Pressure valve assembly

Abstract

The valve assembly has a conical valve needle that is axially displaceable within a bore in the valve body, and when the valve is closed, a portion of the larger diameter of the valve needle is located downstream of the annular ring. Even when the nozzle for liquid input is closed, an open area exists between one end of the valve body and the annular ring. The inner wall of the valve body includes at least one opening for admitting liquid under pressure after the slurry or liquid exits the tube or pipe. The valve assembly is particularly useful for maintaining a semi-continuous or continuous flow of pressurized biomass from an extruder.

Description

[Technical Field]

[0001] cross reference

[0001] This application claims the benefits of U.S. Provisional Application No. 63 / 087,077 filed 2 October 2020, U.S. Provisional Application No. 63 / 146,608 filed 6 February 2021, and U.S. Provisional Application No. 63 / 153,740 filed 25 February 2021, each of which is incorporated herein by reference as a whole. [Background technology]

[0002]

[0002] In many industrial processes, valves are used to control the flow of materials. Inside a relief valve is a plug that, when the valve is pressurized, blocks or reduces the outlet of the material source. When the pressure behind the plug is released, the plug is pushed back by the force of the pressure from this outlet. This allows the valve to open until the pressure behind the plug is greater than or equal to the force from the outlet. When the valve is coupled to an actuator that operates in response to the outlet, more precise continuous motion is possible than when using only manually operated or spring-operated valves.

[0003]

[0003] When moving materials under pressure, it can be difficult to control the pressure within the container through which the material is being transported. This is particularly challenging for continuous or semi-continuous flows of material slurries moving in one direction in critical operating conditions resulting from the processing of the medium. To maintain a constant pressure and velocity of the moving material, valves must be designed to allow a specific velocity while operating to maintain a constant pressure within the pipe or barrel. This is especially true for particulate matter such as biomass moving in a liquid under high pressure, where the valve is involved in further processing and the material flow is rapidly surging. Such harsh operating conditions can induce premature failure and leakage of the valve assembly, resulting in jetting and excessive wear. Furthermore, slurry particles can become trapped in the valve sealing cycle, resulting in performance degradation of the valve assembly. Generally, pressure relief valves are not designed to cope with such operations. [Overview of the Initiative] [Means for solving the problem]

[0004]

[0004] In one embodiment, a valve assembly is provided herein, comprising: a valve body having an inlet end, a discharge end, and a chamber formed to connect to the inlet and discharge ends, wherein the inlet end is attachable to a pipe having a fluid or slurry inlet through the valve assembly; a conical valve needle having a conical shape with a broad end opposite to the conical tip and being axially displaceable within the chamber in the valve body; and a housing attached to the discharge end of the valve body, sealing the valve needle when the valve needle is detached from the valve body, wherein the diameter of the broad end of the valve needle is at least 4% larger than the inner diameter of the valve body at its discharge end.

[0005]

[0005] In some embodiments, the valve body has an annular ring located on the inner surface of the valve body at the discharge end within a concave cavity. In some embodiments, the annular ring is replaceable. In some embodiments, the inner surface of the annular ring is aligned with the inner surface of the valve body. In some embodiments, the valve needle is located on the annular ring when closed within the valve body. In some embodiments, the housing includes a removable discharge ring located adjacent to the discharge end of the valve body. In some embodiments, the discharge ring has a tapered shape. In some embodiments, the valve body includes a nozzle for liquid injection. In some embodiments, the chamber of the valve body forms part of a reaction section having a tube for a biomass pretreatment process. In some embodiments, the tube is an extruder. In some embodiments, the extruder is a twin-screw extruder. In some embodiments, the valve needle is operably connected to an actuator via a shaft. In some embodiments, the actuator maintains the pressure on the valve needle. In some embodiments, the actuator maintains the pressure on the valve needle above 816.47 kgf (1,800 lbf). In some embodiments, the actuator maintains the pressure on the valve needle at 22,679.62 to 226,796.19 kgf (50,000 to 500,000 lbf). In some embodiments, the valve body has a circular portion located at the discharge end, a circular collar located at the inlet end with an inner diameter smaller than that of the circular portion at the discharge end, and an intermediate conical portion located between the circular portion and the circular collar. In some embodiments, when the valve needle is closed on the valve body, an annular space is formed between the valve needle and the valve body in the chamber. In some embodiments, the housing includes a discharge pipe. In some embodiments, the inner diameter of the housing at the end of the housing that abuts the valve body is at least 7% larger than the inner diameter of the valve body at its discharge end. In some embodiments, the inner diameter of the housing at the end of the housing that abuts the valve body is about 7% larger than the inner diameter of the valve body at its discharge end. In some embodiments, the cone of the conical valve needle tapers in the range of about 45 to about 75 degrees. In some embodiments, the cone of the conical valve needle tapers at approximately 45 degrees.

[0006]

[0006] In another embodiment, a valve assembly is provided herein comprising a valve body including a large circular portion, an intermediate conical portion, and a small circular collar including one or more nozzles for liquid injection, wherein a chamber is formed within the valve body connecting the injection end and discharge end of the valve body, the inner diameter of the small circular collar being smaller than the large circular portion, a valve needle that is axially displaceable within the chamber of the valve body, and a housing attached to the discharge end of the valve body that seals the valve needle when the valve needle is detached from the valve body.

[0007]

[0007] In another embodiment, a system for processing biomass by an extruder is provided herein, comprising: an extruder including one or more screws, wherein the action of the screws forms an internal plug of biomass, thereby forming one end of a pressurized reaction section; means for supplying steam and chemicals to the reaction section; and a valve assembly located at the outlet end of the extruder, forming the downstream end of the reaction section and adding liquid to the reaction section, wherein the valve assembly is capable of rapidly releasing the pressurized biomass into an unpressurized discharge section.

[0008]

[0008] In one embodiment, a valve assembly is provided comprising a housing, a valve body, and a valve needle, which are mounted on a pipe having an outlet through which a flow passes, wherein the valve comprises a conical valve needle that is axially displaceable within the annular space of the valve body, the valve needle having a conical valve needle tip at one end, and the downstream inner diameter of the valve body is at least 4% larger than the inner wall of the housing. In one embodiment, the valve assembly comprises an annular ring which is part of the valve body and is replaceable.

[0009]

[0009] In another embodiment, the valve assembly housing includes a removable discharge ring. In another embodiment, the valve body includes a nozzle for introducing liquid. In a further embodiment, a valve needle is positioned in the discharge ring when closed within the valve body. In one embodiment, the valve assembly forms part of a reaction section having a tube. In a further embodiment, the valve needle is attached to an actuator. In one embodiment, the actuator maintains the pressure on the valve needle, which is maintained at a pressure greater than 816.47 kgf (1,800 lbf). In another embodiment, the actuator maintains the pressure on the valve needle between 22,679.62 and 226,796.19 kgf (50,000 to 500,000 lbf).

[0010]

[0010] In one embodiment, the tube attached to the valve assembly is an extruder. In a further embodiment, the extruder is a twin-screw extruder.

[0011]

[0011] In another embodiment, a conical valve needle is provided for engaging with a valve body, and when the valve is closed, the conical valve needle extends beyond the valve body into a discharge area. In one embodiment, the annular ring is part of the valve body. In another embodiment, the valve needle is installed downstream of the annular ring. In a further embodiment, the annular ring is replaceable. In one embodiment, a housing containing the valve needle is installed downstream of the valve body, and the housing includes a removable discharge ring. In another embodiment, the valve body includes a nozzle for introducing liquid. In another embodiment, the valve needle is installed in the discharge ring when closed within the valve body. In a further embodiment, the valve body and valve needle form part of a reaction section for a pipe. In another embodiment, the valve needle is attached to an actuator. In a further embodiment, the actuator maintains the pressure on the valve needle. In a further embodiment, the actuator maintains the pressure on the valve needle at more than 816.47 kgf (1,800 lbf). In one embodiment, the actuator maintains the pressure applied to the valve needle at 22,679.62 to 226,796.19 kgf (50,000 to 500,000 lbf).

[0012]

[0012] In one embodiment, the valve needle is positioned within a valve body attached to an extruder. In a further embodiment, the extruder is a two - screw extruder.

[0013]

[0013] In one embodiment, a valve assembly that forms part of a reaction zone is provided when attached to a tube or pipe. In another embodiment, the pipe or tube is an extruder. In a further embodiment, the extruder is a two - screw extruder. In another embodiment, at least a portion of the contents of the extruder is under pressure.

[0014]

[0014] In one embodiment, a valve assembly is provided, and a pressurized section of a tube or pipe or extruder extends into the valve assembly. In another embodiment, the valve assembly has an increase in inner diameter between the end of the valve body where the material is discharged and the diameter of the discharge housing.

[0015]

[0015] In one aspect, a valve assembly for use in a pressurized passage of a fluid, slurry, or other material, comprising a housing, a valve body including a large circular portion, an intermediate conical portion, and a smaller circular collar portion including one or more nozzles for liquid input, and a valve needle, is provided. In another aspect, the housing includes a removable discharge ring. In a further aspect, the discharge ring is tapered. In another aspect, the valve body includes an annular ring. In another aspect, the annular ring is removable. In another embodiment, a space exists between the valve body and the valve needle when the valve needle is installed. In a further embodiment, the nozzles for liquid input transmit water into the space between the valve body and the valve needle. In a further embodiment, the nozzles for liquid input transmit a liquid other than water into the space between the valve body and the valve needle. In a further embodiment, the liquid is selected from the group consisting of acids, bases, alcohols, ketones, aldehydes, solvents, or combinations thereof.

[0016]

[0016] In another embodiment, a system is provided for processing biomass by an extruder, comprising: an extruder having one or more screws, wherein the action of the screws forms an internal plug of biomass, thereby forming one end of a pressurized reaction section; a method for supplying steam and chemicals to the reaction section; and a valve assembly located at the outlet end of the extruder, which forms the downstream end of the reaction section, and which is capable of adding liquid to the reaction section and rapidly releasing the pressurized biomass into an unpressurized discharge section. In another embodiment, the biomass is selected from the group consisting of silage, agricultural residues, maize stalks and leaves, bagasse, sorghum, nuts, nut shells, coconut shells, distillation-dried soluble substances, distillation-dried grains, condensed distillation-dried soluble substances, distillation-moist grains, distillation-dried grains containing soluble substances, woody materials, sawdust, wood chips, wood residues, mill scrap, municipal waste, waste paper, recycled toilet paper, garden trimmings, as well as energy crops such as poplar, willow, switchgrass, alfalfa, and oxgrass, non-woody plant materials, cellulosic materials, lignocellulose materials, hemicellulose materials, carbohydrates, maize, sugarcane, grasses, switchgrass, high-biomass sorghum, bamboo, maize cobs, as well as husks and seeds. In a further embodiment, the biomass is processed in the reaction interval for 60, 55, 50, 45, 40, 35, 30, 25, 20, 19, 18, 17, 16, 15, 14, 13, 12, 10, 9, 8, 7, 6, 5, 4, 3, 2, or less than 1 second. In one embodiment, the temperature in the reaction interval is 50-500°C, 75-400°C, 100-350°C, 150-300°C, 200-250°C, 150-300°C, and 3.516-70.31 kgf / cm². 2 (50~1000PSI), 7.031~52.74kgf / cm 2 (100~750PSI), 14.06~42.19kgf / cm 2 (200~600PSI), 21.09~35.16kgf / cm 2 (300-500 PSI), or 24.61-31.64 kgf / cm² 2(350~450PSI). In another embodiment, the chemical substance is an acid. In a further embodiment, the acid is sulfuric acid.

[0017]

[0017] In one aspect, a system is provided that includes a valve assembly having a housing, a valve body including a large circular portion, an intermediate conical portion, and a smaller circular collar, and including one or more nozzles for liquid input, and a valve needle. In another aspect, the system has a valve assembly, and the housing includes a removable discharge ring. In a further aspect, the discharge ring of the valve assembly tapers. In another embodiment, the valve body of the valve assembly includes an annular ring. In a further embodiment, the annular ring is removable. In another aspect, the valve body includes a space between the valve body and the valve needle when the valve needle is installed. In another embodiment, the valve assembly includes a nozzle for introducing a liquid to convey water into the space between the valve body and the valve needle. In a further embodiment, the nozzle for liquid input conveys a liquid other than water into the space between the valve body and the valve needle. In a further embodiment, the liquid includes an acid, a base, an alcohol, a ketone, an aldehyde, a solvent, or a combination thereof.

[0018]

[0018] In one embodiment, a method of treating a slurry or a liquid in a pipe or a barrel includes forming a pipe or a barrel having a plug at one end of a reaction section, moving a liquid or a slurry through the pipe or the barrel, maintaining the pressure in the reaction section while forming a downstream end of the reaction section using a valve assembly attached to an outflow end of the pipe or the barrel, adding a liquid to an upstream end of the valve assembly when the liquid or the slurry enters the valve assembly, and discharging the treated liquid or slurry into a non-pressurized area using the valve assembly.

[0019]

[0019] In one embodiment, a valve assembly is provided which is mounted on a pipe or barrel and which introduces liquid into a valve body after the liquid or slurry has left the pipe or barrel but before the liquid or slurry reaches the valve needle.

[0020]

[0020] In one embodiment, a valve assembly is provided in which the valve body has a removable annular ring adjacent to a removable release ring in the release housing. In another embodiment, the release ring of the valve assembly tapers. Embedding by reference

[0021] All publications, patents, and patent applications described herein are incorporated by reference in the same way that each individual publication, patent, or patent application is specifically and individually indicated to be incorporated by reference.

[0021]

[0022] Novel features of this disclosure are specifically described in the attached claims. A better understanding of the features and advantages of this disclosure can be gained by referring to the following detailed description, which describes exemplary embodiments in which the principles of this disclosure are used, and to the attached drawings. [Brief explanation of the drawing]

[0022] [Figure 1]

[0023] This is a diagram showing the modified pressure valve assembly. [Figure 2]

[0024] This is a longitudinal view of the valve and its housing. [Figure 3]

[0025] Figure 3A is a longitudinal view of the valve assembly from the top (Figure 3A) and side (Figure 3B). Figure 3B is a longitudinal view of the valve assembly from the top (Figure 3A) and side (Figure 3B). [Figure 4]

[0026] This is a longitudinal view of the valve assembly as seen from above. [Figure 5]

[0027] This is an enlarged view of cross-section A shown in Figure 4. [Figure 6]

[0028] This is a cross-sectional view of the valve body through which the valve needle passes. [Figure 7]

[0029] Figure 7A is a cross-sectional view of the valve in the closed annular shape. Figure 7B is a cross-sectional view of the valve in the annular shape with a stroke of 0.5 mm. Figure 7C is a cross-sectional view of the valve in the annular shape with a stroke of 1.0 mm. Figure 7D is a cross-sectional view of the valve in the annular shape with a stroke of 1.5 mm. [Modes for carrying out the invention]

[0023]

[0030] As used herein and in the appended claims, the singular “a,” “an,” and “the” also include multiple references unless otherwise clearly specified in the context. Thus, for example, a reference to “purified monomer” includes a mixture of two or more purified monomers. In this specification, the terms “comprising” are synonymous with “including,” “containing,” or “characterized by,” and are comprehensive and open-ended, not excluding additional undescribed elements or method steps.

[0024]

[0031] The term "approximately" means that the numerical expression mentioned is within a range of plus or minus 10% of that expression. For example, the term "approximately 4" should encompass a range of 3.6 to 4.4. All numbers used herein to express quantities of components, reaction conditions, etc., should be understood in all cases as being modified by the term "approximately." Therefore, unless otherwise indicated, the numerical parameters described herein are approximations that may vary depending on the desired properties to be obtained. At the very least, this is not intended to limit the application of the doctrine of equivalents to the scope of any claim in any application claiming priority to this application, but each numerical parameter should be interpreted in light of significant figures and common rounding practices.

[0025]

[0032] Whenever the words "for example," "etc.," or "including" are used herein, they shall be understood to be followed by the phrase "and without limitation," unless otherwise expressly specified. Thus, "for example, ethanol production" means "for example, ethanol production, but without limitation."

[0026]

[0033] In this specification and the subsequent claims, several terms are defined as having the following meanings: definition

[0034] "Optional" or "optionally" means that the following events or situations may or may not occur, and the description includes both cases in which such events or situations occur and cases in which they do not occur. For example, the phrase "the medium may optionally contain glucose" means that the medium may or may not contain glucose as an ingredient, and the description includes both glucose-containing and glucose-free mediums.

[0027]

[0035] Unless otherwise specified, the technical and scientific terms used herein have the same meanings as those commonly understood by those skilled in the art.

[0028]

[0036] In this specification, the term “biomass” has the ordinary meaning known to those skilled in the art and may include one or more carbonaceous bio-derived materials that can be converted into biofuels, chemicals, or other products. In this specification, biomass is synonymous with the term “supply material” and includes silage, agricultural residues (such as corn stalks, grasses, straw, grain husks, and bagasse), nuts, nut shells, coconut shells, animal waste (compost from cattle, poultry, and pigs), distillation-dried soluble materials, distillation-dried grains, condensed distillation-soluble materials, distillation-moist grains, distillation-dried grains containing soluble materials, woody materials (wood or bark, sawdust, wood chips, wood residues, and mill scraps), municipal waste (such as waste paper, recycled toilet paper, and garden trimmings), and energy crops (such as poplar, willow, switchgrass, alfalfa, oxgrass, green algae, brown algae, and some red algae, including macroalgae). One exemplary source of biomass is plant matter. Plant matter can include, for example, woody plant matter, non-woody plant matter, cellulosic materials, lignocellulosic materials, hemicellulosic materials, sugarcane, grasses, switchgrass, sorghum, high-biomass sorghum, bamboo, algae, and materials derived therefrom. Plants can be in their natural state or genetically modified plants, for example, to increase the cellulose or hemicellulosic portion of the cell wall, or to increase the separation distance of cell wall components by producing additional exogenous or endogenous enzymes. Plant matter can be further described by referring to the chemical species in which it exists, such as proteins, polysaccharides, and oils. Polysaccharides include polymers and derivatives of various monosaccharides, including glucose, fructose, lactose, galacturonic acid, and rhamnose. Plant-based materials also include agricultural waste, by-products, or by-products such as pomace, corn steep liquor, corn cobs, corn fiber, corn steep solids, distilled grains, husks, seeds, fermentation waste, straw, milling, sewage waste, food scraps, and leftovers. Peels may include, but are not limited to, citrus fruits, including tangerine peel, grapefruit peel, orange peel, lime peel, and lemon peel.These materials can originate from farms, forests, industrial sources, households, etc. Other non-limiting examples of biomass include animal products, such as milk, bones, meat, fat, animal processing waste, and animal excrement. “Supply materials” is often used to refer to biomass used in processes such as those described herein.

[0029]

[0037] In this specification, “pretreatment” or “pretreated” is used to refer to any mechanical, chemical, thermal, biochemical process, or combination thereof, that results in the crushing or expansion of biomass so that the biomass is more susceptible to attack by enzymes and / or microorganisms, and such processes may be performed in combination or sequentially, and may include enzymatic hydrolysis of the released carbohydrate polymers or oligomers to monomers. In one embodiment, pretreatment includes removing or crushing lignin so that cellulose and hemicellulose polymers in plant biomass are more readily available to cellulose-degrading enzymes and / or microorganisms, for example, by treatment with an acid or a base. In one embodiment, pretreatment includes crushing or expansion of cellulosic and / or hemicellulose materials. In another embodiment, pretreatment may refer to starch release to glucose and / or enzymatic hydrolysis. Steam explosion and ammonia fiber expansion (or explosion) (AFEX) are well known thermal / chemical techniques. Hydrolysis methods including those utilizing acids, bases, and / or enzymes may be used. Other thermal, chemical, biochemical, and enzymatic techniques may also be used.

[0030]

[0038] In this specification, “steam explosion” refers to a physicochemical method that uses high-pressure steam to break down bonds between polymer components and then uses reduced pressure to destroy the lignocellulose structure. In this method, a lignocellulose slurry is treated with high-pressure steam for a period of time and then rapidly reduced to atmospheric pressure.

[0031]

[0039] As intended herein, a “liquid” composition may include a solid, and a “solid” composition may include a liquid. A “liquid composition” refers to a composition in which the material is primarily liquid, and a “solid composition” refers to a composition in which the material is primarily solid. A “slurry” refers to a solid that is dissolved or not dissolved in a liquid. explanation

[0040] The following descriptions and examples illustrate some exemplary embodiments of the Disclosure. Those skilled in the art will recognize that numerous variations and modifications of the Disclosure are encompassed within the scope of the Disclosure. Therefore, the descriptions of specific exemplary embodiments should not be considered limiting to the scope of the Disclosure.

[0032]

[0041] In one embodiment, the valve assembly described herein has a structure and design to address the collapse stresses that occur in a high-pressure flow of a treated liquid or slurry of material flowing through a pipe or tube. The valve assembly is designed to incorporate a portion of the processing of such liquid or slurry as the flow enters the valve assembly upstream from the pipe or tube to which it is attached and enters the discharge area downstream through the valve assembly.

[0033]

[0042] In one embodiment, a valve assembly for use at a fluid end is provided. In another embodiment, the valve assembly disclosed herein can be used to process liquids, material slurries, high-density liquids, or any liquefiable substance continuously or semi-continuously under pressure. A process is understood to be the ability to modify a material by heat, pressure, and / or the addition of chemicals, either alone or by mixing, heating, chemical reactions by combinations of two or more components (simultaneous or subsequent additions) under pressure, or by the addition of chemical components such as acids, bases, mixed components, or dyes. Examples of such components include plastics, plant materials, foodstuffs, polymers, polyurethanes, and the like.

[0034]

[0043] In one embodiment, the material slurry may include pre-treated biomass or partially hydrolyzed biomass. Using this configuration, a constant velocity and pressure can be obtained as the material flows through a passage such as a tube or pipe. Water or steam can be added by an intermediate plug and a valve assembly at the outlet to increase and maintain a constant pressure in the passage. The section between the plug and the valve assembly is the reaction section where the material modification takes place. This section involves pushing the material through the end of the valve needle.

[0035]

[0044] In one embodiment, a material can be processed using an extruder and valve assembly. The extruder moves liquid, slurry, solid, and viscous material through a barrel by a screw element. Depending on the shape of the element, the material is decelerated, mixed, or compressed through the barrel. The extruder can be a single-screw extruder, a twin-screw extruder, or a tri-screw extruder. For biomass materials, a twin-screw extruder is preferred. Extruders with specially configured screws designed to allow the addition of very large amounts of steam to increase pressure enable high-speed pretreatment of biomass. Rapid extruder pretreatment systems, such as those described in U.S. Patent Application No. 2016 / 0273009(A1) or WO2018 / 151833(A1), each incorporated herein by reference as a whole, provide unique pathways for the deconstruction of biomass and the release of cellulose and lignin from other biomass components. The combination of mechanical fibrillation, dilute acid hydrolysis, and vapor explosion is achieved in less than 20 seconds, yielding a very clean slurry of soluble carbohydrates, microcrystalline cellulose, and lignin. The short but intensive processing duration results in unique cellulose, hemicellulose, and lignin products that are highly reactive, without causing superheating or sulfonation, which occurs in most other processes.

[0036]

[0045] In the past, devices for restricting and removing liquids and materials flowing through pipes or barrels have been proposed. Some of these include intermediate valves in the extruder barrel itself. One such device described in U.S. Patent Application No. 2007 / 0237022(A1) is an adjustable valve assembly in the center of the barrel. Others include end valves, such as those found in U.S. Patent Application No. 2009 / 0053800(A1), WO2010 / 056940A2, or U.S. Patent No. 10,344,757(B1). None of these functions enable high-speed continuous processing as part of a processing system.

[0037]

[0046] Extrusion can be carried out continuously or semi-continuously, and the process can be performed even when the material is at high or low temperatures. Common extruded materials include metals, polymers, ceramics, concrete, craft clay, and foodstuffs, but biomass can also be processed in extruders. Extruders can have one or more shafts. A twin-screw extruder is a machine with two identical, self-cleaning, simultaneously penetrating screws, which are mounted on the shafts in a fixed, closed housing called a “barrel” and rotate in the same direction. Twin-screw extruders can operate continuously with very short residence times under high temperature and high pressure.

[0038]

[0047] In one embodiment, the acid, heat, and explosion pretreatment process for extracting biomass components is a rapid treatment process including a steam explosion. This treatment is carried out by treating small-sized biomass particles with pressurized acid hydrolysis and high temperatures with steam, followed by a steam explosion. Because the entire process is uniform throughout and takes only a few seconds, a fast-moving, effective valve system is required to maintain pressure for continuous treatment.

[0039]

[0048] In biomass processing, steam is injected into the barrel to increase temperature and pressure. In one embodiment, a screw element also functions to slow the flow of material and form an intermediate plug, which seals the material into the barrel after injection and further builds pressure within the barrel. See, for example, U.S. Patent Application No. 15 / 932,340, incorporated herein by reference.

[0040]

[0049] The example of the valve assembly is provided not to limit the extruder, but as an example demonstrating its functional value. In this system, one functional embodiment of the pressure valve assembly is to help initiate and maintain a constant pressure through the valve body within the extruder. This is the reaction section where much of the biomass processing takes place. The intermediate plug within the extruder facilitates deceleration by using a specific screw, and steam is used to build pressure within the reaction section. An actuator sets the pressure applied to the valve needle to maintain the required pressure within the extruder and valve body. Precise continuous motion is possible when the valve is coupled to an actuator that operates in response to internal pressure at the end of the pipe or barrel, rather than a manually operated or spring-operated valve.

[0041]

[0050] The actuator is preferably a hydraulic or pneumatic actuator, such as those manufactured by Kyntronics (Solon, OH44139, USA). The actuator maintains a valve needle that moves in and out infinitely and rapidly with very small movements along the longitudinal axis. The actual force that the needle valve must maintain for the biomass in the reaction section of the extruder barrel body can range from 816.47 kgf (1,800 lbf) to 37,194.57 kgf (82,000 lbf) and above (over 226,796.19 kgf (500,000 lbf)). A constant force is achieved by controlling the annular space through which the processed biomass material or liquid flows. The actuator system sends an electrical signal directly to the operating mechanism. The actuator system is set to operate at a specific pressure and to respond to the force exerted by the material flowing out of the tube or extruder.

[0042]

[0051] In one embodiment, when the liquid or slurry is pushed outside the annular ring (the boundary between the annular ring and the discharge ring (see below)), the reaction section includes the area between the plug and the steam explosion area through the valve body, thus shortening the length of the reaction section required in the tube or pipe. In the example of biomass processing in an extruder, this shortens the length of the extruder reaction section and reduces the metallurgical costs required for processing in the extruder.

[0043]

[0052] As shown in Figure 1, in an example of a pressure valve assembly, the valve comprises a valve body 10 with a conical valve needle 11 and a housing 12 with a discharge pipe 13. The valve body and valve needle can be made from any material that can withstand the abrasion of different chemical liquids or slurries traveling from the upstream inlet 30 through the valve body and housing to the discharge pipe 13, but are constructed from an inert metal or a metal with an inert coating. The valve needle is mounted on a shaft 14. The valve body 10, shown in the longitudinal section in Figure 2, has a cylindrical portion 15, an intermediate conical portion 16, and another substantially cylindrical collar 17 with a smaller diameter than the first portion 15. The valve body includes an annular (wear) ring 19 in its widest portion. The annular ring 19 is set in a concave cavity within the valve body portion 15. The inner surface of the annular ring 19 is aligned with the rest of the valve body 10 and functions as a replaceable wear part. The annular ring 19 is located inside the reaction section of the valve and extends to the minimum annular space 21 (see Figure 7A), after which it is pushed out into the atmosphere (steam explosion).

[0044]

[0053] The tapered discharge ring 20 is located outside the valve body 10 within the housing 12 and is not part of the reaction section. The discharge ring 20 is a means of ensuring that the liquid or slurry is guided into the discharge pipe 13 and enters a flush tank (not shown). The discharge ring 20 is also a wear part and is easily replaceable. The tapering of the discharge ring 20 (see Figures 3A and 3B) avoids a right-angle connection to the valve body that could cause material accumulation and interfere with the movement of the substance flowing from the tip of the needle to the outlet.

[0045]

[0054] Figures 3A and 3B are longitudinal cross-sectional views of the top and side of the valve and its housing, respectively. The material flows from the tube, barrel, or pipe upstream under pressure through the valve body into section 17 (hydrodynamic force) and is released downstream into the housing 12. Force from the actuator is applied to the valve needle through the shaft 14.

[0046]

[0055] An annular space 21 exists between the valve body 10 and the valve needle 11. The diameter of the cavity 22 in the housing 12 is 7% larger at the point where the discharged liquid or slurry (material) is received compared to the inner diameter of the valve body 10 at the point where the material is extruded.

[0047]

[0056] During operation, the differential pressure acting on the valve needle 11 causes it to displace along its longitudinal axis 75. The pressure from the valve shaft 14 causes the valve to enter the valve body 15, positioning it directly in front of the widest end of the needle 11.

[0048]

[0057] The widest part of the valve needle 11 is slightly larger than the widest part of the valve body 10, and therefore, when closed, is positioned at the location of the annular ring 19 within the valve body portion 15. In one embodiment, the diameter of the widest end of the needle is at least 4% larger than the diameter of the valve body at the discharge end. In one embodiment, the diameter of the widest end of the needle is about 4% larger than the diameter of the valve body at the discharge end. In one embodiment, the diameter of the widest end of the needle is 416 mm, and the diameter of the discharge end of the valve body is 400 mm. The diameter of the widest end of the needle may be larger or smaller than that. In one embodiment, the cone tapers 45 degrees from its widest diameter to the needle tip 18. In other embodiments, the taper of the cone can range from 45 to 75 degrees. This measurement is based on the material, feedstock, process requirements, space requirements, and the force required to move the valve needle.

[0049]

[0058] The collar 17 is a means of connecting the pressure relief valve to an extruder or other pipe. When the valve is fully installed and the extruder is attached, the valve needle tip 18 extends to the tip of the collar, which is just at the end of the conical portion 16, and a space exists between the needle tip and the discharge end 35 of the pipe or extruder and the end of the screw 38. In the process of pre-treating biomass in the extruder, water is injected through the injection nozzle 36 in the collar 17 (see Figures 4 and 5) before the material leaves the extruder but reaches the valve needle tip 18. This water is used to dilute the material, improve the rheology due to steam explosion, and thus reduce the torque on the extruder to pass through the valve. During processing, the material, especially the slurry, does not flow much, but flows slightly as it is processed through the pipe or barrel. The flow at the outlet is turbulent, but when mixed with water, it becomes a smooth laminar flow and proceeds downstream through the valve space 21. Any liquid can be added just before exiting the pipe to facilitate the flow of material through the valve system and / or to further process the material. In one embodiment, liquids such as water, acids, bases, alcohols, solvents, aldehydes, and ketones can be used for this purpose.

[0050]

[0059] In the closed position of the valve, the valve needle tip 18 rests within the inner space of the valve body 10, near the boundary between the intermediate conical portion 16 and the smaller cylindrical collar 17. See Figure 5. The valve needle tip 18 is located approximately 3-6 mm downstream of the liquid injection section.

[0051]

[0060] Figure 6 is a cross-sectional view of a valve body 10 without a valve needle 18, facing the discharge end of an extruder having twin-screw 38. After the material exits the extruder, the input nozzle 36 injects the liquid into the collar 17.

[0052]

[0061] Figure 7A is a cross-sectional view of the seal between the conical needle 11 and the conical valve body 15 in the annular ring 19. At this point, the pressure behind the valve shaft 14 is greater than the pressure of the fluid and / or material flowing out of the pipe, thus stopping the flow. Figure 7B shows the movement of the valve needle 11 when the pressure inside the pipe increases and the valve needle 11 moves approximately 0.5 mm toward the housing. The valve needle 11 is separated from its installation position within the annular ring 19, and thus the fluid and / or material can flow through the valve needle 11 and passage 21 toward the discharge area 22 (shown in Figure 3). Increasing the pressure from the pipe causes the valve needle 11 to move further toward the discharge area, widening the gap between the needle and the annular ring 19, allowing for a larger flow of fluid and / or material. The valve needle 11 moves, i.e., 1.0 mm (Figure 7C) and 1.5 mm (Figure 7D).

[0053]

[0062] During operation, the valve needle 18 moves in and out several times per second to maintain the required setpoint pressure, and thus moves between a fully closed state and a state that allows for a maximum annular space of 2 mm. A hydraulic actuator attached to the valve needle keeps the valve needle moving in and out very rapidly and indefinitely with very small movements along the longitudinal axis.

[0054]

[0063] Under certain circumstances, it is desirable to have a continuous process of materials, liquids, or both under constant pressure. For example, pretreatment of biomass is not economical in large quantities. It is time-consuming and wastes material. The problem is how to maintain a constant, precise pressure during processing while simultaneously releasing the pressurized material through pipes or barrels to atmospheric pressure. This is even more difficult when dealing with slurries, as the heterogeneous nature of the mixture can cause pulsation.

[0055]

[0064] The valve described in this specification can be used at high speeds. For example, the continuous biomass processing measured by the annular ring 19 is 185 - 190 m / s at a stroke of 0.5 mm. The possible range is about 90 m / s to 250 m / s. In other embodiments, speeds of 95 m / s, 100 m / s, 110 m / s, 120 m / s, 130 m / s, 140 m / s, 150 m / s, 160 m / s, 170 m / s, 180 m / s, 190 m / s, 200 m / s, 210 m / s, 220 m / s, 230 m / s, 240 m / s, and higher are possible.

[0056]

[0065] In some embodiments, the liquid or slurry is processed in less than 60, 55, 50, 45, 40, 35, 30, 25, 20, 19, 18, 17, 16, 15, 14, 13, 12, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 second within the reaction interval. In some embodiments, the biomass is processed within about 5 - 15 seconds within the reaction interval. For larger systems, the biomass is processed in 30 seconds or less, or 60 seconds or less.

[0057]

[0066] In another embodiment, the liquid or slurry can be processed at high pressure. In one embodiment, the biomass is pretreated in a pressure range of about 0.07031 kgf / cm 2 (1 psi) to about 2.109 (kgf / cm 2 )(30 psi). In another embodiment, the biomass is about 3.516 kgf / cm 2 (50 psi), 7.031 kgf / cm 2 (100 psi), 10.55 kgf / cm 2 (150 psi), 14.06 kgf / cm 2 (200 psi), 17.58 kgf / cm 2 (250 psi), 21.09 kgf / cm 2 (300 psi), 24.61 kgf / cm 2 (350 psi), 28.13 kgf / cm 2 (400 psi), 31.64 kgf / cm 2 (450 psi), 35.16 kgf / cm 2(500 psi), 38.67 kgf / cm² 2 (550 psi), 42.19 kgf / cm² 2 (600 psi), 45.7 kgf / cm² 2 (650 psi), 49.22 kgf / cm² 2 (700 psi), 52.74 kgf / cm² 2 (750 psi), 56.25 kgf / cm² 2 (800 psi), or a maximum of 63.28 kgf / cm² 2 The biomass is pretreated at a pressure of 900 psi. In some embodiments, the biomass can be treated under high pressure by injecting steam into the container containing the biomass. In one embodiment, the biomass can be treated under vacuum conditions before or after alkaline or acid treatment or any other treatment method provided herein. Exemplary Embodiments Embodiment 1. A valve assembly comprising a housing, a valve body, and a valve needle, which are attached to a pipe having an outlet through which fluid flows, wherein the valve is (a) A conical valve needle is provided which is displaceable in the axial direction within the annular space of the valve body, and the valve needle has a conical valve needle tip at one end, (b) A valve assembly in which the downstream inner diameter of the valve body is at least 4% larger than the inner wall of the housing.

[0058] Embodiment 2. The valve assembly according to Embodiment 1, wherein the annular ring is part of the valve body.

[0059] Embodiment 3. The valve assembly according to Embodiment 2, wherein the annular ring is replaceable.

[0060] Embodiment 4. The valve assembly according to Embodiment 1, wherein the housing includes a removable release ring.

[0061] Embodiment 5. The valve assembly according to Embodiment 1, wherein the valve body includes a nozzle for introducing liquid.

[0062] Embodiment 6. The valve assembly according to Embodiment 2, wherein the valve needle is installed in the release ring when closed within the valve body.

[0063] Embodiment 7. The valve assembly according to Embodiment 1, which forms part of a reaction section having a tube.

[0064] Embodiment 8. The valve assembly according to Embodiment 1, wherein the valve needle is attached to the actuator.

[0065] Embodiment 9. The valve assembly according to Embodiment 8, wherein the actuator maintains the pressure applied to the valve needle.

[0066] Embodiment 10. The valve assembly according to Embodiment 8, wherein the actuator maintains the pressure applied to the valve needle at more than 816.47 kgf (1,800 lbf).

[0067] Embodiment 11. The valve assembly according to Embodiment 9, wherein the actuator maintains the pressure applied to the valve needle at 22,679.62 to 226,796.19 kgf (50,000 to 500,000 lbf).

[0068] Embodiment 12. The valve assembly according to Embodiment 8, wherein the pipe is an extruder.

[0069] Embodiment 13. The valve assembly according to Embodiment 13, wherein the extruder is a twin-screw extruder.

[0070] Embodiment 14. A conical valve needle for engaging with a valve body, wherein when the valve is closed, the conical valve needle extends beyond the valve body into the discharge area.

[0071] Embodiment 15. The valve needle according to Embodiment 14, wherein the annular ring is part of the valve body.

[0072] Embodiment 16. The valve needle according to Embodiment 15, wherein the valve needle is installed downstream of the annular ring.

[0073] Embodiment 17. The valve needle according to Embodiment 15, wherein the annular ring is replaceable.

[0074] Embodiment 18. The valve needle according to Embodiment 14, wherein the housing is mounted downstream of the valve body and includes a removable release ring.

[0075] Embodiment 19. The valve needle according to Embodiment 14, wherein the valve body includes a nozzle for introducing liquid.

[0076] Embodiment 20. The valve needle according to Embodiment 14, wherein the valve needle is installed in the release ring when it is closed within the valve body.

[0077] Embodiment 21. A valve needle according to Embodiment 14, which forms part of a reaction section having a tube.

[0078] Embodiment 22. The valve needle according to Embodiment 14, wherein the valve needle is attached to an actuator.

[0079] Embodiment 23. The valve needle according to Embodiment 22, wherein the actuator maintains the pressure applied to the valve needle.

[0080] Embodiment 24. The valve needle according to Embodiment 23, wherein the actuator maintains the pressure applied to the valve needle at more than 816.47 kgf (1,800 lbf).

[0081] Embodiment 25. The valve needle according to Embodiment 24, wherein the pressure applied to the valve needle is 22,679.62 to 226,796.19 kgf (50,000 to 500,000 lbf).

[0082] Embodiment 26. The valve needle according to Embodiment 14, wherein the valve body is attached to an extruder.

[0083] Embodiment 27. The valve needle according to Embodiment 1, wherein the extruder is a twin-screw extruder.

[0084] Embodiment 28. A valve assembly that becomes part of a reaction section having a tube or pipe.

[0085] Embodiment 29. The valve assembly according to Embodiment 28, wherein the pipe or tube is an extruder.

[0086] Embodiment 30. The valve assembly according to Embodiment 29, wherein the extruder is a twin-screw extruder.

[0087] Embodiment 31. The valve assembly according to Embodiment 30, wherein at least a portion of the contents of the extruder is under pressure.

[0088] Embodiment 32. The valve assembly according to Embodiment 30, wherein the pressurized section extends into the valve assembly.

[0089] Embodiment 33. A valve assembly having an increase in inner diameter between the end of the valve body from which the material is discharged and the diameter of the discharge housing.

[0090] Embodiment 34. A valve assembly for use in a pressurized passage for a fluid, slurry, or other material, (a) Housing and (b) It is a valve body, i. Large circular section, ii. The intermediate conical portion, iii. A valve body including a smaller circular collar containing one or more nozzles for liquid injection, (c) A valve assembly comprising a valve needle.

[0091] Embodiment 35. The valve assembly according to Embodiment 34, wherein the housing includes a removable release ring.

[0092] Embodiment 36. The valve assembly according to Embodiment 35, wherein the discharge ring tapers.

[0093] Embodiment 37. The valve assembly according to Embodiment 34, wherein the valve body includes an annular ring.

[0094] Embodiment 38. The valve assembly according to Embodiment 37, wherein the annular ring is removable.

[0095] Embodiment 39. The valve assembly according to Embodiment 34, wherein a space exists between the valve body and the valve needle when the valve needle is installed.

[0096] Embodiment 40. The valve assembly according to Embodiment 34, wherein a nozzle for liquid injection transmits water into the space between the valve body and the valve needle.

[0097] Embodiment 41. The valve assembly according to Embodiment 34, wherein a nozzle for liquid injection delivers a liquid other than water into the space between the valve body and the valve needle.

[0098] Embodiment 42. The valve assembly according to Embodiment 41, wherein the liquid is selected from the group consisting of acids, bases, alcohols, ketones, aldehydes, solvents, or combinations thereof.

[0099] Embodiment 43. A system for processing biomass by an extruder, (a) An extruder comprising one or more screws, wherein the action of the screws forms an internal plug of biomass, thereby forming one end of a pressurized reaction section, (b) means for supplying steam and chemicals to the reaction section, (c) A valve assembly located at the outlet end of the extruder, which forms the downstream end of the reaction section and adds liquid to the reaction section, comprising a valve assembly (d) A system in which the valve assembly is capable of rapidly releasing pressurized biomass into an unpressurized discharge area.

[0100] Embodiment 44. The system according to Embodiment 43, wherein the biomass is selected from the group consisting of silage, agricultural residues, corn stalks and leaves, bagasse, sorghum, nuts, nut shells, coconut shells, distillation-dried soluble substances, distillation-dried grains, condensed distillation-soluble substances, distillation-moist grains, distillation-dried grains containing soluble substances, woody materials, sawdust, wood chips, wood residues, mill scraps, municipal waste, waste paper, recycled toilet paper, garden trimmings, as well as energy crops such as poplar, willow, switchgrass, alfalfa, and oxgrass, non-woody plant materials, cellulosic materials, lignocellulose materials, hemicellulose materials, carbohydrates, corn, sugarcane, grasses, switchgrass, high biomass sorghum, bamboo, corn cobs, as well as husks and seeds.

[0101] Embodiment 45. The system according to Embodiment 43, wherein the biomass is processed in a reaction interval for 60, 55, 50, 45, 40, 35, 30, 25, 20, 19, 18, 17, 16, 15, 14, 13, 12, 10, 9, 8, 7, 6, 5, 4, 3, 2, or less than 1 second.

[0102] Embodiment 46. The temperature within the reaction interval is 50-500°C, 75-400°C, 100-350°C, 150-300°C, 200-250°C, 150-300°C, and 3.516-70.31 kgf / cm². 2 (50~1000PSI), 7.031~52.74kgf / cm 2 (100~750PSI), 14.06~42.19kgf / cm 2 (200~600PSI), 21.09~35.16kgf / cm 2 (300-500 PSI), or 24.61-31.64 kgf / cm² 2 The system according to embodiment 43, which rises to (350-450 PSI).

[0103] Embodiment 47. The system according to Embodiment 43, wherein the chemical substance is an acid.

[0104] Embodiment 48. The system according to Embodiment 47, wherein the acid is sulfuric acid.

[0105] Embodiment 49. The valve assembly is (a) Housing and (b) It is a valve body, i. Large circular section, ii. The intermediate conical portion, iii. A valve body including a smaller circular collar containing one or more nozzles for liquid injection, (c) The system according to embodiment 43, further comprising a valve needle.

[0106] Embodiment 50. The valve assembly according to Embodiment 49, wherein the housing includes a removable release ring.

[0107] Embodiment 51. The valve assembly according to Embodiment 50, wherein the discharge ring tapers.

[0108] Embodiment 52. The valve assembly according to Embodiment 49, wherein the valve body includes an annular ring.

[0109] Embodiment 53. The valve assembly according to Embodiment 52, wherein the annular ring is removable.

[0110] Embodiment 54. The valve assembly according to Embodiment 49, wherein a space exists between the valve body and the valve needle when the valve needle is installed.

[0111] Embodiment 55. The valve assembly according to Embodiment 49, wherein a nozzle for liquid injection transmits water into the space between the valve body and the valve needle.

[0112] Embodiment 56. The valve assembly according to Embodiment 55, wherein a nozzle for liquid injection transmits a liquid other than water into the space between the valve body and the valve needle.

[0113] Embodiment 57. The valve assembly according to Embodiment 56, wherein the liquid is selected from the group consisting of acids, bases, alcohols, ketones, aldehydes, solvents, or combinations thereof.

[0114] Embodiment 58. A method for processing a slurry or liquid in a pipe or barrel, a. A step in which a pipe or barrel having a plug forms one end of the reaction section, b. The step of moving a liquid or slurry through a pipe or barrel, c. Using a valve assembly attached to the outlet end of a pipe or barrel, the step of maintaining the pressure within the reaction section while forming the downstream end of the reaction section, d. When the liquid or slurry enters the valve assembly, the step of adding the liquid to the upstream end of the valve assembly, e. A method comprising the step of using a valve assembly to discharge the processed liquid or slurry into a non-pressurized area.

[0115] Embodiment 59. A valve assembly mounted on a pipe or barrel, which injects a liquid or slurry into a valve body after the liquid or slurry has left the pipe or barrel but before the liquid or slurry reaches the valve needle.

[0116] Embodiment 60. A valve assembly having a valve body with a removable annular ring adjacent to a removable discharge ring within a discharge housing.

[0117] Embodiment 61. The valve assembly according to Embodiment 60, wherein the discharge ring tapers.

[0118] [1] A valve assembly, A valve body having an inlet end, a discharge end, and chambers formed to connect to the inlet and discharge ends, wherein the inlet end is attachable to a pipe having a fluid or slurry inlet through the valve assembly, A conical valve needle having a conical shape, with a broad end opposite the tip of the cone, and being displaceable axially within the chamber of the valve body, It comprises a housing attached to the discharge end of the valve body, which seals the valve needle when the valve needle is detached from the valve body, A valve assembly in which the diameter of the wider end of the valve needle is at least 4% larger than the inner diameter of the valve body at its discharge end.

[0119] [2] The valve assembly according to paragraph [1], wherein the valve body has an annular ring located on the inner surface of the valve body at the discharge end within a concave cavity.

[0120] [3] The valve assembly described in paragraph [2], wherein the annular ring is replaceable.

[0121] [4] The valve assembly according to paragraph [2] or [3], wherein the inner surface of the annular ring is aligned with the inner surface of the valve body.

[0122] [5] The valve assembly according to any one of paragraphs [2] to [4], wherein the valve needle is located in an annular ring when closed within the valve body.

[0123] [6] The valve assembly according to any one of paragraphs [1] to [5], wherein the housing comprises a removable release ring located adjacent to the release end of the valve body.

[0124] [7] The valve assembly according to paragraph [6], wherein the release ring has a tapered shape.

[0125] [8] A valve assembly according to any one of paragraphs [1] to [7], [8], or [9], wherein the valve body comprises a nozzle for introducing liquid.

[0126] [9] A valve assembly according to any one of paragraphs [1] to [8], wherein the valve chamber forms part of a reaction section having a tube for a biomass pretreatment process.

[0127]

[10] The valve assembly described in paragraph [9], wherein the tube is an extruder.

[0128]

[11] The valve assembly described in paragraph

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

[0129]

[12] A valve assembly according to any one of paragraphs [1] to

[11] , wherein the valve needle is operably connected to an actuator via a shaft.

[0130]

[13] The valve assembly described in paragraph

[12] , wherein the actuator maintains the pressure applied to the valve needle.

[0131]

[14] The valve assembly according to paragraph

[12] or

[13] , wherein the actuator maintains the pressure on the valve needle at more than 816.47 kgf (1,800 lbf).

[0132]

[15] A valve assembly according to any one of paragraphs

[12] to

[14] , wherein the actuator maintains the pressure on the valve needle at 22,679.62 to 226,796.19 kgf (50,000 to 500,000 lbf).

[0133]

[16] The valve assembly according to any one of paragraphs [1] to

[15] , wherein the valve body has a circular portion located at the discharge end, a circular collar located at the inlet end having an inner diameter smaller than that of the circular portion at the discharge end, and an intermediate conical portion located between the circular portion and the circular collar.

[0134]

[17] A valve assembly according to any one of paragraphs [1] to

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

[0135]

[18] A valve assembly according to any one of paragraphs [1] to

[17] , wherein the housing comprises a discharge pipe.

[0136]

[19] The valve assembly according to any one of paragraphs [1] to

[18] , wherein the inner diameter of the housing at the end of the housing that abuts the valve body is at least 7% larger than the inner diameter of the valve body at its discharge end.

[0137]

[20] The valve assembly according to any one of paragraphs [1] to

[19] , wherein the inner diameter of the housing at the end of the housing that abuts the valve body is about 7% larger than the inner diameter of the valve body at its discharge end.

[0138]

[21] A valve assembly according to any one of paragraphs [1] to

[20] , wherein the cone of the conical valve needle tapers to a range of approximately 45 to 75 degrees.

[0139]

[22] A valve assembly according to any one of paragraphs [1] to

[21] , wherein the cone of the cone-shaped valve needle tapers at approximately 45 degrees.

[0140]

[23] A conical valve needle for engaging with a valve body, the conical valve needle extending beyond the valve body into the discharge area when the valve is closed.

[0141]

[24] The valve needle described in paragraph

[23] , wherein the annular ring is part of the valve body.

[0142]

[25] The valve needle according to paragraph

[24] , wherein the valve needle is positioned downstream of the annular ring.

[0143]

[26] The valve needle according to paragraph

[24] or

[25] , wherein the annular ring is replaceable.

[0144]

[27] A valve needle according to any one of paragraphs

[23] to

[26]

[27]

[28]

[30]

[31] , wherein the housing is mounted downstream of the valve body and includes a removable release ring.

[0145]

[28] A valve needle according to any one of paragraphs

[23] to

[27] , wherein the valve body includes a nozzle for introducing liquid.

[0146]

[29] A valve needle as described in any one of paragraphs

[23] to

[28] , which is set in the release ring when the valve needle is closed within the valve body.

[0147]

[30] A valve needle according to any one of paragraphs

[23] to

[29] , which forms part of a reaction section having a tube.

[0148]

[31] A valve needle according to any one of paragraphs

[23] to

[30] , wherein the valve needle is attached to an actuator.

[0149]

[32] The valve needle according to paragraph

[31] , wherein the actuator maintains the pressure applied to the valve needle.

[0150]

[33] The valve needle according to paragraph

[32] , wherein the actuator maintains the pressure on the valve needle at more than 816.47 kgf (1,800 lbf).

[0151]

[34] The valve needle described in paragraph

[33] , wherein the pressure on the valve needle is 22,679.62 to 226,796.19 kgf (50,000 to 500,000 lbf).

[0152]

[35] A valve needle according to any one of paragraphs

[23] to

[34] , wherein the valve body is attached to an extruder.

[0153]

[36] The valve needle according to paragraph

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

[0154]

[37] A valve assembly that becomes part of a reaction section having a tube or pipe.

[0155]

[38] The valve assembly described in paragraph

[37] , wherein the pipe or tube is an extruder.

[0156]

[39] The valve assembly described in paragraph

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

[0157]

[40] The valve assembly described in paragraph

[39] , wherein at least a portion of the contents of the extruder is under pressure.

[0158]

[41] The valve assembly described in paragraph

[39] , wherein the pressurized section extends into the valve assembly.

[0159]

[42] A valve assembly having an increase in inner diameter between the end of the valve body from which the material is discharged and the diameter of the discharge housing.

[0160]

[43] A valve assembly, A valve body comprising a large circular portion, an intermediate conical portion, and a small circular collar containing one or more nozzles for liquid injection, wherein a chamber is formed inside the valve body connecting the injection and discharge ends of the valve body, and the inner diameter of the small circular collar is smaller than that of the large circular portion, A valve needle that can be displaced axially within the valve chamber, A valve assembly comprising a housing attached to the discharge end of the valve body, which seals the valve needle when the valve needle is detached from the valve body.

[0161]

[44] The valve assembly described in paragraph

[43] , wherein the housing includes a removable release ring.

[0162]

[45] The valve assembly described in paragraph

[44] , wherein the release ring tapers.

[0163]

[46] A valve assembly according to any one of paragraphs

[43] to

[45] , wherein the valve body includes an annular ring.

[0164]

[47] The valve assembly described in paragraph

[46] , wherein the annular ring is removable.

[0165]

[48] ​​A valve assembly according to any one of paragraphs

[43] to

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

[0166]

[49] A valve assembly according to any one of paragraphs

[43] to

[48]

[49] , wherein a nozzle for liquid injection is used to deliver water into the chamber.

[0167]

[50] A valve assembly according to any one of paragraphs

[43] to

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

[0168]

[51] The valve assembly described in paragraph

[50] , wherein the liquid is selected from the group consisting of acids, bases, alcohols, ketones, aldehydes, solvents, or combinations thereof.

[0169]

[52] The valve assembly according to any one of paragraphs

[43] to

[51] , wherein the inner diameter of the housing at the end of the housing that abuts the valve body is at least 7% larger than the inner diameter of the valve body at its discharge end.

[0170]

[53] The valve assembly according to any one of paragraphs

[43] to

[52] , wherein the inner diameter of the housing at the end of the housing that abuts the valve body is about 7% larger than the inner diameter of the valve body at its discharge end.

[0171]

[54] The valve assembly according to any one of paragraphs

[43] to

[53] , wherein the valve needle has a conical shape and a broad end opposite to the tip of the cone.

[0172]

[55] The valve assembly described in paragraph

[54] , wherein the cone is tapered in the range of 45 to 75 degrees.

[0173]

[56] The valve assembly described in paragraph

[54] , wherein the cone is tapered at approximately 45 degrees.

[0174]

[57] The valve assembly according to any one of paragraphs

[54] to

[56] , wherein the diameter of the broad end of the valve needle is at least 4% greater than the inner diameter of the valve body at its discharge end.

[0175]

[58] The valve assembly according to any one of paragraphs

[54] to

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

[0176]

[59] A system for processing biomass by an extruder, (a) An extruder comprising one or more screws, wherein the action of the screws forms an internal plug of biomass, thereby forming one end of a pressurized reaction section, (b) means for supplying steam and chemicals to the reaction section, (c) A valve assembly located at the outlet end of the extruder, which forms the downstream end of the reaction section and adds liquid to the reaction section, comprising a valve assembly A system in which a valve assembly can rapidly release pressurized biomass into an unpressurized discharge area.

[0177]

[60] The system described in paragraph

[59] , wherein the biomass is selected from the group consisting of silage, agricultural residues, maize stalks and leaves, bagasse, sorghum, nuts, nut shells, coconut shells, distilled-dried soluble substances, distilled-dried grains, condensed-distilled-distilled soluble substances, distilled-moist grains, distilled-dried grains containing soluble substances, woody materials, sawdust, wood chips, wood residues, mill scraps, municipal waste, waste paper, recycled toilet paper, garden trimmings, as well as energy crops such as poplar, willow, switchgrass, alfalfa, and oxgrass, non-woody plant materials, cellulosic materials, lignocellulose materials, hemicellulose materials, carbohydrates, maize, sugarcane, grasses, switchgrass, high-biomass sorghum, bamboo, maize cobs, as well as husks and seeds.

[0178]

[61] The system described in paragraph

[59] or

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

[0179]

[62] The temperature within the reaction interval is 50-500°C, 75-400°C, 100-350°C, 150-300°C, 200-250°C, 150-300°C, and 3.516-70.31 kgf / cm². 2(50~1000PSI), 7.031~52.74kgf / cm 2 (100~750PSI), 14.06~42.19kgf / cm 2 (200~600PSI), 21.09~35.16kgf / cm 2 (300-500 PSI), or 24.61-31.64 kgf / cm² 2 A system described in any one of paragraphs

[59] to

[61] , which rises to (350-450 PSI).

[0180]

[63] A system described in any one of paragraphs

[59] through

[62] , wherein the chemical substance is an acid.

[0181]

[64] The system described in paragraph

[63] , wherein the acid is sulfuric acid.

[0182]

[65] The valve assembly, A valve body comprising a large circular portion, an intermediate conical portion, and a small circular collar containing one or more nozzles for liquid injection, wherein a chamber is formed inside the valve body connecting the injection and discharge ends of the valve body, and the inner diameter of the small circular collar is smaller than that of the large circular portion, A valve needle that can be displaced axially within the valve chamber, The system according to any one of paragraphs

[59] to

[64] , comprising a housing attached to the discharge end of a valve body, which seals the valve needle when the valve needle is detached from the valve body.

[0183]

[66] The system according to paragraph

[65] , wherein the housing includes a removable discharge ring.

[0184]

[67] The system described in paragraph

[66] , wherein the release ring tapers.

[0185]

[68] The system according to any one of paragraphs

[65] to

[67] , wherein the valve body includes an annular ring.

[0186]

[69] The system according to paragraph

[68] , wherein the annular ring is removable.

[0187]

[70] The system according to any one of paragraphs

[65] to

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

[0188]

[71] The system according to any one of paragraphs

[65] to

[70] , wherein a nozzle for liquid injection delivers water into the chamber.

[0189]

[72] The system according to any one of paragraphs

[65] to

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

[0190]

[73] The system according to paragraph

[72] , wherein the liquid is selected from the group consisting of acids, bases, alcohols, ketones, aldehydes, solvents, or combinations thereof.

[0191]

[74] The system according to any one of paragraphs

[65] to

[73] , wherein the inner diameter of the housing at the end of the housing that abuts the valve body is at least 7% larger than the inner diameter of the valve body at its discharge end.

[0192]

[75] The system according to any one of paragraphs

[65] to

[74] , wherein the inner diameter of the housing at the end of the housing that abuts the valve body is about 7% larger than the inner diameter of the valve body at its discharge end.

[0193]

[76] The system according to any one of paragraphs

[65] to

[75] , wherein the valve needle has a conical shape and a broad end opposite to the tip of the cone.

[0194]

[77] The system described in paragraph

[76] , wherein the cone tapers to a range of 45 to 75 degrees.

[0195]

[78] The system described in paragraph

[76] , wherein the cone tapers at approximately 45 degrees.

[0196]

[79] The system according to any one of paragraphs

[76] to

[78] , wherein the diameter of the broad end of the valve needle is at least 4% greater than the inner diameter of the valve body at its discharge end.

[0197]

[80] The system according to any one of paragraphs

[76] to

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

[0198]

[0067] Preferred embodiments of the Disclosure have been illustrated and described herein, but it will be apparent to those skilled in the art that such embodiments are provided for illustrative purposes only. Numerous variations, modifications, and substitutions will be conceivable to those skilled in the art without departing from the Disclosure. When implementing the Disclosure, it should be understood that various alternative means may be used to the embodiments of the Disclosure described herein. The following claims define the scope of the Disclosure and are intended to encompass the methods and structures within the scope of these claims and their equivalents.

Claims

1. A system for processing biomass by an extruder, (a) An extruder comprising one or more screws, wherein the action of the screws forms an internal plug of biomass, thereby forming one end of a pressurized reaction section, (b) means for supplying steam and chemicals to the reaction section, (c) A valve assembly located at the outlet end of the extruder, which forms the downstream end of the reaction section and adds liquid to the reaction section, comprising: The valve assembly is capable of rapidly releasing pressurized biomass into an unpressurized discharge area. The valve assembly is A valve body having an inlet end, a discharge end, and chambers formed to connect to the inlet end and the discharge end, wherein the inlet end is attachable to a pipe having a fluid or slurry inlet through which fluid flows through the valve assembly, A conical valve needle having a conical shape, having a broad end opposite to the tip of the cone, being axially displaceable within the chamber in the valve body, and the valve needle contacting the valve body at its discharge end when the conical valve needle is closed on the valve body, The valve body is attached to the discharge end and comprises a housing that seals the conical valve needle when the conical valve needle is separated from the valve body, The diameter of the wider end of the conical valve needle is at least 4% larger than the inner diameter of the valve body at its discharge end. A valve assembly comprising a valve body having a circular portion located at the discharge end, a circular collar located at the inlet end having an inner diameter smaller than that of the circular portion at the discharge end, and an intermediate conical portion located between the circular portion and the circular collar.

2. The system according to claim 1, wherein the valve body has an annular ring located on the inner surface of the valve body at the discharge end within a concave cavity.

3. The system according to claim 2, wherein the annular ring is replaceable.

4. The system according to claim 2, wherein the inner surface of the annular ring is aligned with the inner surface of the valve body.

5. The system according to claim 2, wherein the conical valve needle is located in the annular ring when closed within the valve body.

6. The system according to claim 1, wherein the housing comprises a removable discharge ring positioned adjacent to the discharge end of the valve body.

7. The system according to claim 6, wherein the discharge ring has a tapered shape.

8. The system according to claim 1, wherein the valve body is equipped with a nozzle for introducing liquid.

9. The system according to claim 1, wherein the chamber of the valve body forms part of a reaction section having the tubing for a biomass pretreatment process.

10. The system according to claim 9, wherein the pipe is an extruder.

11. The system according to claim 10, wherein the extruder is a twin-screw extruder.

12. A system according to claim 1, wherein the valve assembly further comprises an actuator and a shaft, and the conical valve needle is operably connected to the actuator via the shaft.

13. The system according to claim 12, wherein the actuator maintains the pressure applied to the conical valve needle.

14. The system according to claim 12, wherein the actuator is configured to maintain a force greater than 816.47 kgf (1,800 lbf) applied to the conical valve needle.

15. The system according to claim 1, wherein when the conical valve needle is closed on the valve body, an annular space is formed between the conical valve needle and the valve body within the chamber.

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

17. The system according to claim 1, wherein the cone shape of the conical valve needle tapers to a degree within the range of approximately 45 degrees to approximately 75 degrees.

18. The system according to claim 1, wherein the cone shape of the conical valve needle tapers at approximately 45 degrees.

19. A system for processing biomass using an extruder, (a) An extruder comprising one or more screws, wherein the action of the screws forms an internal plug of biomass, thereby forming one end of a pressurized reaction section, (b) means for supplying steam and chemicals to the reaction section, (c) A valve assembly located at the outlet end of the extruder, which forms the downstream end of the reaction section and adds liquid to the reaction section, comprising: The valve assembly is capable of rapidly releasing pressurized biomass into an unpressurized discharge area. The valve assembly is A valve body comprising a large circular portion at the discharge end of the valve body, an intermediate conical portion, and a small circular collar with one or more nozzles for liquid injection at the inlet end of the valve body, wherein a chamber connecting the inlet end and the discharge end of the valve body is formed inside the valve body, and the inner diameter of the small circular collar is smaller than that of the large circular portion, A valve needle that is axially displaceable within the chamber of the valve body, A housing is attached to the discharge end of the valve body, and when the valve needle is separated from the valve body, the housing seals the valve needle. A valve assembly system that includes the following features.

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