Method and system for manufacturing dealkalized wood fiber materials and bio-based products

Abstract

The present invention relates to an integrated system, apparatus, and method for dealkalization of wood cellulose materials and production of bio-based products. In particular, the system generates dealkalized wood cellulose raw materials that can be used as raw materials for various downstream bio-based products. The system includes a slurry generation subsystem that combines pre-treated particles of wood cellulose material with a water mixture containing water and chemical agents to obtain a slurry; an ultrasonic treatment subsystem that breaks down the cellular structure of the wood cellulose material in the slurry, relaxes the wood cellulose matrix, and removes and neutralizes alkali at the cellular level; a hydrodynamic cavitation subsystem that decomposes the wood cellulose material in the slurry at the cellular level using high shear mechanical decomposition; and a direct steam injection subsystem connected to the slurry generation subsystem and / or the cavitation subsystem to achieve hydrostatic cavitation and alkali neutralization in the slurry.

Description

Technical Field

[0001] The present invention relates to producing de-alkalized bio-based products from de-alkalized lignocellulosic materials. In particular, the present invention relates to the development of systems and methods for converting lignocellulosic materials into various bio-products, including but not limited to solid fuels, biogas, bio-chemicals, biomaterials, etc. The present invention mainly includes the de-alkalization treatment of lignocellulosic materials and the downstream processes for converting the de-alkalized materials into various forms of bio-based products.

Background Art

[0002] In a global trend aiming to reduce dependence on fossil fuels and shift towards a more sustainable energy mix, the potential of utilizing lignocellulosic materials as a coal alternative resource has attracted attention. Lignocellulosic materials, which are regarded as renewable and carbon-neutral, can significantly reduce carbon dioxide emissions during power generation. Moreover, the utilization of lignocellulosic materials also contributes to strengthening energy security, developing regional economies, and promoting sustainable development.

[0003] Advances in lignocellulose conversion technologies such as torrefaction, gasification, and pyrolysis have made it possible to produce high-quality solid, liquid, and gaseous fuels from de-alkalized lignocellulosic materials, which is a promising means to meet the reduction of greenhouse gas emissions and the increase in energy demand.

[0004] As used herein, the term "lignocellulosic material" mainly refers to the main structural components of plants composed mainly of lignin, cellulose, and hemicellulose. These materials can be obtained from various lignocellulosic biomasses such as agricultural wastes, forestry residues, grasses, rice straw, bamboo, wood-related products, energy crops, and waste paper. These resources have attracted great attention as renewable and sustainable resources for producing biofuels, bio-products, and bio-chemicals.

[0005] Wood cellulose materials are abundant and widely available, and have the potential to reduce the environmental impact of human activities while decreasing reliance on fossil fuels. However, untreated cellulose materials cannot be directly used for energy or steel production unless they undergo pretreatment or heat treatment for the following reasons.

[0006] Firstly, raw cellulose materials have a high alkali ash content. Wood fiber materials have a higher ash content than fossil fuels, which causes contamination and corrosion in power generation and steelmaking facilities. In particular, due to the high concentrations of potassium and chlorine, raw or reformed biomass cannot currently be used for power generation or steelmaking. Although attempts are being made to remove alkali, effectively removing ash is key to opening up these applications.

[0007] Secondly, raw cellulose materials have a high moisture content. Typically, raw wood fiber materials have a high moisture content, which reduces their calorific value and makes transportation and storage difficult. Thirdly, their lower energy density compared to fossil fuels such as coal and natural gas limits their use in power generation and steelmaking.

[0008] Fourth, wood cellulose materials consist of a complex mixed structure of cellulose, hemicellulose, and lignin. These components form a rigid cellular structure and possess different properties, requiring different processing methods to facilitate energy extraction and enzyme utilization. Furthermore, variations in quality due to differences in raw material type, tree age, and harvesting region also pose a challenge.

[0009] As is known from conventional technology, plant cells are characterized by a rigid cell wall, and the cell wall is retained even under stress, while the cytoplasm separates. The cell wall and cell membrane are generally supported by potassium ions (K) present in plant cells. + It prevents the osmotic movement of molecules and ions such as ).

[0010] Even if the cytoplasmic membrane detaches from the cell wall or ruptures, ionized alkaline components such as potassium ions remain within the cell's organelles, vacuoles, and cytoplasmic structures. These organelles retain ionized substances and continue to function within the cell. Understanding this characteristic of plant cells is crucial for designing dealkalization systems and provides a foundation for understanding how alkaline components are distributed and retained within cells.

[0011] Potassium ions (K + Potassium ions are one of the major cations present in plant cells and are involved in various physiological functions, including osmotic regulation, enzyme activation, and charge balance. Potassium ions are mainly held in the cytoplasm and vacuoles. The cytoplasm is the liquid portion that fills the cell and contains a variety of organelles. Potassium ions are attracted to negatively charged molecules such as proteins and nucleic acids in the cytoplasm and are often involved in enzymatic reactions.

[0012] Vacuoles are membrane-bound organelles that occupy most of the cell volume and contain water, sugars, amino acids, and inorganic ions (especially potassium). Potassium is one of the most abundant cations in vacuoles and plays a crucial role in maintaining turgor pressure and regulating cell volume. Potassium ions are also present in the cell walls of some plant cells, where they may function in maintaining structural strength, regulating cell expansion, and even as a defense mechanism, but in much smaller quantities than in the cytoplasm or vacuoles. Lignin and cellulose, the main components of the cell wall, typically contain very few potassium ions.

[0013] The passage of potassium ions and other alkali compounds through the cell wall is restricted by the high rigidity and complex structure of the cell wall. The cell wall is composed of polysaccharides, proteins, etc., and acts as a physical barrier that prevents the free movement of molecules and ions. Furthermore, the cell wall is negatively charged due to the presence of carboxyl and phenolic groups, and has the property of repelling cations such as potassium.

[0014] Furthermore, the movement of alkali ions is controlled by transport proteins and channels embedded in the cell membrane. These regulate the influx and efflux of potassium ions, maintaining their intracellular concentration within a certain range.

[0015] Conventional methods are inefficient and unsustainable, involving excessive chemical use, energy consumption, mass loss, and prolonged processing times. Conventional techniques rely on long-term immersion, countercurrent washing, and the use of expensive solvents. Existing technologies lack a device that minimizes water, energy, and chemical use while removing alkali at the cellular level, suppressing lignin and cellulose loss, and ensuring reproducibility and scalability.

[0016] Furthermore, conventional technologies lack a high-capacity, continuous alkali removal system. Existing methods, due to the high alkali content in wood cellulose, lead to reduced heat transfer efficiency, increased emissions, slugging, corrosion, and a decline in steelmaking quality. Moreover, the complex molecular structure of wood cellulose materials presents technical challenges in pretreatment systems, making it difficult to convert them into effective biofuels, biogas, and biochemicals.

[0017] Existing technologies face difficulties in the large-scale processing of low-density, high-moisture, and fibrous raw materials, hindering the securing of solid fuel hardness and preventing the meeting of customer-required Hargraves Grindability Index (HGI). Therefore, meeting the index requirement is necessary for using wood cellulose as a raw material in existing coal processes. Current technologies have not been able to provide an integrated continuous processing system that effectively removes impurities such as alkali while simultaneously imparting properties suitable for downstream processes such as torrefaction, gasification, pyrolysis, and enzymatic / chemical treatment. This invention solves these technical challenges and provides an innovative solution that has remained unresolved in conventional technologies, making an important and necessary contribution to the bioenergy field.

[0018] Thus, while conventional technologies offer methods and systems sufficient for specific applications, a new, integrated end-to-end system and method for producing the multi-purpose dealkalized wood fiber raw material targeted by the present invention has not yet been provided. [Overview of the project] [Problems that the invention aims to solve]

[0019] The following is a brief summary to help understand the basics of the present invention. This summary is neither a comprehensive explanation of the present invention nor intended to specify the essential parts of the invention. Rather, it generalizes and presents some of the original concepts of the present invention prior to the detailed explanation described below.

[0020] The present invention aims to provide a system, apparatus, and method that enables the production of dealkalized wood fiber materials useful in downstream processes and the conversion of wood fiber materials and wood fiber waste into bio-based products. In particular, this system enables the use of wood fiber materials as a sustainable alternative to coal in the power generation and steelmaking sectors, and further opens up a novel raw material source for the biofuel, biogas, biochemical, and bioproduct industries. For example, this system can dealkalize oil palm wood fiber biomass and convert it into a raw material useful for the production of fuel pellets. [Means for solving the problem]

[0021] The integrated systems and methods of the present invention combine advanced technological systems with process intensification to effectively address complex challenges that conventional technologies could not solve. By integrating multiple unit operations and innovative technologies, process intensification optimizes chemical and industrial processes, achieving higher efficiency, productivity, and sustainability. As a result, the system delivers superior performance, overcomes critical technical challenges, reduces waste and emissions, minimizes environmental impact, and improves overall efficiency, reliability, and flexibility.

[0022] The present invention targets the cell-level decomposition of cell walls, organelles, vacuoles, and cytoplasmic structures of lignocellulosic materials, and further provides a system, apparatus, and method for removing alkali and ionic wastes from each cell by combining the use of steam that drives the osmotic potential of each cell, high shear force, and high-pressure treatment. In addition, the present system further relaxes the complex structure of the material after dealkalization and enhances the accessibility to downstream processes (such as enzymatic treatment, chemical treatment, etc.), thereby providing a general-purpose dealkalized lignocellulosic raw material adaptable to multiple downstream processes.

[0023] The system, apparatus, and method of the present invention are applicable to either batch operation or continuous operation. In one aspect, the present invention provides a scalable and low-chemical-use continuous system that can remove more than 95% of the alkali from lignocellulosic cells without reducing the lignin and cellulose content. It will be understood that the high concentration of alkali in lignocellulose is undesirable as it causes reduced heat transfer, increased emissions, slugging, corrosion, and reduced steel quality.

[0024] The system and method of the present invention preferably granulate the lignocellulosic material to improve the mixing and transportability throughout the system. Also, the reduction in particle size relatively decreases the sedimentation rate and reduces the possibility of blockage and clogging within the system.

[0025] In one aspect, a system for producing dealkalized lignocellulosic materials and biobased products includes the following: (a) A size reduction subsystem that processes the lignocellulosic material into small-sized particles; (b) A pretreatment subsystem that pretreats the particles with electromagnetic frequencies and electric fields; (c) A slurry generation subsystem that combines the pretreated particles with a water mixture containing water and chemicals to obtain a slurry; (d) An ultrasonic treatment subsystem that performs cell structure destruction, relaxation of the lignocellulosic matrix, alkali removal and neutralization at the cell level on the lignocellulosic material in the slurry; (e) A hydrodynamic cavitation subsystem that mechanically decomposes lignocellulosic materials in the slurry at the cell level with high shear; (f) A direct steam injection subsystem connected to the slurry generation subsystem and / or the hydrodynamic cavitation subsystem to achieve hydrostatic cavitation and alkali neutralization within the slurry; (g) An automatic test subsystem for monitoring and adjusting the dealkalization treatment conditions in real time; (h) A separation subsystem for separating the treated slurry into solid dealkalized material and treated water; (i) A water recycling and treatment subsystem for recycling the system treated water or manufacturing bio-based products using the treated water; (j) A slurry pumping subsystem configured to generate positive pressure and high-shear cavitation throughout the system; and (k) A densification subsystem for converting the solid dealkalized material into a densified bio-product.

[0026] The system is applicable by connecting to a water treatment plant, and through the water recycling subsystem, it can take in wastewater from the plant or discharge wastewater to the plant.

[0027] Preferably, the water mixture contains fresh water and / or recycled water and a chemical agent capable of binding to alkali ions in the pretreated lignocellulosic material.

[0028] Preferably, the densification subsystem includes a drying module, a mixing unit for adding a binder and a chemical agent to form a heat-resistant silicate compound by contact with alkali, and a densification device for compressing the solid dealkalized material.

[0029] In one embodiment, the pretreatment subsystem for wood fiber material includes (i) an electromagnetic processing unit that decomposes wood fiber material in particles at 100 MHz to 5000 MHz, and (ii) a PEF processor connected to the electromagnetic energy processing unit that exposes the particles to a pulsed electric field (PEF) of 10 to 100 kV.

[0030] In one embodiment, the direct steam injection subsystem includes (i) a mixing vessel having a steam inlet, a slurry inlet, and a heated slurry outlet, wherein the slurry inlet pipe has a helical baffle insert and a plurality of steam jets, the heated slurry outlet is connected to a flow-through hydrodynamic cavitation subsystem, and the slurry and steam are mixed by direct injection within the vessel during operation and processed at a maximum temperature of 350°C and a maximum pressure of 2 MPa; and (ii) a cooling system connected to the vessel to reduce the slurry temperature after mixing.

[0031] In one embodiment, the ultrasonic processing subsystem includes (i) an ultrasonic-compatible reaction vessel comprising a high-shear agitator having at least one ultrasonic device and a rotor-stator configuration, wherein at least one ultrasonic device is positioned near the rotor-stator configuration to concentrate the emission of an ultrasonic field around the configuration; (ii) a heating vessel for heating the slurry before and / or after the reaction vessel; (iii) a cooling vessel for cooling the slurry to a temperature suitable for ultrasonic processing; and (iv) an ultrasonic flow cell positioned before and / or after the reaction vessel, comprising a cylindrical flow vessel containing a helical insert and one or more ultrasonic devices.

[0032] The system of the present invention comprises a progressive cavity pump and a pressure relief valve.

[0033] Preferably, the ultrasonic-compatible reaction vessel further comprises a supercritical fluid dispersion unit.

[0034] Advantageously, the system further comprises a collection subsystem configured to aggregate wood fibrous materials using a sensor-based identification system, which is capable of identifying materials based on type, state, and processing suitability.

[0035] Preferably, the collection subsystem includes an artificial intelligence (AI)-enhanced digital management platform, which is integrated with an autonomous transport mechanism to enable efficient material collection and logistics management.

[0036] Advantageously, the preprocessing subsystem further includes a **microwave-assisted extraction (MAE)** system that integrates microwave and ultrasonic technologies.

[0037] Advantageously, the system further includes a renewable energy subsystem that powers the dealkalization process, which includes photovoltaic modules, hydrogen fuel cell modules, and biomass conversion modules, all managed by an AI-enhanced control unit.

[0038] Advantageously, the slurry separation subsystem further incorporates a sensor array module to monitor water quality and ionic waste concentration.

[0039] Advantageously, the system further comprises a thermal conversion subsystem connected to a densification subsystem, which performs torrefaction and / or carbonization of the dealkalized densification material, the subsystem including a torrefaction module, a carbonization module, and a gas emission control module.

[0040] Advantageously, the system further comprises a biogas generation subsystem that generates biogas from dealkalized woody fiber material and treated water, the subsystem including a dealkalized material processing module, an anaerobic digestion unit, and a biogas purification system.

[0041] Advantageously, the system further includes a storage and transport subsystem for handling, storing, and transporting wood fiber materials, dealkalized wood fiber materials, and the resulting bio-based products, the subsystem utilizing a sustainable fleet of transport vehicles and a digital management platform for logistics optimization.

[0042] Advantageously, the system is adaptable to a carbon credit / REC subsystem configured to generate carbon credits and renewable energy certificates (RECs) based on the sustained operation of greenhouse gas emission reduction and dealkalization processes.

[0043] Advantageously, the system is adaptable to a renewable energy subsystem that powers the system using renewable energy sources, which may include photovoltaic modules, hydrogen fuel cell modules, and biomass conversion modules.

[0044] In one embodiment, the present invention provides a dealkalization apparatus for wood fiber materials, the apparatus comprising: (a) A cooling vessel to reduce the slurry temperature to 2–20°C after the second flow-through hydrodynamic cavitation (FTHC); (b) A first set of ultrasonic flow cells, preferably comprising a helical flow cell container insert, which transfers the slurry from a cooling container to an ultrasonically compatible reaction vessel via a helical path and exposes the slurry to a pressure of 0.1 to 20 MPa and an ultrasonic frequency range of 10 to 50 MHz; (c) One or more ultrasonically compatible reaction vessels comprising a high-shear agitator having at least one ultrasonic device and a rotor-stator configuration, wherein at least one ultrasonic device is positioned near the rotor-stator configuration and concentrates an ultrasonic field of 10 to 50 MHz around the configuration; (d) A second set of ultrasonic flow cells, preferably comprising a helical flow cell container insert, which transfers the slurry from a cooling container to an ultrasonically compatible reaction vessel via a helical path and exposes the slurry to a pressure of 0.1 to 20 MPa and an ultrasonic frequency range of 10 to 50 MHz; (e) A flow-type FTHC unit that induces hydrodynamic cavitation by transferring a steam-injected slurry under pressurization of approximately 0.1 to 100 MPa; (f) Direct steam injection device for injecting steam into wood fiber slurry at a maximum temperature of 250°C and a maximum pressure of 21 MPa; (g) A network of reaction tubes for transporting a heated slurry for a predetermined time at a maximum temperature of 200°C and a maximum pressure of 10 bar; and (h) A heating vessel that receives the slurry from the reaction tube and heats it to a maximum of 200°C while stirring.

[0045] Preferably, the ultrasonic-compatible reaction vessel is connected to a supercritical fluid supply source.

[0046] Preferably, the direct steam injection includes a cylindrical container having a spiral baffle inside the container inlet tube.

[0047] Preferably, the ultrasonic-compatible reaction vessel comprises a plurality of ultrasonic devices, each arranged to provide a uniform ultrasonic field within the reactor, one of which is located at the bottom of the reactor.

[0048] Preferably, the high-shear agitator includes a motor, a rotor shaft, and a rotor-stator configuration, the rotor shaft having at least one rotor blade.

[0049] Preferably, the stator includes an extension skirt portion that connects to an ultrasonic device attached to the bottom of the reactor and is configured to transmit ultrasonic radiation from the ultrasonic device to the reactor.

[0050] Preferably, the high-shear agitator further comprises a stabilizing means having one side in contact with the reactor and the other side fixed to the stator, thereby stabilizing the agitator.

[0051] Preferably, the stabilization means is configured as a channel connected to a supercritical fluid supply source.

[0052] Preferably, the stabilization means is connected to the skirt portion of the stator and is configured to distribute the supercritical fluid into the reactor.

[0053] In one embodiment, the present invention provides a method for producing dealkalized wood fiber materials and bio-based products based on the aforementioned system and method, the method comprising the following steps: (a) A process of reducing the size of wood fiber material into granular particles; (b) Processes for pre-treating materials using electromagnetic and electric field processes; (c) A step of mixing pre-treatment material with a water mixture containing a chemical agent to form a slurry; (d) A step of exposing the slurry to ultrasonic resonance and flow cavitation with high shear under a pressurized environment to induce hydrodynamic cavitation, causing cellular-level disruption and promoting the extraction of alkaline components from the slurry; (e) A process of inducing hydrodynamic cavitation by exposing a slurry to flow cavitation accompanied by high shear under a pressurized environment; (f) A step of inducing hydrostatic cavitation by direct steam injection under rapid heating and rapid cooling of the slurry material to promote alkali neutralization; (g) A process that continuously monitors and adjusts the process based on alkalinity levels; (h) A step of separating the slurry into a solid dealkalization material and treated water; (i) A step of washing the slurry to remove ionic waste and solid particles larger than 1 μm to obtain a dealkalized wood fiber material; (j) A process of recirculating treated water separated by the process, or a process of manufacturing bio-based products using the treated water; and (k) A process to obtain a dealkalized bio-product by increasing the density of a solid dealkalization material.

[0054] In one embodiment, the method further includes collecting wood fiber material and washing, breaking it down, and / or adding chemical agents prior to particle formation.

[0055] Preferably, step (d) is carried out in the presence of **supercritical carbon dioxide (CO2)**.

[0056] Preferably, step (d) is performed in an ultrasonic frequency range of 10 Hz to 50 MHz.

[0057] Preferably, step (a) includes a step of processing the wood fiber material into particles with an average particle size of less than 10 mm.

[0058] Preferably, step (b) includes the following steps: (i) A step of exposing the particles to electromagnetic energy treatment at 500 to 5000 MHz; and (ii) A step of obtaining porous particles by exposing particles to a pulsed electric field (PEF) applied by a voltage pulse of 10 to 100 kV.

[0059] Preferably, the ratio of the water mixture to the particles in step (c) is 1:1 to 1:25.

[0060] Preferably, step (f) is carried out by heating the slurry by direct steam injection under conditions of 1°C to 250°C and 0.01 MPa to 21 MPa.

[0061] Preferably, the water mixture comprises water and / or recirculated water and a chemical agent capable of binding with alkali ions in the pre-treated wood fiber material.

[0062] Preferably, the densification process is carried out by drying the solid dealkalization material, mixing it with a binder and a chemical agent, and then compressing it.

[0063] Preferably, step (f) is carried out under a pressure of 0.1 MPa to 50 MPa.

[0064] Preferably, the rapid heating in step (f) is carried out under a pressure of 0.1 to 21 MPa, giving a heating rate of up to 250°C / min.

[0065] Preferably, the rapid heating step is carried out in the presence of an inert gas to prevent oxidation of the wood fiber material in the slurry.

[0066] Preferably, the rapid cooling in step (f) is carried out under a pressure of 0.1 to 10 MPa, giving a cooling rate of 20°C / min or more.

[0067] Preferably, the high-shear environment in process (d) has a maximum shear rate of 5000 rpm.

[0068] Preferably, the continuous monitoring and adjustment process based on alkali levels is supported by the use of an AI (artificial intelligence)-enhanced control unit within the automated dealkalization test subsystem, which refines the processing parameters based on real-time alkali levels.

[0069] Preferably, the slurry formation step includes the addition of ionized water to adjust the pH and improve the reactivity of the chemical process.

[0070] Preferably, the method further includes a step of optimizing the energy efficiency and sustainability of the dealkalization process by utilizing an energy recovery module within the slurry separation subsystem.

[0071] Preferably, the method further includes optimizing the process of converting dealkalized biomass into high-density bioproducts using a high-density subsystem.

[0072] Preferably, the method further includes a step of improving the calorific value and carbon content of the high-density dealkalized bio-product by heat treatment using a heat conversion subsystem.

[0073] Preferably, the method further includes a step of utilizing a biogas generation subsystem to generate biogas from the treated woody fiber material and extracted water obtained during the dealkalization process.

[0074] Preferably, the method further includes a step of generating carbon credits and **renewable energy certificates (RECs)** through sustained operation and emission reductions by the system, utilizing a carbon credit / REC subsystem. [Effects of the Invention]

[0075] Preferably, the method is powered by renewable energy sources via a renewable energy subsystem, minimizing environmental impact and enhancing sustainability.

[0076] Preferably, the method further includes a step of transporting and storing wood fiber material, dealkalized wood fiber material, and bio-based products, thereby achieving sustainable logistics using a bio-product storage and transport subsystem.

[0077] In one embodiment, the present invention provides a dealkalized material obtained by the method described above.

[0078] In one embodiment, the present invention provides a dealkalized bioproduct obtained by the system and / or method described above. For example, the bioproduct is a solid biofuel material containing a dealkalization material, the solid biofuel material containing the dealkalization material carbonized at 400 to 1000°C in the absence of oxygen.

[0079] The present invention will be described by non-limiting embodiments with reference to the following drawings. [Brief explanation of the drawing]

[0080] [Figure 1] Figure 1 shows an overview of the system, apparatus, and method for producing wood fiber raw materials in the present invention. [Figure 2] Figure 2 shows one embodiment of the ultrasonic flow cell in the apparatus of the present invention. [Figure 3] Figure 3 shows one embodiment of the ultrasonic-compatible reaction vessel and high-shear stirrer in the apparatus of the present invention. [Figure 4]Figure 4 shows the connection relationship between the high-shear agitator and the ultrasonic device shown in Figure 3. [Figure 5] Figure 5 shows the connection between the stabilization means (stabilizer) shown in Figure 3 and the agitator. [Figure 6] Figure 6 shows one embodiment of the stator skirt portion (lower left), **stator with base plate (right), and impeller (upper)** in the apparatus of the present invention. [Figure 7] Figure 7 shows the radial dispersion (enclosed area) formed during operation of the ultrasonic-responsive reaction vessel of the present invention. [Modes for carrying out the invention]

[0081] One or more specific and alternative embodiments of the present invention will be described below with reference to the accompanying drawings. However, it will be obvious to those skilled in the art that the present invention can be carried out without such specific details. Some details may be omitted in order to avoid hindering the understanding of the invention. When referring to the same or similar features common to the drawings, a common reference numeral or sequential number is used for convenience of reference.

[0082] Unless otherwise specified, all technical and scientific terms used herein have meanings generally understood by those skilled in the art. Terms used in the description of the invention herein are for the purpose of describing embodiments and are not intended to limit the invention. In this specification and in the claims, unless the context clearly indicates otherwise, the singular forms "a," "an," and "the" are used with the intention of encompassing the plural forms as well. All publications, patent applications, patents, and other references referenced herein are incorporated herein by reference in their entirety.

[0083] Unless otherwise indicated, all numerical values ​​in this specification and the claims, representing ingredient amounts, reaction conditions, etc., are understood to always be modified by the word "about." Accordingly, unless otherwise explicitly stated, the numerical parameters listed in the following specification and the appended claims are approximations that may vary depending on the desired characteristics to be obtained by the present invention. At the very least, and not to limit the scope of application of the principle of equivalents, each numerical parameter should be interpreted taking into account the number of significant figures and normal rounding.

[0084] While the broad ranges and parameters defining the present invention are described as approximations, the numerical values ​​shown in specific embodiments are described as accurately as possible. However, any numerical value inevitably contains a certain degree of error due to the standard deviation inherent in its measurement. All numerical ranges given throughout this specification are intended to encompass any narrower numerical ranges included within such broader ranges, and should be interpreted as if those narrower numerical ranges were explicitly described.

[0085] As shown in Figure 1, the dealkalization of lignocellulosic material and the production of bio-products are carried out using an integrated system consisting of specifically defined subsystems, modules, and apparatus designed to process lignocellulosic raw materials into a dealkalized state. This system includes: (a) Collection subsystem (1): Equipped with a systematic collection module, configured to selectively collect woody fiber materials from diverse sources, including agricultural residues and forestry residues, using a sensor-based identification system capable of identifying woody fiber materials based on type, material condition, and processing suitability; (b) Size reduction subsystem (2): Processes the material into particulate form so that it can be easily mixed with treated water and chemical agents to obtain a consistency suitable for flow; (c) Particle pretreatment subsystems (3, 4): A combination of electromagnetic energy processing modules, pulsed electric field (PEF), and ultrasonic technology significantly improves the porosity and permeability of woody cell cells. This synergistic approach effectively disrupts the cell wall and membrane, promoting the depolymerization of the woody cell matrix and improving the efficiency of the subsequent dealkalization process; (d) Slurry generation subsystem (5): Pre-treated reduced-particle-size wood fiber particles are mixed with treated water and chemical agents under high shear to form a fluid slurry; (e) Direct steam injection subsystem (integrated into 5): Precisely contacts and mixes a predetermined amount of steam with the woody cellulose slurry to induce hydrostatic cavitation, hydrolysis, cell structure damage, relaxation of complex woody cellulose structures, alkali neutralization, extraction of cell contents based on osmosis, and conversion of alkali into an extractable aqueous phase; (f) Ultrasonic flow cell subsystem (14): Under a pressurized and high-shear environment, the mechanical and thermal effects of hydrodynamic cavitation by ultrasonic frequency waves are imparted to the slurry, further disrupting the cellular structure of the biomass and enhancing the removal of alkaline and lignin components at the cellular level. The strong cavitation generated by ultrasound produces microjet and shear force, promoting the breakdown of the complex woody cellulose matrix and cell walls, and improving accessibility to the enzymatic hydrolysis of cellulose and hemicellulose; (g) Flow-through hydrodynamic cavitation (FTHC) subsystem (8): By disrupting cell wall structures, generating microturbulence and high-pressure regions, it degrades lignin-carbohydrate complexes, increasing accessibility to enzymatic hydrolysis of cellulose and hemicellulose, and assists in dealkalization by removing alkali metals and alkaline substances; (h) Ultrasonic processing subsystem (15): For woody fiber material in slurry, it performs cellular structure disruption, relaxation of the woody fiber matrix, alkali removal and neutralization at the cellular level; (i) Slurry separation subsystem (18): The slurry is separated into a liquid phase (treated wastewater) and a solid dealkalized wood fiber material, and ionic waste is removed from the solid separated particles to obtain a dealkalized wood fiber raw material; (j) Reaction tube network (60): configured to transport heated slurry at a maximum temperature of 200°C and a maximum pressure of 10 bar for a predetermined time; (k) Heating vessel (16): Receive the slurry from the reaction tube, heat to a maximum of 200°C, and stir; and (l) Water recirculation and treatment subsystems (12, 13): The separation subsystem 18 and the slurry generation subsystem 5 are connected to recirculate the water discharged from the separation subsystem to the slurry generation subsystem, or to the biogas generation subsystem, or to treat it to meet the requirements for discharge into the environment. Note that the water discharged from the separation subsystem may not be recirculated for the production of bioproducts because the ultrasonic treatment activates molecular vices that loosen the woody fiber matrix.

[0086] Furthermore, as shown in Figure 1, the system includes the following: (m) Additional subsystem (22): Connects the water recirculation subsystems (12, 13) to the water treatment plant and takes in wastewater from the plant or discharges wastewater to the plant; (n) Automated dealkalization test subsystem (17): A combination of an advanced sensor network, automated high-precision volume sampling, and a test reactor is used throughout the entire dealkalization system; (o) Slurry pumping subsystem (7): Transports wood fiber slurry throughout the system under pressurized and high-shear conditions; and (p) Dealkalization material densification subsystem (80): Designed to efficiently compress processed biomass and convert it into environmentally friendly solid bio-based products suitable for various applications (30, 81-89).

[0087] Furthermore, Figure 1 shows that the system is adapted to increase the calorific value and carbon content of high-density dealkalized bioproducts through heat treatment using a heat conversion subsystem (87), thereby improving them to a quality suitable for use as a substitute for coal and coke in the cement, steelmaking, and supercritical power generation industries, and also includes a biogas generation subsystem (22) that generates biogas from recycled water and water extracted during the compression of wood fiber material.

[0088] The system is adaptable to a carbon credit / REC subsystem (not shown) that is compliant with the registration and generation of carbon credits and renewable energy certificates (RECs), and handles emission allowances, tax incentives, and RECs obtained through the application of the system and methods. It is also adaptable to a renewable energy subsystem (not shown) that supplies power to the dealkalization system, and a bio-product storage and transport subsystem (not shown) that procures wood fiber materials using green transport, custom containers, and an AI-enhanced digital logistics network, and transports bio-products to customers.

[0089] Based on Figure 1, the system may be operated in continuous mode or in batch mode by disconnecting any of the subsystems and / or devices mentioned. The system has a modular design, enabling flexible integration and scalable deployment in various industrial applications. Each module functions independently or synergistically to ensure optimal performance in processing wood cellulose materials into high-quality, high-density bio-products. This modular configuration not only facilitates customization and expansion to meet specific operational requirements but also improves maintenance efficiency and enhances system adaptability to evolving technologies and processes.

[0090] In particular, the collected wood cellulose material is reduced in size using the size reduction subsystem 2, allowing it to be easily mixed with treated water and chemical agents, achieving a consistency suitable for flow. Subsystem 2 includes one or more sieving and washing modules that remove silica and foreign matter from the wood cellulose material using treated water and chemical agents, and is equipped with a continuous pressurized heated feed plug screw feeder device that can inject chemical agents into the wood cellulose material at the screw outlet to soften it. The continuous feed plug screw feeder device is characterized by its ability to variably control the chemical agent injection rate based on the characteristics of the outlet material and the desired treatment result.

[0091] Subsystem 2 may further include a pressurized particle digester device that cooks and preheats the wood cellulose material under pressure to soften and weaken the complex bonds within the material. The particle size reduction module 2 may consist of one or more of the following devices and methods (crusher, grinder, wet room temperature / high pressure mill, jet mill, ball mill, roll mill, ultrafine grinding mill, pressurized refiner, particle air sorting mill, and / or colloidal mill). The selection of devices and methods is customized according to the characteristics of the wood cellulose material in question. For example, the particle size reduction unit 2 may sequentially include a crushing / cutting device, followed by a dry or wet mill, then an air sorter, a wet mill, or a colloidal mill to obtain a uniform particle size. Preferably, the particle size reduction unit 2 provides solid particles of about 10 mm, preferably about 5 mm, and more preferably about 2 mm, with a moisture content of **about 40% to about 60% by mass**, thereby overcoming the challenges of the prior art. Biomass washing equipment may include rotary drum type, screw type, vibrating / shaking screen, paddle type, hydrocyclone, spray washing, immersion tank, etc.

[0092] Therefore, the particle pretreatment subsystems (3, 4) are used to pre-treat the material to increase its cellular porosity. Specifically, electromagnetic energy is applied to the particles using the continuous electromagnetic energy processing module 3, and the pulsed electric field (PEF) module 4 is used. As shown in Figure 1, the particles are first introduced into the continuous flow microwave furnace 3 (output range 1-5000 MHz). Exposure to high-power continuous electromagnetic energy allows the wood cellulose material to undergo **low molecular weight reduction (depolymerization / fragmentation)** due to energy transfer from the electromagnetic energy processing module. The components can be connected by conveyors to create a continuous system.

[0093] The pretreatment subsystem further disrupts particles at the molecular / cellular level through exposure to an electromagnetic energy treatment module and PEF. Alternatively, particles may be subjected to an electromagnetic energy treatment module-assisted extraction (MAE) system (not shown), where the electromagnetic energy treatment module and ultrasonic technology are combined to promote molecular / cellular level disturbance, followed by exposure to a PEF module. Ultrasonic technology utilizes cavitation to physically damage cell walls and membrane layers, resulting in the release of target compounds, increased mass transfer, and accelerated solvent penetration. The radiation from the electromagnetic energy treatment module rapidly heats the biomaterial, inducing the movement of dissolved molecules. Therefore, higher alkaline extraction efficiency can be achieved by applying ultrasonic and electromagnetic energy treatment simultaneously or sequentially.

[0094] The disclosed electromagnetic energy processing module converts electromagnetic energy into thermal energy through non-contact energy transfer via ion conduction and dipole rotation. Non-ionizing radiation induces molecular motion through ion movement and dipole rotation. High-power electromagnetic energy processing exposure can depolymerize (depolymerize / fragment) the molecules of wood fibrous materials through energy transfer from the module. Electromagnetic energy processing technology offers advantages such as rapid energy absorption at the cellular level, reduced thermal gradients, high efficiency in short extraction times, and selective heating. Furthermore, electromagnetic heating of the water within each cell of the processed biomaterial generates high pressure in the cell wall, causing mechanical fracture. Recent studies have shown that solvent penetration, including water as a liquid or vapor, is promoted, allowing penetration to deep into tissues.

[0095] The disclosed PEF is based on electroporation / electrical permeability. By applying a high-voltage electric field, it is expected that the barrier function of all cell membranes will be lost, leading to leakage of intracellular contents, loss of cellular activity, and membrane pore formation. This will greatly improve membrane permeability and enhance the diffusion efficiency of the target compound.

[0096] As shown in Figure 1, the particle size reduction unit 2 is connected by a conveyor to the electromagnetic energy processing module 3 and the pulsed electric field (PEF) device 4. The particle size reduction module 2 is preferably connected by a conveyor so that particles can be continuously or automatically transported to the electromagnetic energy processing module 3. The electromagnetic energy processing module 3 is equipped with an electromagnetic energy processing furnace capable of processing particles in an output range of approximately 500 to approximately 5000 MHz. The electromagnetically processed particles are then supplied to the PEF device 4 by the conveyor, and a high-voltage pulse is applied to break down the cell walls and membranes of each cell in the particles passing through the PEF. In one embodiment, the PEF is preferably operated with microsecond pulses of approximately 10 to 100 kV.

[0097] The present invention further includes a method for forming a fluid slurry in a slurry generation subsystem 5 by high-shear mixing pre-treated reduced-particle-size wood fiber particles with treated water and chemical agents. The subsystem includes: a. Treated Water Preparation Module: Freshwater and recirculated dealkalized treated water are treated through a series of purification and conditioning processes to optimize their properties for slurry formation. Auxiliary chemical agents may be added as needed, with downstream treatment in mind. b. Pressurized / High-Shear Mixing Module: Using one or more cylindrical flow containers and a high-shear mixing / cavitation pump, woody cellulose particles transported from particle pretreatment subsystems 3 and 4 are received and mixed together with treated water in a high-shear cavitation mixer / pump device. c. Control unit: Controls the dealkalization agent and liquid volume based on the target dealkalization level. d. Pump: Connected to the mixing tank, it circulates the slurry within the dealkalization system. e. Sensor array and digital control system: Monitors slurry characteristics, and the control unit adjusts the slurry composition based on feedback. f. Slurry cooling module: Reduces slurry temperature to below 25°C. g. Pressurized cylindrical flow container: The slurry is transported directly to the steam injection subsystem via one or more ultrasonic flow cell subsystems. h. Measuring valve: Preferably used to adjust the amount and / or rate of powder addition.

[0098] For the sake of understanding, the following terms are defined: “Treated water” means water that has been treated to alter its chemical composition, physical properties, and biological content in order to meet the specific requirements of the dealkalization processes described herein. This includes, but is not limited to, the following: Ionized water: Water whose ion concentration has been adjusted (especially for pH adjustment or improved chemical reactivity). Distilled water: Water that has been purified by distillation to remove impurities, making it suitable for dealkalization reactions. Recirculated treated water: Water that has been used in a preceding process, has had impurities removed or its composition adjusted, and is then recycled to minimize waste and improve resource efficiency. Water mixture (water with added chemical agents): Water to which specific chemical agents such as acids, bases, salts, and other compounds are added to enhance its effectiveness in the dealkalization process.

[0099] The present invention includes a method for further disrupting the cellular structure of biomass by the mechanical and thermal effects of ultrasound, and enhancing the removal of alkaline and lignin components, by passing biomass through one or more ultrasonic flow cells equipped with cell disruption capabilities using an ultrasonic processing subsystem 15. The strong cavitation generated by ultrasound generates microjet and shear forces, promoting the breakdown of the complex woody cellulose matrix and cell walls, and improving access to the enzymatic hydrolysis of cellulose / hemicellulose.

[0100] The ultrasonic processing subsystem 15 includes at least the ultrasonic reaction vessel module shown in Figure 3. This module has an inlet and an outlet, is connected to an ultrasonic flow cell 14, and receives slurry via a progressive pump 7. The ultrasonic reaction vessel is equipped with a double jacket (not shown) and can rapidly heat and cool the slurry inside the vessel. According to Figure 3, the reactor is equipped with a heating / cooling jacket outlet 37, which circulates a heating / cooling medium such as water, oil, or molten salt for rapid and efficient temperature control. Furthermore, it may be equipped with a safety valve, a sound insulation layer, and water and / or chemical agent inlets.

[0101] The ultrasonic-compatible reaction vessel is equipped with means for holding one or more ultrasonic devices. As shown in Figure 3, the reactor has a number of ports 35, and ultrasonic devices are arranged on the top 34, bottom 41, and side walls 42 to generate uniform and high ultrasonic resonance within the vessel. In particular, the ports on the bottom 41 of the reactor allow the probe 50 and transducer 49 of the flow cell 14 to be connected near the rotor-stator configuration 26 to which high shear forces are applied.

[0102] As shown in Figure 3, in an ultrasonic-compatible reaction vessel, it is preferable to position the high-shear agitator 38 slightly offset from the center of the vessel to prevent vortices from forming in the center of the vessel during operation. In one embodiment shown in Figures 3 and 4, the high-shear agitator 38 includes a motor 23, a rotor shaft 24, and a rotor-stator configuration 26, the rotor shaft having at least a downdraft impeller 25, and at least one rotor blade having a surface angled with respect to the axis of rotation. According to Figure 6, the blade has a wedge-shaped surface 50, which increases the shear force during operation.

[0103] According to Figure 4, the rotor-stator configuration 26 is located at the base of the stirrer 38 and is connected to ultrasonic devices 49 and 50 mounted at the bottom of the reactor to transmit radiation from the ultrasonic devices to the reactor. The configuration 26 includes a rotating rotor and a stator side wall and has multiple slot openings 27 to accommodate the ultrasonic devices 49 and 50. Furthermore, as shown in Figures 4 and 6, the configuration 26 is equipped with an extension skirt portion 28, which has a vent portion 52 and multiple openings 51 to which stabilization means can be connected. The vent portion 52 may have a wedge-shaped pattern.

[0104] Accordingly, the high-shear agitator 38 further comprises a stabilization means having one side that abuts against the reactor wall and the other side that is fixed to the stator 26 via a skirt portion 28, thereby stabilizing the agitator within the reactor. According to Figures 4 and 5, the stabilization means consists of a pair of vertical rods 31 and horizontal rods 32. More specifically, the horizontal rods 32 are fixed to the stator, and the vertical rods 31 extend perpendicularly from both ends of the horizontal rods 32. The horizontal rods 32 pass through the opening 51 and reach the two opposing walls of the reactor, and the vertical rods 31 extend along the height direction of the reactor to counteract the forces resulting from the operation of the agitator and the proximity of the ultrasonic field.

[0105] Preferably, the stabilization means is configured as a channel connected to the supercritical fluid supply source 70. In one embodiment, a transverse rod 32 may be used to function as a channel for receiving the supercritical fluid through the vent portion 52 of the skirt 28. Alternatively, the agitator 38 may have a perforated annulus 47 located near the skirt 28 of the rotor-stator configuration to receive the supercritical fluid supply source 70. As shown in Figures 2 and 3, **supercritical carbon dioxide (CO2)** can be pumped into the reactor from a flow cell attached to the bottom of the reactor and distributed near the rotor-stator configuration 26.

[0106] In view of the above configuration, the arrangement of the impeller 25 and ultrasonic probe devices 49 and 50 mounted on the bottom wall of the reactor concentrates the ultrasonic output around the rotor-stator 26, generating a high-shear agitated flow with radial dispersion 99 as shown in Figure 7. In this configuration, it is desirable for the slurry in the reactor to pass through the rotor-stator 26 multiple times per minute, enabling efficient slurry mixing and processing.

[0107] Supercritical CO2 introduced into the reactor is used as an extraction co-solvent along with water. Generally, the temperature range for alkaline extraction using supercritical CO2 is 40-80°C and the pressure is 10-40 MPa. By adding water to supercritical CO2 to form a two-component solvent system, extraction efficiency can be improved. In this system, supercritical CO2 acts as the main solvent, and water functions as a co-solvent that increases the solubility of hydrophilic compounds (e.g., potassium-containing compounds). Water molecules penetrate the cell walls of plant materials, dissolving the hydrophilic compounds, which are then transported by the supercritical CO2 solvent. The supercritical CO2 / water two-component solvent system is non-toxic, non-flammable, and environmentally friendly, and is useful for extracting a variety of natural product components, including potassium-containing compounds. Furthermore, supercritical CO2 allows for precise control of temperature and pressure conditions, enabling a more efficient and selective extraction system.

[0108] In one embodiment, other agitators within the system or apparatus (e.g., within the direct steam injection subsystem 5) may also be configured similarly to the reactor agitator 38, and in particular to include a rotor-stator configuration 26. Modifications may be made as appropriate during integration.

[0109] Subsequently, the slurry is sent from the reactor outlet through another flow cell 14 under positive pressure by a high-shear pump to the inlet of yet another heating vessel 16, where pressurized liquid extraction (PLE) is completed to extract intercellular substances and ionized alkali ions. Chemical agents are added to the slurry as needed. The heating vessel 16 is equipped with an inlet / outlet, a rapid heating jacket, an additional inlet for water and / or chemical agents, sound insulation, a high-shear agitator similar to the reactor agitator 38, and an automatic high-pressure relief valve. The heating vessel 9 is specifically designed to rapidly and efficiently heat the slurry while providing high-shear stirring in a temperature range of 50-250°C. As an advantage, extraction in vessel 9 reduces solvent consumption and shortens extraction time. The slurry discharged from vessel 16 is then subjected to alkali testing in the alkali testing subsystem 17.

[0110] The ultrasonic flow cell subsystem 14 consists of the following: an ultrasonic probe device (typically made of piezoelectric material that generates ultrasonic waves when an electrical signal is applied), which is the core element that radiates ultrasonic waves into the liquid passing through the flow cell. As shown in Figure 3, subsystem 14 comprises: (i) a pressurized cylindrical flow container 44: equipped with a cooling jacket and high-shear shaped inlets 43 / outlets 45, constructed of a material suitable for the measurement liquid and ultrasound (stainless steel, glass, resin, etc.), housing the ultrasonic probe 50 and the slurry inside the container 44; (ii) a spiral baffle 48 inside the container 44 to guide the slurry along the spiral flow path, ensuring that each particle in the slurry is uniformly ultrasonically treated; (iii) an ultrasonic signal generator / receiver: the flow cell provides an electrical signal to the probe, and the reflected signal from the liquid is detected to calculate the sound velocity and flow rate, etc.; (iv) a pressure sensor: monitors the internal pressure of the flow cell; (v) a temperature sensor: measures the liquid temperature inside the cell and compensates for temperature-dependent changes in the sound velocity in the liquid; and (vi) a digital control center enhanced with AI machine learning: adjusts the flow rate, pressure, temperature, and ultrasonic treatment. An advantage is that the inlets 43 / outlets 45 are designed to allow the slurry to pass through in a consistent high-shear flow while minimizing turbulence within the cell.

[0111] As shown in Figure 1, multiple ultrasonic flow cells 14 are arranged both upstream and downstream of the ultrasonic processing subsystem 15. As shown in Figure 2, the ultrasonic flow cells 14 ultrasonically process the slurry within a housing 44 having a relatively narrowly guided channel. Connecting flow cells upstream and downstream of the ultrasonic processing subsystem 15 enhances the overall ultrasonic effect. Preferably, each housing 44 operates at a pressure of 0.1 to 10 MPa. Each housing 44 is equipped with an ultrasonic probe 50 driven by a transducer 49 and operates in a frequency range of 10 Hz to __ MHz and an output range of 100 W to 20,000 W.

[0112] In one embodiment, the housing 44 includes a helical baffle 48, which provides a helical flow path for the slurry passing through. The advantage of the helical flow path is that it improves the uniformity of stirring across the entire cross-section of the flow cell while minimizing pressure loss and turbulence. The flow cell further includes sensors and regulators (not shown) for monitoring and adjusting pressure and temperature. The flow cell also includes an ultrasonic signal receiver (not shown) connected to a probe 50, which can derive fluid velocity and flow rate.

[0113] In further embodiments, the design employs a configuration in which a helical baffle is arranged along the entire length of the inner wall of a cylindrical flow vessel, either as an insert or integrally cast with the inner wall of the vessel. This configuration improves the fluid dynamics and thermal distribution within the vessel, promoting uniform handling and high-efficiency processing of the material passing through. The helical design also maximizes contact between the fluid and the inner wall, contributing to improved heat transfer and mixing efficiency.

[0114] The present invention further processes the slurry by mechanical cavitation using a flow-through hydrodynamic cavitation (FTHC) subsystem 8. This further disrupts the complex structure of the cell walls and improves access to the enzymatic hydrolysis of cellulose and hemicellulose. The FTHC subsystem generates microturbulence and localized high-pressure regions, which degrade lignin-carbohydrate complexes and promote biomass conversion. In addition, this process plays an important role in dealkalization, helping to remove alkali metals and other alkaline substances. The FTHC subsystem 8 includes: an inlet for receiving slurry; a flow path having at least three distinct zones designed to induce strong vortex formation and intense cavitation in the flow; an outlet for the post-cavitation fluid; a depressurizer actuated to the outlet; an automatic high-pressure step-down / relief valve device configured to dynamically adjust the fluid pressure to maintain optimal cavitation conditions within the at least three zones; and a real-time slurry characterization and adaptive control module including an AI-based analysis unit that continuously evaluates the physical and chemical properties of the slurry using inline sensors and processes data from the sensors to determine optimal operating parameters for the subsystem based on real-time slurry characteristics.

[0115] The system further comprises a direct steam injection subsystem (5) connected downstream of the flow-through hydrodynamic cavitation subsystem (8) (FTHC). This subsystem (5) precisely contacts and mixes high-pressure, high-temperature steam with a slurry of woody cellulose material in predetermined amounts to induce hydrostatic cavitation, hydrolysis, cell structure damage, relaxation of complex woody cellulose structures, alkali neutralization, extraction of cell contents based on osmotic pressure, and conversion of alkali to water-soluble salts. Simultaneously, this subsystem (5) generates hydrostatic cavitation within the slurry. Hydrostatic cavitation involves the rapid expansion and contraction of steam bubbles, generating shock waves that can cause mechanical and chemical disturbances in the woody cellulose material without liquefying the substrate.

[0116] In one embodiment, the direct steam injection subsystem (5) includes: a) A boiler module that generates steam. Preferably, it is powered by a renewable energy source such as biogas, solar power, biomass power generation, or hydrogen; b) A cylindrical circulation vessel for main steam distribution, connected to the boiler and used to transport steam; c) A direct steam injection module comprising: i) Direct steam injection type flow vessel apparatus; ii) A configuration having an inlet for biomass supply and an outlet for treated biomass discharge; iii) A novel spiral baffle system device incorporated within the vessel. This system guides the biomass in a spiral path from inlet to outlet, maximizing exposure to steam to enhance heat transfer and promoting the chemical reactions necessary for dealkalization; iv) Multiple injection nozzles connected to the main steam piping within the container. These are arranged to ensure uniform distribution of steam throughout the biomass material; v) A secondary steam injection nozzle positioned near the outlet of a pressurized cylindrical flow container (preferably equipped with a spiral baffle) for precisely mixing steam into the heated slurry; d) A condensate recovery system that recovers and reuses treated water obtained from steam to improve system efficiency; e) A cylindrical flow-through reaction conduit connected to the outlet of a direct steam injection device, which transports the heated slurry under pressurized and high-temperature conditions. The residence time of the conduit is optimized to maximize the effect of the alkali neutralizer. The pressure and temperature of the conduit are controlled by a machine learning-enhanced digital process control unit, which dynamically influences dealkalization and related chemical reactions; f) Pressurized stirring vessel module. It consists of the following: i. Rapid heating jacket device; ii. One or more inlets for receiving wood fiber slurry, treated water, or chemical agents; iii. One or more outlets connected to a slurry cooling device to reduce the slurry temperature before transferring it to the slurry separation unit; iv. A high-shear agitator mounted on the top or bottom of the tank.

[0117] In this invention, the dealkalization apparatus operates in a pressurized loop. Unless otherwise specified, it is preferable to maintain a pressure of approximately 0.1 MPa to approximately 10 MPa during operation. This pressure application enhances the action of each component in the system and improves the permeability of the plant cell walls of the woody cellulose material, facilitating the extraction of cytoplasmic contents. This is particularly advantageous when conventional extraction and dealkalization methods have been limited in their effectiveness for tough, fibrous raw materials such as oil palm empty fruit bunches (EFB). Furthermore, the pressurized loop optimizes process enhancements such as sonication, flow cavitation, superheated steam treatment, and the penetration of extractants and solvents such as water into each plant cell. This results in more efficient extraction, cellular-level dealkalization, and improved yield of valuable components. Therefore, this dealkalization apparatus operating in a pressurized loop overcomes the limitations and scalability of each technique compared to processing woody cellulose materials using each technique individually.

[0118] In the present invention, each component of the dealkalization apparatus is provided with a pressure regulating device (e.g., a pressure relief valve (9), a differential pressure reducing regulator) or connected by a progressive cavity pump (7). Preferably, the conveying capacity is approximately 3 m 3 / h~500 m 3 A progressive cavity pump with a flow rate of approximately 4.8 MPa or less per hour is used. The apparatus preferably employs a vessel or reactor capable of withstanding the operating pressure.

[0119] In one embodiment, the present invention provides an apparatus for dealkalizing wood fiber material, which includes: (a) A cooling container (4) configured to reduce the slurry temperature to 2-20°C; (b) A first set of ultrasonic flow cells (14), preferably comprising a helical flow cell container insert, which transfers the slurry from a cooling container to an ultrasonically compatible reaction vessel via a helical path and exposes the slurry to an ultrasonic frequency range of 0.1 to 20 MPa and 10 to 50 MHz; (c) One or more ultrasonic reaction vessels (15), comprising at least one ultrasonic device and a high-shear agitator having a rotor-stator configuration, wherein at least one ultrasonic device is positioned near the rotor-stator configuration and concentrates an ultrasonic field of 10-50 MHz around the configuration; (d) A second set of ultrasonic flow cells (14), preferably comprising a helical flow cell container insert, which transfers the slurry from the cooling container to the ultrasonic-compatible reaction vessel via a helical path and exposes the slurry to an ultrasonic frequency range of 0.1 to 20 MPa and 10 to 50 MHz; (e) Flow-type hydrodynamic cavitation (FTHC) unit (8). Fluiddynamic cavitation is induced by transferring a steam-injected slurry under pressurization at approximately 0.1 to 100 MPa; (f) Direct steam injection device (5). Steam is injected into the wood fiber slurry at a maximum temperature of 250°C and a maximum pressure of 21 MPa; (g) Reaction tube network (12). Conveys heated slurry for a predetermined time at a maximum temperature of 200°C and a maximum pressure of 10 bar; (h) Heating vessel (16). Receive the slurry from the reaction tube and heat it to a maximum of 200°C, then stir.

[0120] Preferably, the ultrasonic-compatible reaction vessel is connected to a supercritical fluid supply source (70). (a) to (h) are connected in a loop, and it is preferable that a progressive cavity pump and a pressure relief valve are provided throughout the loop.

[0121] The cooling container (4) has the ability to reduce the temperature of the heated slurry to a temperature suitable for subsequent ultrasonic treatment, more preferably to 50°C or less, and even more preferably to 2-20°C. The cooling container (4) is equipped with an inlet and outlet, a rapid cooling jacket surrounding the container, a heat exchanger, a high-shear agitator for stirring the slurry inside the container, and a high-pressure relief valve, and may also be equipped with an additional inlet for introducing water or chemical agents. After the slurry temperature inside the cooling container (4) has decreased to below 50°C, the slurry is sent to one or more ultrasonic flow cells by a **progressive cavity pump (7)**.

[0122] The alkalinity level of the material is measured using the alkalinity test subsystem (17) after each dealkalization subsystem and each pressurization loop is completed. The subsystem (17) comprises a slurry volume test module equipped with high-precision sensors and an automatic high-precision volume sampling tap device throughout the dealkalization system, and a digital analysis module that continuously measures and communicates the alkalinity concentration in the slurry in each subsystem and slurry storage / reprocessing module in real time. If the test results confirm that the wood cellulose material in the slurry has been dealkalized to a predetermined level, the material is separated into wastewater and solid low-alkali material. If the solid material has not been sufficiently dealkalized, it is recirculated through the pressurization loop to the slurry storage tank and reprocessed until the desired dealkalization level is reached. The recirculated slurry is sent from the slurry storage tank to the first heating vessel and reintroduced into the pressurization loop.

[0123] The alkali testing subsystem also includes a slurry testing reactor apparatus coupled to an automated sampling device. In one embodiment, a spectrophotometric analysis unit is used to determine the alkali concentration by measuring absorbance at a specific wavelength. This enables rapid and highly accurate quantification by using a reagent that reacts with the alkaline component to produce a color change, and by utilizing the fact that the degree of color change is proportional to the alkali concentration. In another embodiment, the test is performed in a reactor vessel equipped with a reagent supply system and a digital monitoring system. In the alkali test, the slurry is mixed with an appropriate alkaline solution and then introduced into the reactor vessel at a controlled flow rate. The alkaline solution reacts with the wood fibrous material in the slurry, breaking down its complex structure and releasing the target compound. The reaction is monitored online by measuring the alkali concentration by monitoring the pH or conductivity in the reactor vessel. The reagent supply system can be adjusted to maintain a constant or variable alkali concentration in the reactor vessel. The continuous flow reactor system provides a highly controlled environment for alkali level testing in wood fibrous material, enabling precise measurement and control of reaction conditions.

[0124] After passing the dealkalization test, the slurry enters the slurry separation subsystem (18), where it is separated into a liquid phase (wastewater) and solid dealkalization material by solid-liquid separation equipment such as a centrifuge, screw press, belt press, hydraulic press, screen, filter, and hydrocyclone. The separator integrates a high-pressure treated water spray module, which selectively sprays to remove ionic waste and neutralize chemical agents during the mechanical and high-pressure separation process. In the slurry separation subsystem (18), the separated solid dealkalization material is mechanically compressed to remove excess water and ionic waste. The high-pressure treated water spray equipment is used inside the separator or outside it in the case of a vertical screen separator to efficiently remove ionic waste. The washing and compression processes are performed continuously, ensuring a consistent supply of dealkalization material particles. The slurry separation subsystem further includes a filtration module (particle filter) for removing particles larger than 1 μm from the separated wastewater, a filtered wastewater storage module (storage tank) for in-system recirculation, and a digital separation management unit, which optimizes the operation of each separation, spray, and filtration process based on real-time analysis of water quality and separation efficiency indicators.

[0125] Furthermore, in one embodiment, a novel sensor array module is integrated into the separation subsystem to comprehensively monitor solid waste composition, water quality, and ionic waste concentration, and input the data to an AI-based management unit.

[0126] As shown in Figure 1, the system comprises a separated water recirculation and treatment subsystem, which includes: a water loop and treatment module (12) using a combination of water treatment devices such as steam distillation, reverse osmosis, ion exchange, chemical precipitation, and anaerobic treatment, with the selection and operation of treatment processes dynamically managed by an AI platform based on real-time water quality indicators, operational efficiency, and compliance requirements; a connection to a treated water biogas subsystem configured to accept recirculated treated water that is not treated by the water treatment module; at least one treated water storage container module; and a treated water chemical saturation test module that monitors the treatment and discharge levels adjusted by the AI ​​management module. Furthermore, the subsystem includes: a treated water discharge module (used when discharging without further treatment); an anaerobic digester or biogas digester (to produce biogas and related bioproducts); a biochemical manufacturing device; and an evaporator, electrochemical, or ion exchange device (to produce potassium from potassium-concentrated treated water). Here, these conversion processes are optimized by a digital AI-enhanced management platform distributed throughout the water recirculation and treatment subsystem to maximize nutrient recovery and minimize environmental impact. Furthermore, the system includes one or more wastewater containers that receive filtered wastewater and remove solid particles, and these containers are connected to a water treatment and recirculation subsystem, conserving water resources and reducing the system's environmental footprint.

[0127] As the concentration of hydrolyzed potassium (including potassium hydroxide (KOH)) and other alkalis increases in water, the system self-sufficiently generates agents and solvents, ensuring cost-effectiveness and sustainability. Recent studies have shown that hydrolyzed alkaline solvents (e.g., KOH, HCl) present in recycled wastewater can swell the biomass structural matrix or decompose the complex structures of lignin and cellulose when their concentration reaches 1% or more of the water volume. These agents are recycled in each cycle, increasing their concentration and forming molecular vices as the slurry passes through the cell sonication subsystem. Molecular vice formation primarily involves deligninization under sonication activation, proceeding through mechanisms such as ether bond cleavage between aromatic groups and side chain removal (Liu et al., 2019). Adding KOH or sodium hydroxide to the slurry can initiate molecular vice formation via hydrolyzed ionic alkalis. These additions can initiate or accelerate the effects of molecular vices formed by hydrolyzed ionic alkalis extracted and recycled in the pressurized loop.

[0128] Furthermore, the introduction of wood fiber material with reduced particle size increases the specific surface area, promoting relaxation and decomposition of the complex structure of the wood fiber material by molecular vice, improving enzyme accessibility and enhancing digestibility. As a result, the efficiency of conversion processes for wood fiber material, including but not limited to anaerobic digestion, biofuels, and biochemicals, is increased.

[0129] When the recirculated water reaches its saturation point, it is sent to a downstream wood fiber raw material processing unit, where the dealkalized wood fiber raw material is used for the production of biogas, biofuels, and / or biochemicals. Examples include a high-potassium fertilizer production unit, a downstream anaerobic water treatment unit, or a downstream unit that utilizes the treated raw material for biogas, biochemicals, or biofuels.

[0130] A configuration that uses a slurry pumping subsystem to transport and process slurry throughout the system under pressurized and high-shear conditions includes the following: (i) Progressive cavity pump module: Includes multiple pumps arranged in series or parallel, 3 to 500 m 3 It transports slurry with a transport capacity of / h, generates a positive pressure of up to 48 bar within the system and subsystems, and establishes an autonomous positive pressure loop that eliminates the need for an external pressure source; (ii) High-shear cavitation pump module: comprising multiple pumps arranged in series or parallel, with variable shear blades and a unique blade design to form microcavitation regions in the slurry. It receives the slurry from the progressive cavity pump subsystem and applies variable shear force during transport based on specific dealkalization requirements, thereby increasing the adaptability and efficiency of the dealkalization process; (iii) AI-enhanced automatic feedback control module: Monitors pressure and shear levels within the system and adjusts the operation of the progressive cavity pump and high-shear cavitation pump in real time to maintain optimal dealkalization conditions and energy efficiency; (iv) Novel gas injection module: Placed between the progressive cavity pump subsystem and the high shear cavitation pump subsystem, it introduces a predetermined amount of gas selected from carbon dioxide (CO2), oxygen (O2), nitrogen (N2), air, hydrogen (H2), etc., into the slurry to promote specific chemical reactions or to create an inert atmosphere within the dealkalization process, further enhancing the efficiency and effectiveness of slurry dealkalization under positive pressure based on the slurry characteristics and the dealkalization requirements of each subsystem; (v) Energy recovery module: This module converts the kinetic energy generated by slurry movement within the system into electricity, which is then used to drive the system's pumps, thereby contributing to energy conservation and sustainability.

[0131] The integrated system generates versatile dealkalized solid raw materials, which are used to create a variety of products in various additional processes. In one embodiment, a dealkalized wood fiber raw material is used in the production of solid fuel pellets, which contain dealkalized material carbonized at 400-1000°C in the absence of oxygen.

[0132] The present invention further processes dealkalized biomass into high-density bioproducts using a dealkalized material densification subsystem. This subsystem is designed to efficiently compress the processed biomass and convert it into environmentally friendly solid bio-based products, and includes: a. Drying module: Removes moisture from wood fiber materials (including rotary dryers, conveyor dryers, flash dryers, fluidized bed dryers, spray dryers, drum dryers, microwave dryers, vacuum dryers, etc.). Dealkalized raw materials are dried to a moisture content of approximately 16-<15% by mass, and then subjected to heat treatment after compression into pellets or briquettes, or after extrusion and application of hardening agents; b. Mixing Unit: A binder and chemical agents are added to the dried wood fiber material. The binder is selected from starch, lignin, vinyl acetate, urea-form, phenol-form, and epoxy resin, and the chemical agents include flame retardants, water repellents, insecticides, and fungicides (microfibrillated cellulose products may be used in combination to improve mechanical properties); c. Densification equipment: Includes equipment capable of compressing a mixture into a densified material and forming a density gradient (hydraulic press, screw press, pellet mill, single-screw / twin-screw extruder (for uniform cross-section products), granulator, roll press, high-pressure homogenizer, etc.); d. AI-enhanced control system: Based on the characteristics of the input raw materials and the desired output specifications, a machine learning algorithm predicts the optimal parameters and dynamically adjusts the binder and drug formulation based on real-time feedback; e. Nanoscale surface modification unit: Chemical agents are used to modify the surface of the wood fiber material at the nanoscale, improving its bonding with the binder and enhancing the mechanical strength of the high-density material. Furthermore, the entire system employs a modular design, and each component can be replaced or customized as required.

[0133] This invention enhances the calorific value and carbon content of high-density dealkalized bio-products through heat treatment using a heat conversion subsystem, improving them to a quality suitable for use as a coal / coke substitute in the cement, steelmaking, and supercritical power generation industries. The system includes: a. Torrefaction Module: In an oxygen-deficient, nitrogen-enriched environment, the dealkalized raw material is heat-treated at 200-400°C for a residence time of 60-120 minutes. The nitrogen-enriched environment significantly suppresses oxidation, reduces the generation of unwanted VOCs, enhances thermal stability, and yields a solid biofuel with high energy density and excellent storability. In one embodiment, the torrefaction module is equipped with an autothermal heating device to efficiently recover heat during processing. The device may include a multi-stage furnace, wet torrefaction, rotary furnace, fluidized bed, etc., and is equipped with a nitrogen supply system; b. Carbonization Module: The torrefacted, dealkalized raw material is further processed in an oxygen-deficient, nitrogen-enriched environment at 500-1000°C for a residence time of 60-120 minutes. The nitrogen-enriched environment reduces the risk of combustion and unwanted reactions, and contributes to the preservation of the carbon structure and improvement of the calorific value. The apparatus may include a multi-stage furnace, wet torrefactor, rotary furnace, fluidized bed reactor, etc., and is equipped with a nitrogen supply system. c. Heat recovery / self-heat regeneration heating module: i) Self-heating regeneration heating device: Uses the heat generated by partial combustion of biomass to maintain torrefaction, reducing the need for an external heat source and improving energy efficiency; ii) Heat recovery mechanism: The residual heat generated during torrefaction and carbonization is recovered and used for preheating the raw material at the torrefaction inlet, driving the pre-treatment drying and auxiliary systems, etc. d. AI Management System Module: Controls and optimizes the operating parameters of the heat treatment subsystem, torrefaction, and carbonization based on real-time raw material characteristics, environmental conditions, and target product characteristics; e. Advanced emission control module: Torrefaction and carbonization-derived VOCs, dust, NO x By collecting and treating emissions such as these, we aim to minimize environmental impact and ensure strict compliance with environmental regulations.

[0134] This invention generates biogas from recirculated water collected in a treated water recirculation and treatment subsystem and water extracted during the compression of wood fiber material, using a biogas generation subsystem. The subsystem includes the following: a. Processing Module: Dealkalization of wood cellulose raw materials (including, but not limited to, EFB (Empty Fruit Bunches) and flax fibers) is performed using chemical, enzymatic, and microbial processes. Here, the raw materials are pulverized to significantly increase their specific surface area, making them more susceptible to enzymatic action and improving accessibility to cellulose / hemicellulose, thereby promoting subsequent anaerobic digestion. The dealkalization process yields dealkalized raw materials and high-BOD treated water; b. Anaerobic digestion unit: The dealkalized raw materials and treated water are introduced and operated under controlled positive pressure conditions created by a combination of biogas recirculation and controlled gas injection. This increases the substrate solubility in the raw material mixture, maintains an optimal methane partial pressure in the system, accelerates the anaerobic digestion rate, and improves the biogas yield. c. Control system: Dynamically adjusts the positive pressure within the digestion unit based on real-time feedback on the composition of the dealkalized raw materials and treated water, and optimizes the conditions for maximum biogas production by adjusting the pH of the treated water to the optimal range for anaerobic digestion before introduction; d. Recirculation system: A portion of the generated biogas is recirculated to an anaerobic digestion unit to maintain positive pressure conditions, and a biogas purification system is integrated to remove impurities and ensure gas quality suitable for downstream applications. e. Energy utilization configuration: The generated biogas will be used for power generation, heat supply, or both, to meet other operating needs of the dealkalization process and system, forming an autonomous energy loop that minimizes reliance on external energy and enhances sustainability. Furthermore, the system is configured as an integrated production facility that can utilize dealkalized raw materials not only for biogas production but also for the generation of biofuels, biochemicals, and bioproducts, enabling the synthesis of diverse bioenergy / bioproducts by leveraging the improved digestibility and low alkalinity of the raw materials.

[0135] The present invention uses a carbon credit / renewable energy certificate (REC) subsystem to register and generate carbon-based tradable credits, tax incentives, and RECs resulting from the application of the system and method. The subsystem includes: a. Production facility registration module: Register production facilities to qualify for carbon credit generation; b. Biogenic Conversion Accounting Module: For example, woody cellulose material containing empty fruit clusters (EFB) is treated in a woody cellulose heat treatment subsystem to produce a treated bio-based product. This treatment promotes biogenic sequestration, avoiding material decomposition and the associated methane emissions, thereby reducing greenhouse gas emissions. c. Biomass Energy Accounting Module: Registers and quantifies biomass-based electricity and biogas power generated using wood fiber materials or dealkalized wood fiber materials as fuel; d. Module for quantifying greenhouse gas emission reductions: Quantify the reductions in carbon dioxide (CO2) and methane (CH4) emissions that are avoided by the biogenic sequestration of methane in wood fiber materials; e. Means for generating carbon credits and RECs: Generate credits based on quantified greenhouse gas reductions and directly link the carbon credits and RECs to the processing products of the dealkalization system; f. Methane capture conversion method: Convert the captured methane into secondary products to further reduce greenhouse gases associated with wood fiber materials; g. The subsystem is designed to be adaptable to variations in the wood fiber material being processed and differences in the configuration of the dealkalization system, and ensures that it meets the certification requirements of the emissions trading scheme based on comprehensive greenhouse gas reductions.

[0136] In one embodiment, the system uses a renewable energy subsystem to power the dealkalization system and method by purchase or self-generation. The subsystem includes: a. Expandable photovoltaic modules: Solar cells (PV) are arranged in an array to convert solar energy into electricity and adjust the power output according to the demands of the dealkalization system; b. Hydrogen fuel cell module: Converts hydrogen into electricity, which is produced by water electrolysis using surplus electricity from a solar power generation module; c. Biomass conversion module: Processes wood fiber material and dealkalized wood fiber material to generate electricity, produces synthesis gas in a gasification unit, burns the synthesis gas in a combustion unit to generate electricity, and further optimizes the raw materials for synthesis gasification in a pretreatment unit; d. Machine Learning (ML) equipped control unit: Predicts the availability of solar power, hydrogen, and wood fiber materials, dynamically adjusts the operation of each module to maximize efficiency and minimize waste, and prioritizes the supply of generated power to the dealkalization system; e. Energy storage unit: Composed of a combination of lithium-ion batteries and hydrogen storage tanks, it stores surplus power from each module and performs optimal charging and discharging based on the operating requirements of the de-alkalization system.

[0137] In one embodiment, the renewable energy subsystem can sell energy generated by any module to consumers.

[0138] In another embodiment, the subsystem can generate renewable energy using dealkalized bio-products.

[0139] This invention provides a bio-product storage and transport subsystem for transporting and storing wood fiber materials, dealkalized wood fiber materials, and bio-based products. The subsystem includes the following: a. Vehicle fleet: Composed of electric, hydrogen, biogas, and biofuel trucks, equipped with a power management system, and capable of long-distance transportation of raw materials and transportation of dealkalized bio-products after production; b. Custom-made container modules: These containers are designed to maintain bio-products under specified conditions during transport. They are suitable for loading, unloading, and securing on electric trucks, and their modular design allows for changes in the configuration of internal compartments. They can accommodate multiple types of bio-products simultaneously, and each compartment maintains its required environmental conditions through individual control. c. Bulk Handling System Module: Integrated into electric trucks and custom-made containers, it transports bio-products between storage facilities and containers, and handles solid, liquid, and gaseous states. Furthermore, this subsystem manages transportation logistics via a digital management platform, optimizing routes based on energy consumption, product stability requirements, and delivery schedules. Custom-made containers are also equipped with sensors to monitor the condition of bio-products in real time and communicate this information to the platform, ensuring product integrity during transport.

[0140] Furthermore, the present invention also provides a method for operating the system and apparatus. Any of the steps described above constitute a part of the method for dealkalizing wood fiber material using the system and apparatus.

[0141] Generally, solid biofuels formed from dealkalized wood fiber raw materials obtained by the aforementioned systems, apparatus, and methods meet the Hargraves pulverability index (HGI) requirements essential for using wood fiber materials as raw materials in existing coal-based processes. Depending on the processing method (torrefaction or carbonization, etc.), these solid biofuels generally have a fixed carbon content of 20% or more, a lower heating value (LHV) of 5 or more, and an HGI of over 35.

[0142] Although specific embodiments have been described and illustrated, it will be obvious to those skilled in the art that numerous changes, modifications, variations, and combinations thereof are possible without departing from the scope of the present invention.

Claims

1. A system for producing dealkalized wood fiber materials and bio-based products, comprising the following components: (a) A size reduction subsystem for processing wood fiber material into smaller particle sizes; (b) A pretreatment subsystem that pretreatments the particles using electromagnetic frequency and electric field; (c) A slurry generation subsystem that combines pre-treated particles with a water mixture containing water and chemical agents to obtain a slurry; (d) An ultrasonic processing subsystem that disrupts the cellular structure, loosens the cellular matrix, and removes and neutralizes alkali at the cellular level of the woody fiber material in the slurry; (e) A hydrodynamic cavitation subsystem that performs high-level shear mechanical decomposition of woody fibrous material in slurry at the cellular level; (f) A direct steam injection subsystem connected to the slurry generation subsystem and / or hydrodynamic cavitation subsystem to realize hydrostatic cavitation and alkali neutralization within the slurry; (g) An automated test subsystem for monitoring and adjusting dealkalization treatment conditions in real time; (h) Separation subsystem for separating the treated slurry into a solid dealkalization material and treated water; (i) Water recirculation and treatment subsystems that recirculate water treated in the system or use treated water to produce bio-based products; (j) A slurry pumping subsystem that generates positive pressure and high shear cavitation throughout the system; and (k) A densification subsystem that converts solid dealkalization materials into densified bio-based products; A system characterized by including

2. A system according to claim 1, which is applicable to a water treatment plant by connecting to a water recirculation and treatment subsystem, and is characterized by taking in wastewater from the plant or discharging wastewater to the plant.

3. A system according to claim 1, characterized in that the water mixture comprises fresh water and / or recirculated water and a chemical agent capable of binding with alkaline ions in a pretreated wood cellulose material.

4. A system according to claim 1, characterized in that the densification subsystem includes a drying module, a mixing unit to which a binder and chemical agents are added to form a heat-resistant silicate compound by contact with alkali, and a densification device for compressing a solid dealkalization material.

5. The system according to claim 1, wherein the wood fiber material pretreatment subsystem is as follows: (i) an electromagnetic processing unit for decomposing wood fiber material in particles at 100 MHz to 5000 MHz; and (ii) A pulsed electric field processing device connected to an electromagnetic energy processing unit that exposes particles to a pulsed electric field (PEF) of 10 to 100 kV; A system characterized by including

6. The system according to claim 1, wherein the direct steam injection subsystem is as follows: (i) A mixing vessel having a steam inlet, a slurry inlet and a heated slurry outlet, wherein the slurry inlet tube has a helical baffle insert and a plurality of steam injection ports, and the heated slurry outlet is connected to a flow-through hydrodynamic cavitation subsystem, and during operation, the slurry and steam are mixed by direct injection at temperatures up to 350 °C and pressures up to 2 MPa; and (ii) A cooling system for reducing the slurry temperature after mixing; A system characterized by including

7. The system according to claim 1, wherein the ultrasonic processing subsystem is as follows: (i) An ultrasonically compatible reaction vessel comprising at least one ultrasonic device and a high-shear agitator having a rotor-stator configuration, wherein at least one ultrasonic device is positioned near the rotor-stator configuration and concentrates the emission of an ultrasonic field around the configuration; (ii) A heating vessel for heating the slurry before and / or after the ultrasonic reaction vessel; (iii) A cooling vessel for cooling the slurry to a temperature suitable for ultrasonic treatment; and (iv) An ultrasonic flow cell, positioned before and / or after an ultrasonic reaction vessel, comprising a cylindrical flow vessel containing a helical insert and one or more ultrasonic devices; A system characterized by including

8. The system according to claim 1, characterized in that the slurry pumping subsystem includes a progressive cavity pump and a pressure relief valve.

9. The system according to claim 1, characterized in that the ultrasonic-compatible reaction vessel further comprises a supercritical fluid dispersion unit.

10. The system according to claim 1, further comprising a collection subsystem configured to aggregate wood cellulose material using a sensor-based identification system, wherein the identification system is capable of identifying the material based on type, state and processing suitability.

11. A system according to claim 10, characterized in that the collection subsystem includes an artificial intelligence (AI) enhanced digital management platform and is integrated with an autonomous transport mechanism to perform efficient material collection and logistics management.

12. A system according to claim 1 or claim 5, characterized in that the preprocessing subsystem further comprises a microwave-assisted extraction (MAE) system integrating microwave and ultrasonic technology.

13. The system according to claim 1, further comprising a renewable energy subsystem for driving a dealkalization process, wherein the subsystem includes a photovoltaic module, a hydrogen fuel cell module, and a biomass conversion module, all of which are managed by an AI-enhanced control unit.

14. The system according to claim 1, further characterized in that the separation subsystem incorporates a sensor array module for monitoring water quality and ionic waste concentration.

15. The system according to claim 1, further comprising a thermal conversion subsystem connected to a densification subsystem for torrefaction and / or carbonization of a dealkalized densification material, wherein the thermal conversion subsystem includes a torrefaction module, a carbonization module, and a gas emission control module.

16. The system according to claim 1, further comprising a biogas generation subsystem that generates biogas from dealkalized wood fiber material and treated water, wherein the subsystem includes a dealkalized material processing module, an anaerobic digestion unit, and a biogas purification system.

17. The system according to claim 1, further comprising a storage and transport subsystem for handling, storing and transporting wood fiber material, dealkalized wood fiber material and the obtained bio-based product, wherein the subsystem utilizes a sustainable fleet of transport vehicles and a digital management platform for logistics optimization.

18. The system according to claim 1, characterized in that it is applicable to a carbon credit and REC subsystem configured to generate carbon credits and renewable energy certificates (RECs) based on the sustained operation of greenhouse gas emission reduction and dealkalization processes.

19. A system according to claim 1, applicable to a renewable energy subsystem that drives the system using a renewable energy source, wherein the subsystem includes a photovoltaic module, a hydrogen fuel cell module, and a biomass conversion module.

20. An apparatus for dealkalizing wood fiber material, comprising the following components: (a) A cooling vessel (4) configured to reduce the slurry temperature to 2–20 °C; (b) A first set of ultrasonic flow cells (14) comprising a helical channel insert, which transfers slurry from a cooling vessel to an ultrasonically compatible reaction vessel via a helical path and exposes the slurry to an ultrasonic frequency range of 0.1 to 20 MPa and 10 to 50 MHz; (c) One or more ultrasonically compatible reaction vessels (15) comprising at least one ultrasonic device and a high-shear agitator having a rotor-stator configuration, wherein at least one ultrasonic device is positioned near the rotor-stator configuration and concentrates an ultrasonic field of 10 to 50 MHz around the configuration; (d) A second set of ultrasonic flow cells (14) comprising a helical channel insert, which transfers the slurry from a cooling vessel to an ultrasonically compatible reaction vessel via a helical path and exposes the slurry to an ultrasonic frequency range of 0.1 to 20 MPa and 10 to 50 MHz; (e) A flow-through hydrodynamic cavitation (FTHC) unit (8) that induces hydrodynamic cavitation by transferring a steam-injected slurry under pressurization of approximately 0.1 to 100 MPa; (f) Direct steam injection device (5) for injecting steam into wood fiber slurry under conditions of up to 250 °C and up to 21 MPa; (g) A network of reaction tubes (60) for transporting a slurry at a maximum temperature of 200 °C and a maximum pressure of 10 bar for a predetermined time; and (h) A heating vessel (16) that receives the slurry from the reaction tube (60) and heats and stirs it to 200 °C; An apparatus characterized by including

21. The apparatus according to claim 20, characterized in that the ultrasonic-compatible reaction vessel is connected to a supercritical fluid supply source.

22. The apparatus according to claim 20, characterized in that the direct steam injection device includes a cylindrical container having a spiral baffle in the inlet pipe.

23. The apparatus according to claim 20, characterized in that the ultrasonic-compatible reaction vessel comprises a plurality of ultrasonic devices, each arranged to provide a uniform ultrasonic field within the reactor, and one of the devices is located at the bottom of the reactor.

24. The apparatus according to claim 20, wherein the high-shear agitator comprises a motor, a rotor shaft, and a rotor-stator configuration, and the rotor shaft has at least one rotor blade.

25. The apparatus according to claim 24, characterized in that the stator is provided with an extension skirt portion connected to an ultrasonic device attached to the bottom of the reactor, and is configured to transmit ultrasonic radiation from the ultrasonic device to the reactor.

26. The apparatus according to claim 20, wherein the high-shear agitator further comprises a stabilizing means having one side in contact with the reactor and the other side fixed to the stator, thereby stabilizing the agitator.

27. The apparatus according to claim 26, characterized in that the stabilization means is configured as a channel connected to a supercritical fluid source.

28. The apparatus according to claim 26, characterized in that the stabilizing means is connected to the skirt portion of the stator and configured to distribute a supercritical fluid into the reactor.

29. A method for producing a dealkalized wood fiber material and a bio-based product based on the system described in claim 1, comprising the following steps: (a) A process of reducing the size of wood fiber material into particles; (b) Processes for pre-treating materials using electromagnetic and electric field processes; (c) A step of mixing the pre-treated material with a water mixture containing water and chemical agents to form a slurry; (d) A step of exposing the slurry to ultrasonic resonance and flow cavitation with high shear under a pressurized environment to induce hydrodynamic cavitation, which disrupts cells at the cellular level and promotes the extraction of alkaline components from the slurry; (e) A process of inducing hydrodynamic cavitation by applying flow cavitation with high shear under a pressurized environment to a slurry; (f) A step of inducing hydrostatic cavitation by direct steam injection while rapidly heating and cooling the slurry material to promote alkali neutralization; (g) A process of continuously monitoring and adjusting the process based on alkali levels; (h) A step of separating the slurry into a solid dealkalization material and treated water; (i) A step of washing the slurry to remove solid particles larger than 1 micron and ionic waste to obtain a dealkalized wood fiber material; (j) A process of recirculating treated water or using treated water to produce bio-based products; and (k) A process of producing a dealkalized bio-product by increasing the density of a solid dealkalization material; A method characterized by including the following.

30. A method according to claim 29, further comprising the steps of collecting a wood fiber material, then washing, decomposing and / or adding chemical agents, and then atomizing it.

31. The method according to claim 29 or 30, wherein step (d) is supercritical carbon dioxide (CO2) 2 A method characterized by being carried out in the presence of ).

32. A method according to claim 29 or 30, characterized in that step (d) is carried out in an ultrasonic frequency range of 10 Hz to 50 MHz.

33. A method according to claim 29 or 30, characterized in that step (a) includes a step of processing a wood fiber material into particles with an average particle size of less than 10 mm.

34. The method according to claim 29 or 30, wherein step (b) is the following step: (i) A step of exposing the particles to electromagnetic energy treatment in the range of 500 to 5000 MHz; and (ii) A step of obtaining porous particles by pulsed electric field (PEF) treatment with a voltage pulse of 10 to 100 kV; A method characterized by including

35. A method according to claim 29 or 30, characterized in that the ratio of the water mixture to the particles in step (c) is 1:1 to 1:

25.

36. A method according to claim 29 or 30, characterized in that step (f) is carried out by heating the slurry by direct steam injection at a temperature of 1°C to 250°C and a pressure of 0.01 MPa to 21 MPa.

37. A method according to claim 29 or 30, characterized in that the water mixture comprises water and / or recirculated water and a chemical agent capable of binding with alkali ions in the pretreated wood fiber material.

38. A method according to claim 29 or 30, characterized in that the densification step is carried out by drying the solid dealkalization material, mixing it with a binder and a chemical agent, and then compressing it.

39. A method according to claim 29 or 30, characterized in that step (f) is carried out under a pressure of 0.1 MPa to 50 MPa.

40. A method according to claim 29 or 30, characterized in that the rapid heating in step (f) is carried out under a pressure of 0.1 to 21 MPa and has a heating rate of up to 250°C / min.

41. A method according to claim 29 or 30, characterized in that the rapid heating step is carried out in the presence of an inert gas to prevent oxidation of the wood fiber material in the slurry.

42. A method according to claim 29 or 30, characterized in that the rapid cooling in step (f) is carried out under a pressure of 0.1 to 10 MPa and has a cooling rate of 20°C / min or more.

43. A method according to claim 29 or 30, characterized in that the high-shear environment in step (d) has a maximum shear rate of 5000 rpm.

44. A method according to claim 29 or 30, characterized in that the step of continuously monitoring and adjusting the process based on alkali levels is supported by the use of an AI-enhanced control unit in an automated dealkalization test subsystem, and the process parameters are optimized based on real-time alkali levels.

45. A method according to claim 29 or 30, characterized in that ionized water is added to the slurry formation step to adjust the pH level and improve chemical reactivity.

46. A method according to claim 29 or 30, further comprising the step of optimizing the energy efficiency and sustainability of a dealkalization process by utilizing an energy recovery module within a slurry separation subsystem.

47. A method according to claim 29 or 30, characterized in that it optimizes the process of converting dealkalized biomass into high-density bioproducts using a high-density subsystem.

48. A method according to claim 29 or 30, further comprising a heat treatment step using a heat conversion subsystem to improve the calorific value and carbon content of a high-density dealkalized bioproduct.

49. A method according to claim 29 or 30, further comprising the step of utilizing a biogas generation subsystem to produce biogas from wood cellulose material and extracted water treated during a dealkalization process.

50. A method according to claim 29 or 30, further comprising the step of generating carbon credits and renewable energy certificates (RECs) through the sustained operation of a system and emission reductions, characterized in that it utilizes a carbon credit / REC subsystem.

51. A method according to claim 29 or 30, characterized in that it is driven by a renewable energy source via a renewable energy subsystem, thereby minimizing environmental impact and enhancing sustainability.

52. A method according to claim 29 or 30, further comprising the steps of transporting and storing wood fiber material, dealkalized wood fiber material and bio-based products, characterized in that sustainable logistics are achieved by utilizing a bio-product storage and transport subsystem.

53. A dealkalizing material obtained by the method described in any one of claims 29 to 52.

54. A dealkalized bio-based product obtained from the system described in any one of claims 1 to 19.

55. A solid biofuel material comprising the dealkalization material described in claim 53, characterized in that it comprises the dealkalization material carbonized at a temperature of 400 to 1000°C under conditions in the absence of oxygen.

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