forms. Thus, for example, reference to “purified monomer” includes a mixture of two or more purified monomers. The term “comprising” as used herein is synonymous with “containing,” “including,” or “characterized by,” and is inclusive or open-ended, not excluding additional, unlisted elements or method steps.

[0037] "About" means a reference figure plus or minus 10% of that reference figure. For example, the term "about 4" would include a range of 3.6 to 4.4. All figures used in this specification to indicate the amount of ingredients, reaction conditions, etc., should be understood to be modified by the term "about" in all cases. Therefore, unless otherwise stated, the numerical parameters described herein are approximate values ​​that may vary depending on the desired properties sought. At least, and without attempting to limit the application of the doctrine of equivalents to the scope of any claim in any application that claims priority to this application, each numerical parameter should be interpreted according to the number of significant figures and common rounding methods.

[0038] Unless otherwise expressly stated, whenever the phrases “for example,” “such as,” “including,” etc., are used in this document, the phrase “but not limited to” should be understood to follow it. Thus, “for example, ethanol production” means “for example, but not limited to ethanol production.”

[0039] In this specification and the following claims, many terms will be referenced, which should be defined as having the following meanings.

[0040] definition

[0041] The word "optional" or "optionally" means that an event or condition described below may or may not occur, and the description includes both the possibility that the event or condition occurs and the possibility that it does not occur. For example, the phrase "the culture medium may optionally contain glucose" means that the culture medium may or may not contain glucose as a component, and the description includes both culture media containing glucose and culture media not containing glucose.

[0042] Unless otherwise stated, the technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art.

[0043] As used herein, the term "biomass" has the common meaning known to those skilled in the art and can include one or more carbon-containing biological materials that can be converted into biofuels, chemicals, or other products. Biomass as used herein is synonymous with the term "raw material" and includes silage, agricultural residues (corn stalks, grass, rice straw, grain husks, bagasse, etc.), nuts, nut shells, coconut shells, animal manure (cattle, poultry, and pig manure), dried distillers grains solubles, dried distillers grains, concentrated distillers grains solubles, wet distillers grains, dried distillers grains and their solubles, wood materials (timber or bark, sawdust, wood chips, wood balls, wood waste, and factory waste), municipal waste (waste paper, recycled toilet paper, yard cuts, etc.), and energy crops (poplar, willow, switchgrass, alfalfa, steppe bluegrass, and algae including members of large algae such as green algae, brown algae, red algae, etc.). An exemplary source of biomass is plant material. Plant matter can be, for example, woody plant matter, non-woody plant matter, cellulose material, lignocellulose material, hemicellulose material, sugarcane, grass, sorghum, high-biomass sorghum, bamboo, algae, and materials derived from these. Plants can be in their natural state or genetically modified, for example, to increase the cellulose or hemicellulose portion of the cell wall, or to produce additional exogenous or endogenous enzymes to increase the separation of cell wall components. Plant matter can be further described by reference to existing chemical substances such as proteins, polysaccharides, and oils. Polysaccharides include polymers and derivatives of various monosaccharides, including glucose, fructose, lactose, galacturonic acid, rhamnose, etc. Plant matter also includes agricultural waste by-products or sidestreams, such as pomace, corn steep liquor, corn cobs, corn fiber, corn steep liquor solids, distiller's grains, peels, pits, fermentation waste, straw, wood, sewage, garbage, and food scraps. Peels can be citrus fruits, including but not limited to orange peel, grapefruit peel, tangerine peel, mandarin orange peel, lime peel, and lemon peel. These materials can come from farms, forestry, industrial sources, households, etc. Another non-limiting example of biomass is animal matter, including, for example, milk, bones, meat, fat, animal processing waste, and animal manure. The term "raw material" is often used to refer to biomass used in processes such as those described herein.

[0044] As used herein, “pretreatment” or “pretreated” refers to any mechanical, chemical, thermal, biochemical process or combination of these processes, whether performed in combination or sequentially, that achieves the destruction or expansion of biomass to make it more susceptible to enzymatic and / or microbial attack, and may include the enzymatic hydrolysis of released carbohydrate polymers or oligomers into monomers. In one embodiment, pretreatment includes, for example, removing or destroying lignin by treating with an acid or alkali to make cellulose and hemicellulose polymers in plant biomass more susceptible to utilization by cellulolytic enzymes and / or microorganisms. In one embodiment, pretreatment includes the rupture or expansion of cellulose and / or hemicellulose materials. In another embodiment, it may refer to starch release and / or enzymatic hydrolysis into glucose. Steam explosion and ammonia cellulose expansion (or explosion) (AFEX) are known thermochemical techniques. Hydrolysis, including methods utilizing acids, alkalis, and / or enzymes, may be used. Other thermochemical, chemical, biochemical, and enzymatic techniques may also be used.

[0045] The "steam explosion" method used in this paper is a physicochemical approach that uses high-pressure steam to break the bonds between polymer components and depressurize to destroy the lignocellulose structure. In this method, the lignocellulose pulp is treated with high-pressure steam for a period of time, and then rapidly depressurized to atmospheric pressure.

[0046] As described herein, a "liquid" composition may contain a solid, and a "solid" composition may contain a liquid. A liquid composition is a composition in which the materials are primarily liquid, while a solid composition is a composition in which the materials are primarily solid. A "slurry" is a solid that is dissolved or insoluble in a liquid.

[0047] describe

[0048] The following description and examples illustrate some exemplary embodiments of this disclosure. Those skilled in the art will recognize that numerous variations and modifications of this disclosure are covered within the scope of the invention. Therefore, the description of specific exemplary embodiments should not be construed as limiting the scope of this disclosure.

[0049] On one hand, the structure and design of the valve assembly described herein address the degradation stress encountered in high-pressure flows of treated liquids or slurries through pipes or conduits. The valve assembly is designed to incorporate partial treatment of such liquids or slurries as the fluid enters the valve assembly upstream from the attached pipe or conduit, passes through the valve assembly, and flows downstream into the discharge area.

[0050] Another key advantage of using valve assemblies such as those described herein is the ability to reduce material processing time in the extruder barrel. Regardless of the size of the extruder and the end valve assembly, the pressure and velocity of the material moving through the reaction zone remain fairly constant. This is because as the valve size increases, the annular space within the valve increases the length of the reaction zone, thus increasing the reaction zone volume and consequently increasing the material processing time without extending the residence time in the extruder barrel.

[0051] In one embodiment, a valve assembly for the fluid end is provided. In another aspect, the valve assemblies disclosed herein can be used for continuous or semi-continuous processing of liquids, slurries, viscous liquids, or any liquefied substance under pressure. Regarding processing, it should be understood that materials can be modified individually by heating, pressurizing, and / or adding chemicals, or chemically reacted by mixing under pressure, heating, or by adding chemical components (such as acids, alkalis, bleaching agents, dyes, etc.) in combination of two or more components (simultaneously or by subsequent addition). Examples of such components include plastics, plant materials, food, polymers, polyurethanes, etc.

[0052] In one aspect, the slurry of the material may comprise pretreated or partially hydrolyzed biomass. This arrangement can be used to achieve constant velocity and pressure as the material moves through a channel such as a pipe or conduit. Water or steam can be added via a valve assembly at the plug and outlet to increase and maintain a constant pressure in the channel. The section between the plug and the valve assembly is a reaction zone for modifying the material. This zone includes flash evaporation of the material through the valve needle tip.

[0053] In one embodiment, materials can be processed using an extruder and valve assembly. The extruder moves liquids, slurries, solids, and viscous materials through a barrel via a screw element. Depending on the shape of the element, the material can be slowed, mixed, or propelled through the barrel. The extruder can be a single-screw extruder, a twin-screw extruder, or a three-screw extruder. For biomass materials, a twin-screw extruder is preferred. Extruders with specially constructed screws designed to allow the addition of very large amounts of steam to increase pressure enable the pretreatment of biomass at high speeds. Rapid extruder pretreatment systems, such as those described in US2016 / 0273009A1 or WO2018 / 151833(A1) (each incorporated herein by reference in its entirety), provide unique pathways for decomposing biomass and releasing cellulose and lignin from other biomass components. The combination of mechanoporosis, dilute acid hydrolysis, and steam explosion is all completed within 20 seconds, producing a very clean slurry of soluble sugars, microcrystalline cellulose, and lignin. The short, intense processing duration produces unique cellulose, hemicellulose, and lignin products that have been converted to a highly active state without the excessive cooking or sulfonation that occurs in most other processing methods.

[0054] Devices for restricting and releasing liquids and materials moving through pipes or hoppers have been proposed in the past. Several of these devices involve insertion valves within the extruder hopper itself. One such device, described in US2007 / 0237022A1, is a hopper adjustable valve assembly. Others are end valves, such as those found in US2009 / 0053800A1, WO2010 / 056940A2, or US10,344,757B1. None of these can be used as part of a processing system and are not suitable for high-speed continuous processing.

[0055] Extrusion can be continuous or semi-continuous, and processing can be done with hot or cold materials. Common extruded materials include metals, polymers, ceramics, concrete, molded clay, and food; however, biomass can also be processed in extruders. Extruders can have one or more shafts. A twin-screw extruder is a machine with two identical, co-penetrating, and self-cleaning screws mounted on a shaft and rotating in the same direction within a fixed, enclosed housing called a "bucket." Twin-screw extruders can operate continuously at high temperatures and pressures for very short residence times.

[0056] In one embodiment, the acid, heat, and explosion pretreatment process for extracting biomass components is a rapid treatment process that includes steam explosion. This treatment is performed while the reduced-size biomass particles are subjected to pressurized acid hydrolysis and high-temperature steam treatment, followed by steam explosion. Since the entire process is continuous and takes only a few seconds, this requires an efficient and rapidly moving valve system to maintain the pressure for continuous processing.

[0057] In processing biomass, steam is injected into the feed hopper to increase temperature and pressure. In one embodiment, the screw element is also used to slow the flow of material to form a plug, which is used to seal the material in the feed hopper after input and further build up pressure within the feed hopper. See, for example, U.S. Application No. 15 / 932,340, which is incorporated herein by reference.

[0058] The example of the valve assembly is not intended to be limited to extruders, but is provided as an illustration to demonstrate its functional value. In this system, one functional implementation of the pressure valve assembly is to help initiate and maintain a constant pressure within the extruder and through the valve body. This is where most of the biomass processing occurs—through the reaction zone. A plug in the extruder helps to slow down the flow by using a specific screw, and steam is used to build up pressure in the reaction zone. An actuator sets the pressure on the valve needle to maintain the required pressure within the extruder and valve body. Precise, continuous movement can be achieved if the valve is coupled to an actuator that operates in response to internal pressure at the end of a pipe or hopper, rather than a manually or spring-operated valve.

[0059] Preferably, the actuator is a hydraulic or pneumatic actuator, such as those manufactured by Kyntronics (Solon, OH 44139, USA). The actuator keeps the valve needle moving in and out continuously and rapidly along the longitudinal axis with very small movements. The actual force that the needle valve must maintain for the biomass in the reaction zone of the extruder hopper can range from 1,800 lbf to 82,000 lbf, or even higher (over 500,000 lbf). Constant force is achieved by controlling the flow of the treated biomass material or liquid through an annular space. The actuator system transmits electrical signals directly to the actuation mechanism. It is set to operate at a specific pressure and respond to the force applied to the material flowing from the tube or extruder.

[0060] In one respect, when liquids or slurries flash outside the annular ring (the interface between the annular ring and the discharge ring—see below), a shorter reaction zone length is required in the pipe or conduit because the reaction zone includes the area between the plug (through the valve body) and the vapor explosion zone. In the example of processing biomass in an extruder, this shortens the length of the extruder reaction zone and reduces the metallurgical costs required for extruder processing.

[0061] In one example of a pressure valve assembly, such as Figure 1 As shown, the valve has a valve body 10 with a conical valve needle 11 and a housing 12 with a discharge pipe 13. The valve body and valve needle can be made of any material, as long as the material can withstand the abrasion and tearing of liquids or slurries of different chemicals flowing from the upstream inlet 30 through the valve body and housing to the discharge pipe 13, but it must be made of an inert metal or a metal with an inert coating. The valve needle is attached to a shaft 14. Figure 2 As shown in the longitudinal section, the valve body 10 has a cylindrical portion 15, an intermediate conical portion 16, and another generally cylindrical collar 17 with a diameter smaller than the first portion 15. The valve body includes an annular (wear) ring 19 at its widest point. It is located within a recess in the valve body portion 15. The inner surface of the annular ring 19 is aligned with the rest of the valve body 10 and serves as a replaceable wear element. The annular ring 19 is located within the valve's reaction zone and extends to the smallest annular space 21 (see...). Figure 7A Then, it flashes into the atmosphere (steam explosion).

[0062] The conical discharge ring 20 is located outside the valve body 10 within the housing 12 and is not part of the reaction zone. It is a device that ensures liquid or slurry is guided to the discharge pipe 13 and into the flash tank (not shown). It is also a wear part and is therefore easily replaceable. The conical shape on the discharge ring 20 (see...) Figure 3A and Figure 3B This avoids a right-angle connection with the valve body, which could lead to material buildup and interfere with the movement of the substance from the needle tip to the outlet.

[0063] Figure 3A and Figure 3B These are longitudinal sections of the valve and its housing, respectively, in top and side views. Material flows upstream from a pipe, tank, or conduit (fluid force) under pressure, enters through valve body section 17, and is discharged downstream into housing 12. Force from the actuator is applied to the valve needle via shaft 14.

[0064] There is an annular space 21 between the valve body 10 and the valve needle 11. The diameter of the cavity 22 of the housing 12 is also increased by 7% compared with the inner diameter of the valve body 10, wherein the cavity 22 of the housing 12 receives the discharged liquid or slurry (material), and the valve body 10 receives the flashed material.

[0065] During operation, the pressure differential acting on the valve needle 11 causes the valve needle 11 to shift along its longitudinal axis 75. The pressure behind the valve stem 14 positions the valve in the valve body portion 15 just before the widest end of the needle 11.

[0066] The widest part of the needle valve 11 is slightly larger than the widest part of the valve body 10, so that when closed, the needle valve 11 is positioned at the annular ring 19 in the valve body portion 15. In one embodiment, the diameter of the wide end of the needle is at least 4% larger than the diameter of the valve body at the discharge end. In another embodiment, the diameter of the wide end of the needle is approximately 4% larger than the diameter of the valve body at the discharge end. In one embodiment, the diameter of the wide end of the needle is 416 mm, while the diameter of the discharge end of the valve body is 400 mm. This can be increased or decreased. In one embodiment, the cone forms a 45-degree taper angle from its widest diameter to the needle tip 18. In other embodiments, the taper angle of the cone can be in the range of 45 degrees to 75 degrees. This measurement will be based on the material, raw materials, process requirements, space requirements, and the force required to move the needle valve.

[0067] The collar 17 is a device for connecting the pressure-reducing valve to the extruder or other tubing. When the valve is fully in place and attached to the extruder, the valve needle tip 18 extends just to the beginning of the collar at the end of the conical portion 16, and there is space between the tip of the needle and the discharge end of the tubing or extruder 35 and the end of any screw 38. During the pretreatment of biomass in the extruder, water is injected through the injection nozzle 36 in the collar 17 after the material leaves the extruder but before it reaches the valve needle tip 18 (see...). Figure 4 and Figure 5Water is used to dilute the material and improve its rheology through a steam explosion, thereby reducing the torque pushed by the valve on the extruder. During processing, the material, especially the slurry, does not typically flow, but there is some fluctuation as it is processed through pipes or hoppers. The flow at the outlet is turbulent, and when it mixes with water, it smoothly enters the laminar flow traveling downwards within the space of valve 21. Any liquid can be added before exiting from the pipe to facilitate material flow through the valve system and / or further processing of the material. In one embodiment, liquids such as water, acids, bases, alcohols, solvents, aldehydes, ketones, etc., can be used for this purpose.

[0068] In the closed position, the valve needle tip 18 rests within the internal space of the valve body 10, approximately at the interface between the central conical portion 16 and the smaller cylindrical collar 17. See Figure 5 The valve needle tip 18 is located approximately 3-6 mm downstream of the liquid injection point.

[0069] Figure 6 This is a cross-sectional view of the valve body 10 without the valve needle 18, facing the discharge end of the extruder with twin screws 38. After the material leaves the extruder, the inlet nozzle 36 injects liquid into the collar 17.

[0070] Figure 7A This is a cross-sectional view of the seal between the conical needle 11 and the conical valve body 15 at the annular ring 19. At this point, the pressure behind the valve stem 14 is equal to or greater than the pressure of the fluid and / or material flowing out of the pipe, thus preventing flow. Figure 7B The movement of valve needle 11 is depicted as the pressure within the conduit increases and valve needle 11 moves approximately 0.5 mm toward the housing. Valve needle 11 separates from its position within the annular ring 19, allowing fluid and / or material to flow around valve needle 11 through passage (space) 21 to discharge area 22 (shown in Figure 3). The increased pressure from the conduit causes valve needle 11 to move further toward the discharge area, widening the gap between the needle and annular ring 19 and allowing greater fluid and / or material flow; i.e., a movement of 1.0 mm (…). Figure 7C ) and 1.5mm ( Figure 7D ).

[0071] During operation, the valve needle 18 moves in and out several times per second to maintain the required set pressure, thus moving between full closure and the maximum permissible annular space of 2 mm. A hydraulic actuator attached to the valve needle keeps the valve needle moving in and out along the longitudinal axis incessantly, very quickly, and with very small movements.

[0072] The passage provides a unique opportunity to extend the reaction zone beyond the extruder barrel end. In some embodiments, the reaction zone is extended by an extension chamber rather than the passage of the valve assembly disclosed herein. For example, the extension chamber is formed by a container or tube attached to the extruder output. Processing through the extruder and passage 21 is continuous, and the volume of space 21 must be taken into account when measuring pretreatment time. The barrel portions of the extruder, manifold, and injection assembly are designed so that the barrel portions can be repositioned and / or flipped. Therefore, if a change in the length of the reaction zone is required, for example, the steam injection and acid injection ports can be moved so that the injection of steam and acid is done further downstream toward the end of the extruder barrel, shortening the time cycle for pretreating the material in the extruder portion, but maintaining the same volume of space in passage 21. This results in less wear on the expensive extruder portion and coating, reducing the overall cost of pretreatment.

[0073] In another embodiment, increasing the volume of the passage by increasing the size of the valve assembly will result in a longer pretreatment cycle without increasing wear and tear on the extruder. In a further embodiment, if a longer steam cycle and shorter acid treatment are required, the acid tank can be moved downstream to increase the time of contact with steam and theoretically reduce the amount of acid required, rather than moving the acid further downstream. Similarly, if the contact time with acid at the reaction temperature is too long and produces inhibitors, the acid tank can be moved downstream and / or added later to passage 21 to produce less inhibitor.

[0074] Depending on the size of the extrusion system, 30mm, 63mm, 98mm, and 400mm valves are used for stable and continuous biomass pretreatment operations. In other embodiments, valves of 500-600mm and larger can be used.

[0075] This system, consisting of the syringe, along with the hopper and end valve sizing, offers considerable flexibility and almost limited control over injection possibilities and pretreatment duration. The rate of material passing through and flashing out of the valve remains constant, thus increasing the residence time of the material in space 21 as the valve size increases.

[0076] From the examples above, it will be clear to those skilled in the art that combining different volumes with passage 21 can yield a variety of combinations of feed tank sections to maximize the efficiency of biomass pretreatment while minimizing pretreatment costs. While the speed at which the material moves through the system remains constant, temperature and chemicals may vary.

[0077] In some cases, continuous processing of materials, liquids, or both is required under constant pressure. For example, pretreatment of biomass is uneconomical in batch production; it is both time-consuming and wasteful of materials. The challenge is how to maintain a constant, precise pressure during processing while moving the material through pipes or hoppers and simultaneously releasing the pressurized material to atmospheric pressure. Furthermore, this is difficult to achieve when working with slurries because the nature of the non-uniform mixture causes pulsation.

[0078] The valve described herein can be used at high speeds. For example, continuous biomass processing measured at annular ring 19 results in 185-190 m / s with a stroke of 0.5 mm. The potential range is approximately 90 m / s to 250 m / s. In other embodiments, speeds of 95 m / s, 100 m / s, 110 m / s, 120 m / s, 130 m / s, 140 m / s, 150 m / s, 160 m / s, 170 m / s, 180 m / s, 190 m / s, 200 m / s, 210 m / s, 220 m / s, 230 m / s, 240 m / s, and higher are possible.

[0079] The rate of biomass material movement via the system has been established from 55 kg / hr for 30 mm valves to over 96 DMT / day for 400 mm valves. Higher rates can be achieved for larger valves.

[0080] In some embodiments, the liquid or slurry is processed in the reaction zone for less than 60, 55, 50, 45, 40, 35, 30, 25, 20, 19, 18, 17, 16, 15, 14, 13, 12, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 second. In some embodiments, biomass is processed in the reaction zone for about 5 to 15 seconds; in larger systems, biomass is processed for 30 seconds or less, or 60 seconds or less.

[0081] In another embodiment, the liquid or slurry may be treated under elevated pressure. In one embodiment, the biomass is pretreated at a pressure range of about 1 psi to about 30 psi. In another embodiment, the biomass is pretreated at pressures of about 50 psi, 100 psi, 150 psi, 200 psi, 250 psi, 300 psi, 350 psi, 400 psi, 450 psi, 500 psi, 550 psi, 600 psi, 650 psi, 700 psi, 750 psi, 800 psi, or higher up to 900 psi. In some embodiments, the biomass may be treated under elevated pressure by injecting steam into the container holding the biomass. In one embodiment, the biomass may be treated under vacuum conditions before or after alkaline or acid treatment or any other treatment method provided herein.

[0082] Exemplary Implementation

[0083] Implementation 1. A system for processing biomass via an extruder and a valve assembly, comprising:

[0084] (a) An extruder comprising one or more screws, wherein an inner plug of biomass is formed by the action of the screws, thereby forming one end of a pressurized reaction zone;

[0085] (b) A method for supplying steam and one or more chemicals to a reaction zone;

[0086] (c) A valve assembly attached to the output end of the extruder, forming the downstream end of the reaction zone and adding liquid to the reaction zone; and

[0087] (d) The valve assembly is capable of rapidly discharging pressurized, treated biomass into a non-pressurized discharge area.

[0088] Implementation Method 2. The system according to Implementation Method 1, wherein the biomass is selected from: silage, agricultural residues, corn stalks, sugarcane bagasse, sorghum, nuts, nut shells, coconut shells, dried distillers' grains solubles, dried distillers' grains, concentrated distillers' grains solubles, wet distillers' grains, dried distillers' grains and their solubles, wood materials, sawdust, wood chips, wood balls, wood waste, factory waste, municipal waste, waste paper, recycled toilet paper, yard cuts and energy crops such as poplar, willow, switchgrass, alfalfa and steppe bluegrass, non-woody plant matter, cellulose materials, lignocellulose materials, hemicellulose materials, carbohydrates, corn, sugarcane, grass, high biomass sorghum, bamboo, corn cobs, and fruit peels and kernels.

[0089] Implementation Method 3. The system according to Implementation Method 1, wherein the biomass is processed in the reaction zone for less than 60, 55, 50, 45, 40, 35, 30, 25, 20, 19, 18, 17, 16, 15, 14, 13, 12, 10, 9, 8, 7, 6, 5, 4, 3, 2 or 1 second.

[0090] Implementation Method 4. The system according to Implementation Method 1, wherein the temperature in the reaction zone is increased to 50-500°C, 75-400°C, 100-350°C, 150-300°C, 200-250°C or 150-300°C, and the pressure is increased to 50-1000 PSI, 100-750 PSI, 200-600 PSI, 300-500 PSI or 350-450 PSI.

[0091] Implementation Method 5. In the system according to Implementation Method 1, one of the chemicals is an acid.

[0092] Implementation method 6. The system according to implementation method 1, wherein the acid is sulfuric acid.

[0093] Implementation 7. The system according to Implementation 1, wherein the valve assembly includes:

[0094] Embodiment 8. A housing;

[0095] (a) The valve body includes:

[0096] i. The large circular section;

[0097] ii. The middle conical section;

[0098] iii. A small circular collar comprising one or more nozzles for liquid input; and

[0099] (b) Valve needle.

[0100] Embodiment 9. The valve assembly according to Embodiment 7, wherein when the valve needle is in place, there is a space between the valve body and the valve needle.

[0101] Embodiment 10. The valve assembly according to Embodiment 7, wherein a nozzle for liquid input delivers water into the space between the valve body and the valve needle.

[0102] Embodiment 11. The valve assembly according to Embodiment 7, wherein a nozzle for liquid input delivers liquid other than water into the space between the valve body and the valve needle.

[0103] Embodiment 12. The nozzle according to Embodiment 10, wherein the liquid is selected from: acid, base, alcohol, ketone, aldehyde, solvent or combination thereof.

[0104] Embodiment 13. A method for treating slurry or liquid in a pipe or tank attached to a valve assembly, the method comprising:

[0105] a. The pipe or container has a plug at one end that forms the reaction zone;

[0106] b. Transporting liquids or slurries through pipes or tanks;

[0107] c. Attach the valve assembly to the output end of the pipe or tank downstream of the reaction zone, while maintaining the pressure in the reaction zone by inputting steam;

[0108] d. Adding material to the upstream end of the valve assembly as the liquid or slurry enters the valve assembly; and

[0109] e. Use valve assemblies to discharge the treated liquid or slurry into a non-pressurized area.

[0110] Implementation 14. The method according to Implementation 12, wherein the liquid or slurry comprises biomass.

[0111] Implementation Method 15. The method according to Implementation Method 13, wherein the biomass is selected from: silage, agricultural residues, corn stalks, sugarcane bagasse, sorghum, nuts, nut shells, coconut shells, dried distillers' grains solubles, dried distillers' grains, concentrated distillers' grains solubles, wet distillers' grains, dried distillers' grains and their solubles, wood materials, sawdust, wood chips, wood balls, wood waste, factory waste, municipal waste, waste paper, recycled toilet paper, yard cuts and energy crops such as poplar, willow, switchgrass, alfalfa and steppe bluegrass, non-woody plant matter, cellulose materials, lignocellulose materials, hemicellulose materials, carbohydrates, corn, sugarcane, grass, high biomass sorghum, bamboo, corn cobs, and fruit peels and kernels.

[0112] Implementation 16. The method according to Implementation 14, wherein the biomass is processed in the reaction zone for less than 60, 55, 50, 45, 40, 35, 30, 25, 20, 19, 18, 17, 16, 15, 14, 13, 12, 10, 9, 8, 7, 6, 5, 4, 3, 2 or 1 second.

[0113] Implementation Method 17. According to the method of Implementation Method 14, the temperature in the reaction zone is increased to 50-500°C, 75-400°C, 100-350°C, 150-300°C, 200-250°C or 150-300°C, and the pressure is increased to 50-1000 PSI, 100-750 PSI, 200-600 PSI, 300-500 PSI or 350-450 PSI.

[0114] Implementation Method 18. The method according to Implementation Method 14, wherein the substance is an acid.

[0115] Implementation Method 19. The method according to Implementation Method 14, wherein the acid is sulfuric acid.

[0116] Implementation 20. A system for extending a reaction zone downstream of an extruder, comprising:

[0117] (a) An extruder including a reaction zone portion, wherein the extruder reaction zone portion is attached to a downstream valve assembly including an adjacent internal space;

[0118] (b) wherein the reaction zone portion of the extruder is combined with the adjacent internal space of the valve assembly to extend the reaction zone downstream of the extruder.

[0119] Implementation 21. The system according to Implementation 19, wherein the speed at which material moves through the reaction zone portion of the extruder is kept constant with the speed at which material moves through the valve assembly.

[0120] Embodiment 22. The valve assembly according to Embodiment 19, wherein the annular ring is part of the valve body.

[0121] Embodiment 23. The valve assembly according to Embodiment 19, wherein the annular ring is replaceable.

[0122] Embodiment 24. The valve assembly according to Embodiment 19, wherein the valve body includes a nozzle for introducing liquid.

[0123] Embodiment 25. The valve assembly according to Embodiment 19, wherein the valve needle is positioned at the discharge ring when closed in the valve body.

[0124] Embodiment 26. The valve assembly according to Embodiment 24, wherein the valve needle is attached to the actuator.

[0125] Embodiment 27. The actuator according to Embodiment 25, wherein the actuator maintains pressure on the valve needle.

[0126] Embodiment 28. The actuator according to Embodiment 25, wherein the actuator maintains a pressure of more than 1,800 lbf on the valve needle.

[0127] Embodiment 29. The actuator according to Embodiment 25, wherein the actuator maintains a pressure of 50,000 to 500,000 lbf on the valve needle.

[0128] Embodiment 30. The extruder according to Embodiment 19, wherein the extruder is a twin-screw extruder.

[0129] Embodiment 31. The extruder according to Embodiment 19, wherein the extruder has a port for adding steam and / or acid.

[0130] Implementation Method 32. A method for extending the reaction zone downstream of an extruder, comprising:

[0131] (a) Processing biomass in a reaction zone, wherein the reaction zone extends from the extruder into an attached downstream valve assembly.

[0132] Implementation 33. The method according to implementation 31, wherein the valve assembly includes:

[0133] (a) Shell;

[0134] (b) A valve body, comprising:

[0135] iv. Large circular section

[0136] v. The middle conical part

[0137] vi. A smaller circular collar comprising one or more nozzles for liquid input;

[0138] and

[0139] (c) Valve needle.

[0140] Embodiment 34. The valve assembly according to Embodiment 32, wherein the housing includes a removable drain ring.

[0141] Embodiment 35. The valve assembly according to Embodiment 33, wherein the discharge ring is conical.

[0142] Embodiment 36. The valve assembly according to Embodiment 32, wherein the valve body includes an annular ring. Embodiment 37. The valve assembly according to Embodiment 35, wherein the annular ring is removable.

[0143] Embodiment 38. The valve assembly according to Embodiment 32, wherein when the valve needle is in place, there is a space between the valve body and the valve needle.

[0144] Embodiment 39. The valve assembly according to Embodiment 32, wherein a nozzle for liquid input delivers water into the space between the valve body and the valve needle.

[0145] Embodiment 40. The valve assembly according to Embodiment 38, wherein a nozzle for liquid input delivers liquid other than water into the space between the valve body and the valve needle.

[0146] Embodiment 41. The nozzle according to Embodiment 39, wherein the liquid is selected from: acid, base, alcohol, ketone, aldehyde, solvent or combination thereof.

[0147] Implementation 42. The method according to Implementation 31, wherein steam and one or more chemicals are added to the reaction zone of the extruder.

[0148] Implementation Method 43. According to the method of Implementation Method 31, the temperature in the reaction zone is increased to 50-500°C, 75-400°C, 100-350°C, 150-300°C, 200-250°C or 150-300°C, and the pressure is increased to 50-1000 PSI, 100-750 PSI, 200-600 PSI, 300-500 PSI or 350-450 PSI.

[0149] Implementation 44. The method according to Implementation 41, wherein the liquid is an acid.

[0150] Implementation 45. The method according to Implementation 41, wherein the acid is sulfuric acid.

[0151] Implementation 46. The method according to Implementation 31, wherein the rate remains constant throughout the reaction zone.

[0152] Implementation Method 47. A method for processing biomass, comprising:

[0153] (a) conveying biomass through an extruder, wherein the extruder is divided into two zones, an input zone and a reaction zone, separated by biomass plugs formed downstream of an input zone and upstream of a reaction zone;

[0154] (b) Adding steam and / or chemicals to the biomass in the reaction zone to partially treat the biomass;

[0155] (c) Transferring partially processed biomass to an attached valve assembly for a period of time to continue processing; and

[0156] (d) Discharge biomass through valve assembly.

[0157] Implementation 48. The method according to implementation 46, wherein the rate of biomass conveyed is the same in the extruder and valve assembly.

[0158] Implementation Method 49. The method according to Implementation Method 46, wherein the temperature in the reaction zone is increased to 50-500°C, 75-400°C, 100-350°C, 150-300°C, 200-250°C or 150-300°C, and the pressure is increased to 50-1000 PSI, 100-750 PSI, 200-600 PSI, 300-500 PSI or 350-450 PSI.

[0159] Implementation 50. The method according to Implementation 46, wherein the biomass is selected from: silage, agricultural residues, corn stalks, bagasse, sorghum, nuts, nut shells, coconut shells, dried distillers' grains solubles, dried distillers' grains, concentrated distillers' grains solubles, wet distillers' grains, dried distillers' grains and their solubles, wood materials, sawdust, wood chips, wood balls, wood waste, factory waste, municipal waste, waste paper, recycled toilet paper, yard cuts and energy crops such as poplar, willow, switchgrass, alfalfa and steppe bluegrass, non-woody plant matter, cellulose materials, lignocellulose materials, hemicellulose materials, carbohydrates, corn, sugarcane, grass, high biomass sorghum, bamboo, corn cobs, and fruit peels and kernels.

[0160] Implementation 51. The method according to Implementation 46, wherein the biomass is processed in the reaction zone for less than 60, 55, 50, 45, 40, 35, 30, 25, 20, 19, 18, 17, 16, 15, 14, 13, 12, 10, 9, 8, 7, 6, 5, 4, 3, 2 or 1 second.

[0161] Implementation Method 52. The method according to Implementation Method 46, wherein the chemical is selected from acids, bases, alcohols, ketones, aldehydes, solvents, or combinations thereof.

[0162] [1] A system for pretreating biomass, comprising:

[0163] (a) An extruder comprising one or more screws, wherein an inner plug of biomass is formed by the action of the one or more screws, thereby forming an upstream end of a pressurized reaction zone for pre-treating the biomass; and

[0164] (b) A valve assembly attached to the output end of the extruder, wherein the valve assembly forms the downstream end of the reaction zone and adds liquid to the reaction zone.

[0165] [2] According to the system described in paragraph [1], the biomass is selected from: silage, agricultural residues, corn stalks, bagasse, sorghum, nuts, nut shells, coconut shells, dried distillers' grains solubles, dried distillers' grains, concentrated distillers' grains solubles, wet distillers' grains, dried distillers' grains and their solubles, wood materials, sawdust, wood chips, wood balls, wood waste, factory waste, municipal waste, waste paper, recycled toilet paper, garden cuts and energy crops such as poplar, willow, switchgrass, alfalfa and steppe bluegrass, non-woody plant matter, cellulose materials, lignocellulose materials, hemicellulose materials, carbohydrates, corn, sugarcane, grass, high biomass sorghum, bamboo, corn cobs, and fruit peels and kernels.

[0166] [3] According to the system described in paragraph [1] or [2], the biomass is processed in the reaction zone for less than 60, 55, 50, 45, 40, 35, 30, 25, 20, 19, 18, 17, 16, 15, 14, 13, 12, 10, 9, 8, 7, 6, 5, 4, 3, 2 or 1 second.

[0167] [4] The system according to any one of paragraphs [1]-[3], wherein the temperature in the reaction zone is raised to 50-500°C, 75-400°C, 100-350°C, 150-300°C, 200-250°C or 150-300°C, and the pressure in the reaction zone is raised to 50-1000 PSI, 100-750 PSI, 200-600 PSI, 300-500 PSI or 350-450 PSI.

[0168] [5] The system according to any one of paragraphs [1]-[4], wherein the system further includes means for supplying steam and one or more chemicals to the reaction zone.

[0169] [6] According to the system described in paragraph [5], one or more chemicals include acids.

[0170] [7] According to the system described in paragraph [6], the acid is sulfuric acid.

[0171] [8] The system according to any one of paragraphs [1]-[7], wherein the valve assembly comprises:

[0172] A valve body comprising a large circular portion, an intermediate conical portion, and a small circular collar, the small circular collar containing one or more nozzles for liquid input, the valve body having a chamber formed therein connecting the inlet and outlet ends of the valve body, wherein the inner diameter of the small circular collar is smaller than the inner diameter of the large circular portion;

[0173] The valve needle is axially movable within the valve body cavity; and

[0174] The housing is attached to the discharge end of the valve body and closes the valve needle when the valve needle is detached from the valve body.

[0175] [9] The system described in paragraph [8] includes a removable exhaust ring in the housing.

[0176]

[10] According to the system described in paragraph [9], the emission ring is conical.

[0177]

[11] The system according to any one of paragraphs [8]-

[10] , wherein the valve body comprises an annular ring.

[0178]

[12] According to the system described in paragraph

[11] , the annular ring is removable.

[0179]

[13] The system according to any one of paragraphs [8]-

[12] , wherein when the valve needle is closed on the valve body, an annular space is formed in the chamber between the valve body and the valve needle.

[0180]

[14] The system according to any one of paragraphs [8]-

[13] , wherein the nozzle for liquid input delivers water into the chamber.

[0181]

[15] The system according to any one of paragraphs [8]-

[14] , wherein the nozzle for liquid input delivers liquid other than water into the chamber.

[0182]

[16] The system according to paragraph

[15] , wherein the liquid is selected from: acids, bases, alcohols, ketones, aldehydes, solvents or combinations thereof.

[0183]

[17] The system according to any one of paragraphs [8]-

[16] , wherein the inner diameter of the housing at the end of the housing adjacent to the valve body is at least 7% larger than the inner diameter of the valve body at its discharge end.

[0184]

[18] The system according to any one of paragraphs [8]-

[17] , wherein the inner diameter of the housing at the end of the housing adjacent to the valve body is about 7% larger than the inner diameter of the valve body at its discharge end.

[0185]

[19] The system according to any one of paragraphs [8]-

[18] , wherein the valve needle has a cone having a wide end opposite its conical tip.

[0186]

[20] According to the system described in paragraph

[19] , the cone angle of the cone is in the range of 45 degrees to 75 degrees.

[0187]

[21] According to the system described in paragraph

[19] , the cone has a cone angle of about 45 degrees.

[0188]

[22] The system according to any one of paragraphs

[19] -

[21] , wherein the diameter of the valve needle at the wide end is at least 4% larger than the inner diameter of the valve body at its discharge end.

[0189]

[23] The system according to any one of paragraphs

[19] -

[22] , wherein the diameter of the valve needle at the wide end is about 4% larger than the inner diameter of the valve body at its discharge end.

[0190]

[24] The system according to any one of paragraphs [1]-

[23] , wherein the extruder is a twin-screw extruder.

[0191]

[25] The system according to any one of paragraphs [1]-

[24] , wherein the extruder has a port for adding steam and / or acid.

[0192]

[26] A system for pretreating biomass, comprising:

[0193] (a) An extruder comprising one or more screws, wherein an inner plug of biomass is formed by the action of the one or more screws, thereby forming an upstream end of a pressurized reaction zone for pretreatment of the biomass; and

[0194] (b) A valve assembly attached to the output end of the extruder, wherein the valve assembly includes:

[0195] A valve body comprising a large circular portion, an intermediate conical portion, and a small circular collar, the small circular collar containing one or more nozzles for liquid input, the valve body having a chamber formed therein connecting the inlet and outlet ends of the valve body, wherein the inner diameter of the small circular collar is smaller than the inner diameter of the large circular portion;

[0196] The valve needle is axially movable within the valve body cavity; and

[0197] The housing is attached to the discharge end of the valve body and closes the valve needle when the valve needle is detached from the valve body.

[0198]

[27] According to the system described in paragraph

[26] , the biomass is selected from: silage, agricultural residues, corn stalks, bagasse, sorghum, nuts, nut shells, coconut shells, dried distillers' grains solubles, dried distillers' grains, concentrated distillers' grains solubles, wet distillers' grains, dried distillers' grains and their solubles, wood materials, sawdust, wood chips, wood balls, wood waste, factory waste, municipal waste, waste paper, recycled toilet paper, garden cuts and energy crops such as poplar, willow, switchgrass, alfalfa and steppe bluegrass, non-woody plant matter, cellulose materials, lignocellulose materials, hemicellulose materials, carbohydrates, corn, sugarcane, grass, high biomass sorghum, bamboo, corn cobs, and fruit peels and kernels.

[0199]

[28] The system according to paragraph

[26] or

[27] , wherein the biomass is processed in the reaction zone for less than 60, 55, 50, 45, 40, 35, 30, 25, 20, 19, 18, 17, 16, 15, 14, 13, 12, 10, 9, 8, 7, 6, 5, 4, 3, 2 or 1 second.

[0200]

[29] The system according to any one of paragraphs

[26] -

[28] , wherein the temperature in the reaction zone is raised to 50-500°C, 75-400°C, 100-350°C, 150-300°C, 200-250°C or 150-300°C, and the pressure is raised to 50-1000 PSI, 100-750 PSI, 200-600 PSI, 300-500 PSI or 350-450 PSI.

[0201]

[30] The system according to any one of paragraphs

[26] -

[29] , wherein the chamber of the valve body forms the downstream portion of the pressurized reaction zone.

[0202]

[31] The system according to any one of paragraphs

[26] -

[30] , wherein the system further includes means for supplying steam and one or more chemicals to the reaction zone.

[0203]

[32] According to the system described in paragraph

[31] , one or more chemicals include acids.

[0204]

[33] According to the system described in paragraph

[32] , the acid is sulfuric acid.

[0205]

[34] The system according to any one of paragraphs

[26] -

[33] , wherein the housing includes a removable exhaust ring.

[0206]

[35] According to the system described in paragraph

[34] , the emission ring is conical.

[0207]

[36] The system according to any one of paragraphs

[26] -

[35] , wherein the valve body comprises an annular ring.

[37] The system according to paragraph

[36] , wherein the annular ring is removable.

[0208]

[38] The system according to any one of paragraphs

[26] -

[37] and

[29] , wherein when the valve needle is closed on the valve body, an annular space is formed in the chamber between the valve body and the valve needle.

[0209]

[39] The system according to any one of paragraphs

[26] -

[38] and

[37] , wherein the nozzle for liquid input delivers water into the chamber.

[0210]

[40] The system according to any one of paragraphs

[26] -

[39] , wherein the nozzle for liquid input delivers liquid other than water into the chamber.

[0211]

[41] The system according to paragraph

[40] , wherein the liquid is selected from: acids, bases, alcohols, ketones, aldehydes, solvents or combinations thereof.

[0212]

[42] The system according to any one of paragraphs

[26] -

[41] and

[37] , wherein the inner diameter of the housing at the end of the housing adjacent to the valve body is at least 7% larger than the inner diameter of the valve body at its discharge end.

[0213]

[43] The system according to any one of paragraphs

[26] -

[42] , wherein the inner diameter of the housing at the end of the housing adjacent to the valve body is about 7% larger than the inner diameter of the valve body at its discharge end.

[0214]

[44] The system according to any one of paragraphs

[26] -

[43] , wherein the valve needle has a cone having a wide end opposite its conical tip.

[0215]

[45] According to the system described in paragraph

[44] , the cone angle of the cone is in the range of 45 degrees to 75 degrees.

[0216]

[46] According to the system described in paragraph

[44] , the cone has a cone angle of about 45 degrees.

[0217]

[47] The system according to any one of paragraphs

[44] -

[46] , wherein the diameter of the valve needle at the wide end is at least 4% larger than the inner diameter of the valve body at its discharge end.

[0218]

[48] ​​The system according to any one of paragraphs

[44] -

[46] , wherein the diameter of the valve needle at the wide end is about 4% larger than the inner diameter of the valve body at its discharge end.

[0219]

[49] The system according to any one of paragraphs

[26] -

[48] , wherein the extruder is a twin-screw extruder.

[0220]

[50] The system according to any one of paragraphs

[26] -

[49] , wherein the extruder has a port for adding steam and / or acid.

[0221]

[51] A method for pretreating biomass using any one of paragraphs [1]-

[50] .

[52] A method for pretreating biomass, comprising:

[0222] (a) Biomass is conveyed from the feed zone of the extruder to the reaction zone of the extruder via an extruder, wherein the feed zone and the reaction zone are separated by biomass plugs formed downstream of the feed zone and upstream of the reaction zone;

[0223] (b) Adding steam and / or chemicals to the biomass in the reaction zone to partially treat the biomass;

[0224] (c) The partially treated biomass is fed into a valve assembly attached to the output end of the extruder, and the partially treated biomass is processed in the valve assembly to produce pretreated biomass; and

[0225] (d) Discharge pretreated biomass through valve assembly.

[0226]

[53] According to the method described in paragraph

[52] , the biomass is conveyed through the extruder at the same speed as the partially processed biomass is conveyed through the valve assembly.

[0227]

[54] The method according to paragraph

[52] or

[53] wherein the temperature in the reaction zone is raised to 50-500°C, 75-400°C, 100-350°C, 150-300°C, 200-250°C or 150-300°C, and the pressure in the reaction zone is raised to 50-1000 PSI, 100-750 PSI, 200-600 PSI, 300-500 PSI or 350-450 PSI.

[0228]

[55] The method according to any one of paragraphs

[52] -

[54] , wherein the biomass is selected from: silage, agricultural residues, corn stalks, bagasse, sorghum, nuts, nut shells, coconut shells, dried distillers' grains solubles, dried distillers' grains, concentrated distillers' grains solubles, wet distillers' grains, dried distillers' grains and their solubles, wood materials, sawdust, wood chips, wood balls, wood waste, factory waste, municipal waste, waste paper, recycled toilet paper, garden cuts and energy crops such as poplar, willow, switchgrass, alfalfa and steppe bluegrass, nonwoody plant matter, cellulose materials, lignocellulose materials, hemicellulose materials, carbohydrates, corn, sugarcane, grass, high biomass sorghum, bamboo, corn cobs, and fruit peels and kernels.

[0229]

[56] The method according to any one of paragraphs

[52] -

[55] , wherein the biomass is treated in the reaction zone for less than 60, 55, 50, 45, 40, 35, 30, 25, 20, 19, 18, 17, 16, 15, 14, 13, 12, 10, 9, 8, 7, 6, 5, 4, 3, 2 or 1 second.

[0230]

[57] The method according to any one of paragraphs

[52] -

[56] , wherein the chemical is selected from: acids, bases, alcohols, ketones, aldehydes, solvents or combinations thereof.

[0231]

[58] The method according to any one of paragraphs

[52] -

[57] , wherein the extruder includes one or more screws.

[0232]

[59] The method described in paragraph

[58] includes two screws in the extruder.

[0233]

[60] The method according to any one of paragraphs

[52] -

[59] , wherein the valve assembly comprises:

[0234] A valve body comprising a large circular portion, an intermediate conical portion, and a small circular collar, the small circular collar containing one or more nozzles for liquid input, the valve body having a chamber formed therein connecting the input end and the discharge end of the valve body, wherein the inner diameter of the small circular collar is smaller than the inner diameter of the large circular portion;

[0235] The valve needle is axially movable within the valve body cavity; and

[0236] The housing is attached to the discharge end of the valve body and closes the valve needle when the valve needle is detached from the valve body.

[0237]

[61] The method described in paragraph

[60] includes a removable exhaust ring.

[0238]

[62] The method described in paragraph

[61] is wherein the emission ring is conical.

[0239]

[63] The method according to any one of paragraphs

[60] -

[62]

[63] , wherein the valve body comprises an annular ring.

[0240]

[64] The method described in paragraph

[63] is wherein the annular ring is removable.

[0241]

[65] According to any one of the methods in paragraphs

[60] -

[64] , an annular space is formed in the chamber between the valve body and the valve needle when the valve needle is closed on the valve body.

[0242]

[66] The method according to any one of paragraphs

[60] -

[65] , wherein the nozzle for liquid input delivers water into the chamber.

[0243]

[67] The method according to any one of paragraphs

[60] -

[66] , wherein the nozzle for liquid input delivers a liquid other than water into the chamber.

[0244]

[68] The method described in paragraph

[67] wherein the liquid is selected from: acids, bases, alcohols, ketones, aldehydes, solvents or combinations thereof.

[0245]

[69] The method according to any one of paragraphs

[60] -

[68] , wherein the inner diameter of the housing at the end of the housing adjacent to the valve body is at least 7% larger than the inner diameter of the valve body at its discharge end.

[0246]

[70] The method according to any one of paragraphs

[60] -

[69] , wherein the inner diameter of the housing at the end of the housing adjacent to the valve body is about 7% larger than the inner diameter of the valve body at its discharge end.

[0247]

[71] The method according to any one of paragraphs

[60] -

[70] , wherein the valve needle has a cone having a wide end opposite its conical tip.

[0248]

[72] The method described in paragraph

[71] wherein the cone angle of the cone is in the range of 45 degrees to 75 degrees.

[0249]

[73] The method described in paragraph

[72] is wherein the cone has a cone angle of approximately 45 degrees.

[0250]

[74] The method according to any one of paragraphs

[71] -

[73] , wherein the diameter of the valve needle at the wide end is at least 4% larger than the inner diameter of the valve body at its discharge end.

[0251]

[75] The method according to any one of paragraphs

[71] -

[73] , wherein the diameter of the valve needle at the wide end is about 4% larger than the inner diameter of the valve body at its discharge end.

[0252]

[76] The method according to any one of paragraphs

[52] -

[75] , wherein treating the partially treated biomass in the valve assembly includes subjecting the partially treated biomass to the same elevated pressure and / or temperature as the reaction zone.

[0253]

[77] The method according to any one of paragraphs

[52] -

[76] , wherein processing the partially processed biomass in the valve assembly includes adding a substance to the partially processed biomass at the upstream end of the valve assembly.

[0254]

[78] The method described in paragraph

[77] includes substances including acids.

[0255]

[79] The method described in paragraph

[78] includes sulfuric acid.

[0256]

[80] The method according to any one of paragraphs

[52] -

[79] , wherein the extruder is a twin-screw extruder.

[0257]

[81] The method according to any one of paragraphs

[52] -

[80] , wherein the extruder has a port for adding steam and / or acid.

[0258]

[82] A method for pretreating biomass, the method comprising:

[0259] (a) Biomass is conveyed from the feed zone of the extruder to the reaction zone of the extruder via an extruder, wherein the feed zone and the reaction zone are separated by biomass plugs formed downstream of the feed zone and upstream of the reaction zone;

[0260] (b) Add steam and / or chemicals to the biomass in the reaction zone to partially treat the biomass;

[0261] (c) The partially processed biomass is conveyed to an extended compartment attached to the output end of the extruder, and

[0262] (d) Process the partially treated biomass in an extended compartment to produce pretreated biomass.

[0263]

[83] The method according to paragraph

[82] further includes adding acid at the downstream end of the extruder as the biomass leaves the extruder.

[0264]

[84] The method described in paragraph

[82] or

[83] wherein the extended compartment is formed by tubes.

[0265]

[85] The method described in paragraph

[82] or

[83] wherein the extended compartment is formed by a container.

[0266]

[86] The method described in paragraph

[82] or

[83] wherein the extended compartment is formed by a valve assembly.

[0267]

[87] The method according to any one of paragraphs

[82] -

[86] , wherein the extended compartment is capable of discharging pretreated biomass in a continuous manner.

[0268]

[88] The method according to any one of paragraphs

[82] -

[86] , wherein the extended compartment is capable of discharging pretreated biomass in a semi-continuous manner.

[0269]

[89] The method according to any one of paragraphs

[82] -

[86] , wherein the extended compartment is capable of discharging pretreated biomass in batches.

[0270]

[90] The method according to any one of paragraphs

[82] -

[89] , wherein the biomass is conveyed through the extruder at the same speed as the partially processed biomass is conveyed through the extended compartment.

[0271]

[91] The method according to any one of paragraphs

[82] -

[89] , wherein the extended compartment is pressurized.

[0272]

[92] The method according to any one of paragraphs

[82] -

[89] , wherein the extended compartment is equipped with one or more nozzles for liquid input.

[0273]

[93] According to the method described in paragraph

[92] , the nozzle for liquid input delivers water into the chamber.

[0274]

[94] The method described in paragraph

[92] wherein a nozzle for liquid input delivers a liquid other than water into the chamber.

[0275]

[95] The method according to paragraph

[94] wherein the liquid is selected from: acids, bases, alcohols, ketones, aldehydes, solvents or combinations thereof.

[0276]

[96] The method according to any one of paragraphs

[82] -

[95] , wherein the temperature in the reaction zone is raised to 50-500°C, 75-400°C, 100-350°C, 150-300°C, 200-250°C or 150-300°C, and the pressure in the reaction zone is raised to 50-1000 PSI, 100-750 PSI, 200-600 PSI, 300-500 PSI or 350-450 PSI.

[0277]

[97] The method according to any one of paragraphs

[82] -

[96] , wherein the biomass is selected from: silage, agricultural residues, corn stalks, bagasse, sorghum, nuts, nut shells, coconut shells, dried distillers' grains solubles, dried distillers' grains, concentrated distillers' grains solubles, wet distillers' grains, dried distillers' grains and their solubles, wood materials, sawdust, wood chips, wood balls, wood waste, factory waste, municipal waste, waste paper, recycled toilet paper, garden cuts and energy crops such as poplar, willow, switchgrass, alfalfa and steppe bluegrass, nonwoody plant matter, cellulose materials, lignocellulose materials, hemicellulose materials, carbohydrates, corn, sugarcane, grass, high biomass sorghum, bamboo, corn cobs, and fruit peels and kernels.

[0278]

[98] The method according to any one of paragraphs

[82] -

[97] , wherein the biomass is treated in the reaction zone for less than 60, 55, 50, 45, 40, 35, 30, 25, 20, 19, 18, 17, 16, 15, 14, 13, 12, 10, 9, 8, 7, 6, 5, 4, 3, 2 or 1 second.

[0279]

[99] The method according to any one of paragraphs

[82] -

[98] , wherein the chemical is selected from: acids, bases, alcohols, ketones, aldehydes, solvents or combinations thereof.

[0280]

[100] The method according to any one of paragraphs

[82] -

[99] , wherein the extruder includes one or more screws.

[0281]

[101] The method described in paragraph

[100] includes two screws.

[0282] While preferred embodiments of the invention have been shown and described herein, such embodiments will be apparent to those skilled in the art as provided by way of example only. Many variations, modifications, and substitutions will now be apparent to those skilled in the art without departing from this disclosure. It should be understood that various alternatives to the embodiments of this disclosure described herein may be employed in the practice of this disclosure. The following claims are intended to define the scope of this disclosure, and the methods and structures within the scope of these claims and their equivalents are thereby covered.

Claims

1. A system for pre-treating biomass, comprising: (a) An extruder comprising one or more screws, wherein an inner plug of the biomass is formed by the action of the one or more screws, thereby forming an upstream end of a pressurized reaction zone for pre-treating the biomass; and (b) A valve assembly attached to the output end of the extruder, wherein the valve assembly forms the downstream end of the reaction zone and adds liquid to the reaction zone. The valve assembly includes: A valve body comprising a large circular portion, an intermediate conical portion, and a small circular collar, the small circular collar including one or more nozzles for liquid input, the valve body having a chamber formed therein connecting an input end and an output end of the valve body, wherein the inner diameter of the small circular collar is smaller than the inner diameter of the large circular portion; A valve needle, which is axially movable within the cavity of the valve body; and A housing is attached to the discharge end of the valve body, and the housing closes the valve needle when the valve needle is disengaged from the valve body.

2. The system of claim 1, wherein the system further comprises means for supplying steam and one or more chemicals to the reaction zone.

3. The system according to claim 2, wherein one or more chemicals comprise acids.

4. The system according to claim 3, wherein the acid is sulfuric acid.

5. The system of claim 1, wherein the housing includes a removable exhaust ring.

6. The system of claim 5, wherein the emission ring is conical.

7. The system of claim 1, wherein the valve body comprises an annular ring.

8. The system of claim 7, wherein the annular ring is removable.

9. The system of claim 1, wherein when the valve needle is closed on the valve body, an annular space is formed in the chamber between the valve body and the valve needle.

10. The system of claim 1, wherein the inner diameter of the housing at the end of the housing adjacent to the valve body is at least 7% larger than the inner diameter of the valve body at its discharge end.

11. The system of claim 1, wherein the inner diameter of the housing at the end of the housing adjacent to the valve body is 7% larger than the inner diameter of the valve body at its discharge end.

12. The system of claim 1, wherein the valve needle has a cone having a wide end opposite its conical tip.

13. The system of claim 12, wherein the cone angle of the cone is in the range of 45 degrees to 75 degrees.

14. The system of claim 12, wherein the cone has a cone angle of 45 degrees.

15. The system of claim 12, wherein the diameter of the valve needle at the wide end is at least 4% larger than the inner diameter of the valve body at its discharge end.

16. The system of claim 12, wherein the diameter of the valve needle at the wide end is 4% larger than the inner diameter of the valve body at its discharge end.

17. The system of claim 1, wherein the extruder is a twin-screw extruder.

18. A method for pretreating biomass using the system described in any one of claims 1-17.

19. A method for pretreating biomass, the method comprising: (a) The biomass is conveyed from the feed zone of the extruder to the reaction zone of the extruder via an extruder, wherein the feed zone and the reaction zone are separated by a biomass plug formed downstream of the input zone and upstream of the reaction zone; (b) Adding steam and / or chemicals to the biomass in the reaction zone to partially treat the biomass; (c) The partially processed biomass is fed into a valve assembly attached to the output end of the extruder and processed in the valve assembly to produce pretreated biomass; and (d) Discharge the pretreated biomass through the valve assembly. The valve assembly includes: A valve body comprising a large circular portion, an intermediate conical portion, and a small circular collar, the small circular collar including one or more nozzles for liquid input, the valve body having a chamber formed therein connecting an input end and an output end of the valve body, wherein the inner diameter of the small circular collar is smaller than the inner diameter of the large circular portion; A valve needle, which is axially movable within the cavity of the valve body; and A housing is attached to the discharge end of the valve body, and the housing closes the valve needle when the valve needle is disengaged from the valve body.

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