Injection system for extrusion equipment

Abstract

The extruder and valve system uses multiple injector assemblies to convey the biomass stream and includes conduits for providing water or other fluids and / or steam for pretreatment. Each injector in an assembly is connected to a corresponding port in the extruder. The ports can be positioned at discrete locations on or after the extruder to deliver the appropriate amount of fluid or steam for treatment of the biomass or other material.

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] Pretreatment of lignocellulosic biomass is an essential step in obtaining sugars and lignin from such biomass, and aims to break down the unwieldy structure of lignocellulose to facilitate access to carbohydrates by enzymatic hydrolysants. Among the various pretreatment techniques studied in recent years, extrusion is a promising thermomechanical pretreatment. Extrusion can be a very versatile continuous process, has good mixing and heat transfer capabilities, and can operate with high solid loads. However, its design needs further improvement to unlock its potential for biomass processing. For example, continuous deconstruction of several tons of biomass requires not only an increase in the size of the extruder, but also an increase in the input of large amounts of liquid and steam to maintain the required pressure, temperature, and chemicals.

[0003]

[0003] In biomass processing, the extruder may consist of a screw designed to create one or more reaction sections and to allow the pressure and temperature within these sections to be increased during pretreatment by adding steam. However, as the barrel diameter or extruder length is increased for commercial use, additional steam injection is required to maintain high pressure and temperature within the barrel to process the material. If the pressure generated when the material is processed is too low, or if the temperature achieved is too low, the final product will not be sufficiently heated, and a desirable product yield will be lost. Other liquids, such as water, acid, or base, may also be required at various times during processing. Given the volume and rate of biomass material delivered by commercially viable extrusion systems, conventional injector assemblies are insufficient and prone to clogging or backflow.

[0004]

[0004] Various methods have been used in the past to achieve and maintain appropriate levels of pressure, processing control, and fluid within the extruder barrel. For example, it is known to install one or more shear locking devices along the length of the extruder screw. However, these devices are not adjustable. Variable limiting devices have also been proposed in the past to allow for fluctuations in operation in flow limiting. For example, U.S. Patent No. 4,136,968 describes a flow limiting device specifically adapted for use with a twin-screw extruder, but it cannot be used with other extruder types and the degree of limiting it can provide is limited. [Overview of the Initiative] [Problems that the invention aims to solve]

[0005]

[0005] Therefore, there is a need in the art for an improved extrusion injector assembly that can operate efficiently in a high-flow biomass extrusion system without the design and clogging problems of conventional systems. [Means for solving the problem]

[0006]

[0006] Provided herein is a system for introducing one or more additives into a material, comprising: an assembly of injectors, each injector having an internal bore in the range of 2 to 6 mm in diameter; a manifold for controlling the flow of substance within the assembly of injectors; valves incorporated into the manifold so that each injector independently controls the flow of substance within the injector; and an additive supply unit. In some embodiments, the additive is a liquid or vapor. In some embodiments, the additive is water. In some embodiments, the additive is an acid. In some embodiments, the additive is vapor, and the vapor pressure is approximately 5.625 to 42.19 kgf / cm². 2 (80-600 psi). In some embodiments, the additive is vapor, and the vapor pressure is approximately 10.55 kgf / cm². 2 (150 psi). In some embodiments, the additive is vapor, and the vapor pressure is approximately 14.06 kgf / cm². 2 (200 psi). In some embodiments, the additive is vapor, and the vapor pressure is approximately 17.58 kgf / cm². 2 (250 psi). In some embodiments, the additive is vapor, and the vapor pressure is approximately 21.09 kgf / cm². 2 (300 psi).

[0007]

[0007] In some embodiments, the material includes biomass. In some embodiments, the material includes biomass and the material is located in a conduit. In some embodiments, the conduit comprises an extruder. In some embodiments, the conduit further comprises a discharge valve. In some embodiments, the diameter of the inner bore of the injector is approximately 2 mm. In some embodiments, the diameter of the inner bore of the injector is approximately 2.5 mm. In some embodiments, the diameter of the inner bore of the injector is approximately 3 mm. In some embodiments, the diameter of the inner bore of the injector is approximately 3.5 mm. In some embodiments, the diameter of the inner bore of the injector is approximately 4 mm. In some embodiments, the diameter of the inner bore of the injector is approximately 4.5 mm. In some embodiments, the diameter of the inner bore of the injector is approximately 5 mm. In some embodiments, the diameter of the inner bore of the injector is approximately 5.5 mm. In some embodiments, the diameter of the inner bore of the injector is approximately 6 mm.

[0008]

[0008] In some embodiments, the injector assembly includes two or more injectors. In some embodiments, the injector assembly includes four or more injectors. In some embodiments, the injector assembly includes six or more injectors. In some embodiments, the injector assembly includes eight or more injectors. In some embodiments, the injector assembly includes ten or more injectors. In some embodiments, the injector assembly includes twelve or more injectors. In some embodiments, the injector assembly includes fourteen or more injectors. In some embodiments, the injector assembly includes sixteen or more injectors. In some embodiments, the material consists of biomass within the reaction zone.

[0009]

[0009] A method for injecting liquid or vapor into an extruder barrel or valve body, comprising the steps of: providing a plurality of injection ports, wherein the injection ports penetrate the outer wall of the extruder barrel or the outer wall of the valve body; introducing an injector into the plurality of injection ports; and injecting vapor into the extruder barrel or valve body to a concentration of 10.55 to 56.25 kgf / cm² within the extruder barrel or valve body. 2A method is provided herein that includes the steps of maintaining a pressure of (150 to 800 psi) and injecting a liquid into the extruder barrel or valve body.

[0010]

[0010] A method for injecting liquid and vapor into an extruder barrel or valve body, comprising the steps of: providing a plurality of injection ports, wherein the injection ports penetrate the extruder barrel or valve body; introducing an injector into the plurality of injection ports; and injecting the liquid and vapor into the extruder barrel or valve body to achieve a concentration of 10.55 to 56.25 kgf / cm² within the extruder barrel or valve body. 2 A method is provided herein that includes the step of maintaining a pressure of (150 to 800 psi).

[0011]

[0011] In some embodiments, the injector includes a nozzle hole having a diameter of 2 to 6 mm. In some embodiments, the injector includes a nozzle hole having a diameter of 2 to 4 mm. In some embodiments, the injector includes a nozzle hole having a diameter of 2 to 3 mm. In some embodiments, the injector includes a nozzle hole having a diameter of about 2 mm. In some embodiments, to pre-treat at least 1 dry ton of biomass per day, the method further includes the step of supplying biomass to an extrusion system equipped with a barrel at a rate of at least 1 dry metric ton (MT) of biomass per day, the barrel equipped with an inner chamber including a feed section and a reaction section, the extrusion system forming a vapor-impermeable plug by compressing the biomass in a high-pressure section separating the feed section and the reaction section, and an assembly of a vapor injector having an internal nozzle hole diameter of 6 mm or less is constructed and arranged to supply pressure and high temperature to the reaction section.

[0012]

[0012] An extrusion system comprising one or more injector assemblies is provided herein, wherein the injector includes a nozzle hole having a diameter of 6 mm or less. In some embodiments, the injector has a flow rate of 10.55 to 56.25 kgf / cm². 2The extruder provides steam to the extruder bore at a pressure of 150-800 psi. In some embodiments, the inner diameter of the injector is 4 mm or less. In some embodiments, the inner diameter of the injector is 2 mm or less. In some embodiments, the extrusion system comprises at least two injector assemblies, at least three injector assemblies, or at least four injector assemblies. In some embodiments, the diameter of the inner bore of the injector is approximately 2 mm. In some embodiments, the diameter of the inner bore of the injector is approximately 2.5 mm. In some embodiments, the diameter of the inner bore of the injector is approximately 3 mm. In some embodiments, the diameter of the inner bore of the injector is approximately 3.5 mm. In some embodiments, the diameter of the inner bore of the injector is approximately 4 mm. In some embodiments, the diameter of the inner bore of the injector is approximately 4.5 mm. In some embodiments, the diameter of the inner bore of the injector is approximately 5 mm. In some embodiments, the diameter of the inner bore of the injector is approximately 5.5 mm. In some embodiments, the diameter of the inner bore of the injector is approximately 6 mm. In some embodiments, one or more injector assemblies include two or more injectors. In some embodiments, one or more injector assemblies include four or more injectors. In some embodiments, one or more injector assemblies include six or more injectors. In some embodiments, one or more injector assemblies include eight or more injectors. In some embodiments, one or more injector assemblies include ten or more injectors. In some embodiments, one or more injector assemblies include twelve or more injectors. In some embodiments, one or more injector assemblies include fourteen or more injectors. In some embodiments, one or more injector assemblies include sixteen or more injectors.

[0013] An extrusion system is provided herein with a barrel portion having spiral or concentric ports for an injector nozzle assembly. In some embodiments, the barrel portion comprises at least 4 ports. In some embodiments, the barrel portion comprises at least 6 ports. In some embodiments, the barrel portion comprises at least 8 ports. In some embodiments, the barrel portion comprises at least 10 ports. In some embodiments, the barrel portion comprises at least 12 ports. In some embodiments, the barrel portion comprises at least 14 ports. In some embodiments, the barrel portion comprises at least 16 ports. In some embodiments, the extrusion system includes two or more barrel portions. In some embodiments, the barrel portion is interchangeable with other barrel portions. In some embodiments, the spiral or concentric ports are orthogonal to the barrel portion. In some embodiments, the injector is pre - positioned to inject 30 - 50% steam per dry weight of the material.

[0014] A system for introducing one or more additives into a material, comprising at least one assembly of an injector having an inner bore in the range of 2 - 6 mm in diameter, a manifold for controlling the flow of substances within said assembly, a valve incorporated into the manifold such that each injector independently controls the flow of substances within the injector, and a supply of at least one additive is disclosed herein. In some embodiments, the additive is a liquid or a vapor. In another embodiment, the additive is water or an acid. In other embodiments, the additive is steam at a pressure of 5.625 - 42.19 kgf / cm 2 (80 - 600 psi). In other embodiments, the additive is steam at a pressure of 5.625 - 42.19 kgf / cm 2 (80 - 600 psi). In other embodiments, the additive is steam at a pressure of 10.55 kgf / cm 2 (150 psi). In other embodiments, the additive is steam at a pressure of 14.06 kgf / cm 2Steam at a pressure of (200 psi). In other embodiments, the additive is 17.58 kgf / cm 2 Steam at a pressure of (250 psi). In other embodiments, the additive is 21.09 kgf / cm 2 Steam at a pressure of (300 psi). In one embodiment, the material consists of biomass within a conduit. In another embodiment, the conduit is an extruder. In another embodiment, the conduit comprises an extruder and a discharge valve.

[0015]

[0015] The above-described system is also disclosed herein, and the inner diameter of the injector bore is 2 mm, or 2.5 mm, or 3 mm, or 3.5 mm, or 4 mm, or 4.5 mm, or 5 mm, or 5.5 mm, or 6 mm. Some embodiments further comprise an assembly consisting of two or more injectors, four or more injectors, six or more injectors, eight or more injectors, ten or more injectors, twelve or more injectors, fourteen or more injectors, or even sixteen or more injectors. In another embodiment, the material consists of biomass within the reaction section.

[0016]

[0016] A method of injecting liquid or steam into an extruder barrel or valve body, comprising the steps of penetrating a plurality of injection ports through the outer wall of the extruder barrel or the outer valve wall to their holes, including an injector in the injection port, injecting steam into the extruder barrel or valve to maintain a pressure of 10.55 - 56.25 kgf / cm 2 (150 - 800 psi) and injecting liquid into the extruder barrel or valve is also disclosed herein.

[0017]

[0017] In a further embodiment, a method of injecting liquid and steam into an extruder barrel or valve body, comprising the steps of penetrating a plurality of injection ports through the extruder barrel or valve body to their holes, including an injector in the injection port, injecting liquid and steam into the extruder barrel or valve to maintain a pressure of 10.55 - 56.25 kgf / cm 2 (150 - 800 psi) is disclosed.

[0018]

[0018] In some embodiments, the diameter of the injector nozzle hole is 2 to 6 mm. In some embodiments, the diameter of the injector nozzle hole is 2 to 4 mm. In other embodiments, the diameter of the injector nozzle hole is 2 to 3 mm. In yet another embodiment, the diameter of the injector nozzle hole is 2 mm.

[0019]

[0019] Disclosed is a method for pre-treating at least one dry ton of biomass per day, comprising the step of supplying biomass in a proportion of at least one dry metric ton (MT) of biomass per day to an extrusion system having a barrel defining an inner chamber including a feed section and a reaction section, wherein the extrusion system is constructed and positioned to supply pressure and high temperature to the reaction section, by compressing the biomass in a high-pressure section separating the feed section and the reaction section, thereby forming a vapor-impermeable plug, and at least one assembly of a vapor injector having an internal nozzle bore diameter of 6 mm or less.

[0020]

[0020] Extrusion systems are also disclosed that have at least one assembly of one or more injectors having an internal nozzle hole diameter of 6 mm or less. In some embodiments, the injector has an output of 10.55 to 56.25 kgf / cm 2 Steam is supplied to the extruder port at a pressure of (150-800 psi). In some embodiments, the inner diameter of the injector is 4 mm or less. In other embodiments, the inner diameter of the injector is 2 mm or less.

[0021]

[0021] In some embodiments, the system comprises at least two injector assemblies, at least three injector assemblies, or at least four injector assemblies. In another embodiment, the diameter of the injector bore is 2 mm. In yet another embodiment, the diameter of the injector bore is 2.5 mm, or 3 mm, or 3.5 mm, or 4 mm, or 4.5 mm, or 5 mm, or 6 mm.

[0022]

[0022] In some embodiments, the assembly consists of two or more injectors. In some embodiments, the assembly consists of four or more injectors. In some embodiments, the assembly consists of six or more injectors. In some embodiments, the assembly consists of eight or more injectors. In some embodiments, the assembly consists of ten or more injectors. In some embodiments, the assembly consists of twelve or more injectors. In some embodiments, the assembly consists of fourteen or more injectors. In some embodiments, the assembly consists of sixteen or more injectors.

[0023]

[0023] Extrusion systems also disclosed herein include at least one barrel portion having spiral or concentric ports for the assembly of an injector nozzle. In some embodiments, the barrel portion has at least four ports. In other embodiments, the barrel portion has at least six ports. In some embodiments, the barrel portion has at least eight ports. In some embodiments, the barrel portion has at least ten ports. In further embodiments, the barrel portion has at least twelve ports. In another embodiment, the barrel portion has at least fourteen ports. In some embodiments, the barrel portion has at least sixteen ports.

[0024]

[0024] In some embodiments, the extrusion system includes at least two barrel portions. In some embodiments, barrel portions are interchangeable with other barrel portions. In some embodiments, spiral or concentric ports are perpendicular to the barrel portions.

[0025]

[0025] Extrusion systems in which the injector is pre-configured to inject 30-50% steam per dry weight of the material are also disclosed herein. Incorporation by reference

[0026] 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.

[0026]

[0027] Novel features of the present invention are specifically described in the appended claims. A better understanding of the features and advantages of the present invention can be gained by referring to the following detailed description, which describes exemplary embodiments in which the principles of the present invention are used, and to the accompanying drawings. [Brief explanation of the drawing]

[0027] [Figure 1]

[0028] This is a longitudinal cross-sectional view of a twin-screw extruder with a valve assembly. [Figure 2]

[0029] This is a longitudinal view of the extruder barrel section and hole for the injector. [Figure 3]

[0030] Figure 3A is a longitudinal view of the holes for different injectors within the barrel section. Figure 3B is a cross-sectional view of the holes for different injectors within the barrel section. Figure 3C is a longitudinal view of the holes for different injectors within the barrel section. Figure 3D is a cross-sectional view of the holes for different injectors within the barrel section. Figure 3E is a longitudinal view of the holes for different injectors within the barrel section. Figure 3F is a cross-sectional view of the holes for different injectors within the barrel section. [Figure 4]

[0031] This is a longitudinal view of the valve body showing the arrangement of the injector. [Figure 5]

[0032] Figure 5A is a longitudinal view of the injector. Figure 5B is a longitudinal view of the injector. [Figure 6]

[0033] This figure shows the injector assembly attached to the manifold, along with the extruder and discharge valve. [Modes for carrying out the invention]

[0028]

[0034] 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.

[0029]

[0035] 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.

[0030]

[0036] Whenever the words "for example," "etc.," "including," "comprising," or "containing" are used herein, they shall be understood to be followed by the phrase "and without limitation," unless otherwise expressly specified. Thus, "for example, lignin production" means "for example, lignin production, but without limitation."

[0031]

[0037] In this specification and the subsequent claims, several terms are defined as having the following meanings:

[0032]

[0038] "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.

[0033]

[0039] Unless otherwise specified, the technical and scientific terms used herein have the same meanings as those commonly understood by those skilled in the art.

[0034]

[0040] definition

[0041] 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 pellets, 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 plants. Plants can include, for example, woody plants, non-woody plant materials, 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 materials can be further described by referring to the chemical species in which they exist, 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.

[0035]

[0042] 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.

[0036]

[0043] 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.

[0037]

[0044] 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.

[0038]

[0045] explanation

[0046] 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.

[0039]

[0047] While the history of food extrusion dates back to the late 1800s, the control of this process and the design of new extruded products are still largely based on limited empirical knowledge. Regarding biomass pretreatment, extrusion remains a relatively novel pretreatment, involving mixing, heating, and shearing the material to introduce physical and chemical modifications. Even in batch mode, results are inconsistent, with pressure fluctuations, chemicals, and inconsistent material sizing leading to byproducts and low yields rather than providing high sugar and impurity-free lignin yields.

[0040]

[0048] The extrusion of food, animal feed, and plastic materials has been practiced for many years. Biomass processing using extruders has also been attempted, but until recently, it has not been very successful due to the difficulty in handling such cumbersome, heterogeneous materials and fluctuating moisture content. Biomass typically consists mainly of plant cell walls, which are a cross-linked matrix of lignin, cellulose, and hemicellulose. The proportions and composition of these materials can vary depending on the plant species and even environmental factors.

[0041]

[0049] More recently, however, extruder processes for handling such materials have been improved, making large-scale pretreatment economical. See, for example, U.S. Patent No. 10,844,413. Unlike current methods of holding biomass materials in a chamber for extended periods, it has been found that processing these materials allows for the avoidance of prolonged holding under heat and chemical treatment, thereby preventing the degradation of C5 sugars, proteins, and lignin into undesirable products such as hydroxymethylfurfural (HMF) and furfural, while also enabling the separation of both monomeric and polymeric sugar carbohydrate materials from other biomass components. Inhibitory substances generally formed during pretreatment include acetic acid (formed during the release of C5 sugars), formic acid, furfural, and HMF. The formation of the latter three compounds depends primarily on the temperature, pressure, and biomass residence time during pretreatment.

[0042]

[0050] To successfully process biomass materials, it is necessary to introduce precise amounts of steam or liquid at precise times during the process. However, in one embodiment, as shown in U.S. Patent No. 10,844,413, understanding the importance of uniform processing throughout the process can yield very high yields of the desired product without producing the inhibitory levels seen with other pretreatment methods. This is particularly true for the pressure, temperature, and pretreatment time at which the biomass is introduced.

[0043]

[0051] However, when scaling this process, the problem of injector nozzle clogging becomes more pronounced and can interfere with continuous or large-volume pretreatment. Conventional injectors are manufactured with holes larger than 12 mm and often contain limiting elements. Examples of such nozzles used in extruders are described in U.S. Patents 7,521,076, 7,988,884, 9,931,603, 8,858,065, and 8,967,849. Typically, the described processes incorporating these injectors teach the use of less steam and chemicals than is required to successfully process the biomass. To process biomass quickly and efficiently, pretreatment time must be reduced and the material must be uniformly exposed to more steam and chemicals than usual over the reaction period. However, under these conditions, larger holes easily clog. Furthermore, a small number of injectors are insufficient to quickly reach the material moving rapidly through the extruder barrel section.

[0044]

[0052] In one embodiment, the injector assembly described herein overcomes the problems outlined above and enables economical mass production in batch or continuous mode of biomass containing large quantities of plant and fibrous materials exceeding 20% ​​by weight.

[0045]

[0053] Furthermore, it was discovered that short exposure times do not interfere with the solubilization of crystalline cellulose. The method provided herein also allows for the uniform heating and pressurization of the biomass for improved access to the biomass by the reactants. During this process, a concentrated mass (plug) can be created, thereby shearing the biomass into smaller particles, further increasing access by the reactants, allowing for the release and solubilization of C6 polymers while hydrolyzing and releasing C5 polymers. In one embodiment, the biomass passes through a reaction chamber into which steam and pressure are applied, followed by the addition of an acid, and finally the material is released to atmospheric pressure by rapidly opening and closing an end valve. The entire process can occur within seconds, resulting in thermomechanically and / or chemically hydrolyzed biomass with lower or reduced levels of inhibitors compared to pretreatment methods known in the art.

[0046]

[0054] In some embodiments, the biomass is processed in the reaction section 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 some embodiments, the biomass is processed in the reaction section for approximately 5 to 15 seconds, and in larger systems, the biomass is processed for 30 seconds or less, or 60 seconds or less. In other embodiments, the biomass can be pre-treated at high temperatures and / or pressures. In one embodiment, the biomass is pre-treated in a temperature range of 20°C to 400°C. In another embodiment, the biomass is pretreated at temperatures of approximately 20°C, 25°C, 30°C, 35°C, 40°C, 45°C, 50°C, 55°C, 60°C, 65°C, 80°C, 90°C, 100°C, 120°C, 150°C, 200°C, 250°C, 300°C, 350°C, 400°C, or higher. In another embodiment, high temperatures are provided by using steam, hot water, or hot gas. In one embodiment, steam can be injected into a container containing the biomass. In another embodiment, steam, hot water, or hot gas can be injected into the jacket of the container, so that the jacket becomes hot but does not come into direct contact with the biomass.

[0047]

[0055] Generally, the extruder according to the present invention has an elongated barrel, with an inlet adjacent to one end of the barrel and an opening at the opposite end for the material to flow into a valve assembly. The extruder for this purpose can be a single-screw, twin-screw, or even a triple-screw extruder, meaning that the screw elements are assembled on one to three axially rotatable shafts between the inlet and outlet of the extruder barrel.

[0048]

[0056] The screw element within the extruder comprises a plurality of screw components, each including an elongated shaft, with its ends aligned, including an inlet component and an outlet component, and a helical flitting extending outward along the length of the shaft, indicating the flitting diameter, inlet portion, and discharge portion. The screw components are further arranged between their ends such that the discharge portion of the inlet screw component is located proximal to the inlet portion of the outlet screw component.

[0049]

[0057] To provide flow restriction and greater shear in the extruder section, flow restriction elements and / or mixing elements are provided between the discharge and inlet sections of the screw assembly components. These elements may include means for forming plugs from the material to form sections within the extruder. In a preferred embodiment, vapor-impermeable plugs are formed by compressing biomass in a high-pressure section that separates the feed section from the reaction section. These are one or more vapor-permeable plugs formed by compressing biomass, where the biomass, rather than the screw elements, forms a barrier against vapors and / or acids being sent into the reaction section.

[0050]

[0058] The pressure achieved within this section arises from the direct injection of steam in combination with a flow limiting valve at the outlet, supporting directional flow and facilitating turbulence and thorough mixing within the system. The plug prevents steam from backflowing (flowing upstream) into the extruder feed section, thereby working in conjunction with the end valve to maintain high pressure and temperature within the reaction section. To accelerate the conversion process, dilute acids (or optionally bases, or optionally ionic liquids) are also added to the reaction section. Furthermore, the resulting high-pressure section maintains the reactive materials and liquids within the reaction section and allows for the use of inexpensive and durable metals in the manufacture of barrel liners and screw elements within the transport section.

[0051]

[0059] By connecting the discharge (end) valve and the high-pressure section configuration described later, the loop is closed in the actual configuration of the high-pressure reaction section within the extruder. Within the reaction section, a backflow of steam does not occur in the high-pressure section, and the pressure is 0.07031 kgf / cm². 2 (1 psi) ~ 56.25 kgf / cm² 2 (800 psi), and furthermore, 70.31 kgf / cm² 2 High pressures exceeding (1000 psi) are achieved. In one embodiment, the steam is at least about 35.16 kgf / cm². 2 (500 psi), at least approximately 42.19 kgf / cm² 2 (600 psi), at least approximately 49.22 kgf / cm² 2 (700 psi), at least approximately 56.25 kgf / cm² 2 (800 psi), at least approximately 63.28 kgf / cm² 2 (900 psi), or at least about 70.31 kgf / cm² 2 A pressure of 1000 psi is reached and maintained. This pressure is maintained for at least approximately 1 hour, at least approximately 2 hours, at least approximately 4 hours, at least approximately 5 hours, at least approximately 6 hours, at least approximately 8 hours, at least approximately 10 hours, at least approximately 12 hours, at least approximately 13 hours, at least approximately 14 hours, at least approximately 15 hours, at least approximately 16 hours, at least approximately 17 hours, or at least approximately 18 hours or longer. In these cases, the biomass supply rate is in the range of approximately 60 to approximately 350 dry kg / hour.

[0052]

[0060] Direct steam injection through the injection port allows for extremely rapid and uniform heating of the biomass, especially when the biomass particle size is small. The combination of high temperature, thorough mixing, small particle size, and even reactive solutions (dilute acids, ionic liquids, etc.) results in a very rapid pretreatment process with minimal inhibitory effects.

[0053]

[0061] In some cases, the pretreatment methods provided herein enable the release and depolymerization of sugars in a very rapid timeframe. This process occurs in less than 20 seconds to several minutes, depending on the size of the extruder. Generally, the time within the reaction interval can range from 1 second to less than 20 seconds, preferably less than 10 seconds. In larger systems, pretreatment can be carried out over several minutes. The thus shortened pretreatment period allows the biomass to move continuously through the tube and end valve sections, resulting in rapidly pretreated biomass that contains little to no inhibitors, or substantially no inhibitors.

[0054]

[0062] Improved, low-cost, and energy-efficient pretreatment devices and methods for the rapid treatment of lignocellulose, cellulose, hemicellulose, and similar biomass materials prior to enzymatic hydrolysis are described herein, and such treatments include thermomechanical treatments, whether or not chemicals and reaction extrusions are controlled by high-pressure sections and pressure-driven variable end valves. Methods disclosed herein may include the use of devices comprising a cylindrical chamber divided into tubular sections, through which biomass can be moved continuously or in large quantities, reducing the size of the biomass, and the biomass can be treated by pressure, heat, chemicals, or a combination thereof in different tubular sections before being subjected to rapid temperature differences and differential pressures (e.g., explosive depressurization). The biomass can be moved by screw-type mechanisms such as single-screw, twin-screw, or even triple-screw, as found in extruders. Alternatively, the biomass can be moved by mechanisms such as air, oil, pistons, vacuum, or blocks controlled by gravity, or other mechanical pressure, hydrostatic pressure differences. These mechanisms may also have the function of advancing biomass or separating biomass into chambers or sections for specific processing or addition of materials.

[0055]

[0063] Generally, the extruders used in this system include an elongated barrel with material inlets and outlets located adjacent to both ends of the barrel, and one or more elongated, axially rotatable screws within the barrel are responsible for advancing the material from the inlet end to the outlet end of the barrel. The screws are designed to reduce the flow size while smoothing the material flow, and various screw elements are arranged to increase or decrease the flow or to form a plug of biomass within the barrel. The screws, coupled to an end valve under pressure at the outlet, control the speed, pressure, and partially temperature applied to the biomass as it moves through the barrel and out of the barrel.

[0056]

[0064] The systems and methods disclosed herein can be used for high-volume, industrial-scale pretreatment of biomass. For example, biomass can be moved through a twin-screw extruder according to some of the methods disclosed herein, and it is estimated that such a twin-screw extruder can be processed by continuous operation according to Table 1 below.

[0057] Table 1

[0058] [Table 1]

[0059]

[0065] A barrel screw reactor can be comprised of a cylindrical metal barrel (which can be lined with special materials such as ceramic, glass, aluminum, Hastelloy, or titanium), the barrel size can range, for example, from 30 mm to 220 mm or more in diameter, and it can be comprised of one or more screws oriented horizontally or vertically. The barrel can be divided into separate parts (barrel sections) and may have multiple use ports along the top, sides, and / or bottom. Such multiple use ports may be sealable ports. Multiple use ports may allow for the injection of water, steam, acid, or other chemicals. Multiple use ports may allow for the insertion of thermocouples and / or pressure gauges for measuring the temperature and pressure inside the barrel. Additional ports may be added if necessary. The reactor barrel may be equipped with an electric heating element or a steam jacket to further heat the barrel. Alternatively or additionally, heating may be supplied by steam injection. The reactor barrel can be mounted on a pipe that discharges into a flush tank or other vessel. The flush tank may be constructed using stainless steel. The barrel can be separated from the flush tank by a pipe, and the installation end, which has a pressure-operated release valve mechanism, can be continuously adjusted in position according to the back pressure on the valve and the pressure in the system. The release valve mechanism may have a metal or ceramic sealing sheet in between to allow for the explosive release of biomass. The pressure-operated valve mechanism may have a conical nozzle connected to a shaft. The diameter of the end valve can vary with the size of the machine, typically ranging from 30 mm to 220 mm or more. The conical nozzle can be connected to a shaft mounted on an actuator in a back pressure generator. The actuator can provide pneumatic pressure, which is regulated by a back pressure generator that monitors the pressure. The pressure can be high to prevent backflow and restrict the flow of material out of the pipe. The back pressure on the conical nozzle and sheet can be adjustable.For example, 3.516 kgf / cm² applied to the shaft connected to the conical nozzle of an end shear valve. 2 (50 psi) ~ 42.19 kgf / cm² 2 The valve can operate using a back pressure of 600 psi (gauge pressure) or higher. The conical shape of the end shear valve can move between a fully closed position, a fully open position, and any intermediate position. The pipe at the outlet of the end shear valve can guide the processed solid to the bottom of the flash tank, where the solid and vapor can be separated and easily removed.

[0060]

[0066] A complete extruder, consisting of barrel sections, typically has multiple ports for injecting steam and / or acid within the barrel's range, with these ports located adjacent to at least some inlet sections of the screw components. In a preferred embodiment, the injection ports are positioned at a 90° angle to the longitudinal axis of the barrel and comprise steam injection assemblies with nozzles, the ends of which are coplanar with the inner wall of the barrel or slightly penetrate the inner wall of the barrel. A barrel section can have 16 or more injection assemblies. This differs from other systems in the art that utilize 2 to 4 nozzles per barrel section. Increasing the number allows for the injection of large quantities of steam, chemicals, or water in amounts precisely as required. The barrel sections are interchangeable and therefore the introduction of materials can be modified as required by the nature of the biomass to be processed. In one embodiment, the number of nozzles in a barrel section is at least 2, at least 4, at least 6, at least 8, at least 10, at least 12, at least 14, at least 16, or more. These nozzles are also arranged in a circular pattern around the end valve cylindrical section to ensure uniform distribution of the liquid.

[0061]

[0067] In the injection section located immediately behind the extruder outlet and in front of the end valve needle, the nozzle can extend further into the opening of the end valve body. A feature of the present invention is that the extruder is designed to process biomass material using steam / water injection and acid derived from relatively high levels of specific thermal energy to reach the required pressure level in the barrel without causing backflow or clogging of the nozzle assembly, compared to conventional equipment. For this purpose, the extruder screw assembly in the extruder barrel is designed to allow the injection of a considerable amount of steam into the barrel while alternating between transporting, plugging, and working with the biomass material. Thus, the extruder provides a section of high friction and shear in the steam injection section so that the material is uniformly hydrated and processed. At the same time, the operation of the extruder does not require very high horsepower, and as a result does not cause excessive wear on the extruder parts.

[0062]

[0068] The end valve assembly serves at least two purposes. The first purpose is to maintain pressure within the extruder barrel by restricting the outflow of steam and material. In this way, the material released from the valve assembly undergoes a rapid pressure drop from a pressure higher than atmospheric pressure to atmospheric pressure. The purpose of this sudden release is to subject the material to a steam explosion that further decomposes the biomass processed by the extruder. The second purpose is to guide the steam-decomposed material to a connected flash tank.

[0063]

[0069] Nozzles and valve assemblies are provided to add water or another chemical to the material entering the end valve assembly downstream, enabling a smooth flow through the end valve. The number of these inlets can range from 4 to 16 or more within the barrel or valve section, depending on the barrel size, flow velocity, and density of the material. In one embodiment, the number of nozzles in the inlet section is at least 2, at least 4, at least 6, at least 8, at least 10, at least 12, at least 14, at least 16 or more within the end valve section. These nozzles are also arranged in a circular pattern around the cylindrical section of the end valve to ensure a uniform distribution of the liquid.

[0064]

[0070] Figure 1 shows one embodiment of the design of one type of reactor, provided in a longitudinal section view. The reactor can be a commercial-scale reactor. The reactor comprises a horizontal cylindrical barrel 45 having a twin-screw with screw elements 51, 52 assembled on a shaft 38, and a partially shown discharge valve body 10 and needle 11. The extruder and discharge valve form a conduit through which biomass moves to a discharge unit (not shown).

[0065]

[0071] The barrel can be insulated and may have impermeable walls. A support 7 for the extruder is shown in Figure 6. A motor 24 or other means for driving the screw may be mounted near the first end. The motor may be, for example, an electrically driven motor and gearbox combination with or without pulleys and a V-belt or any other mechanism for turning the screw. The motor may also be, for example, a synchronous torque motor. A hopper (not shown) may be mounted at the inlet of the barrel 45. Biomass may be added through the opening of the hopper. The biomass may be any of the biomass described above. To control the addition of biomass from the hopper to the barrel 45, a feeder for incompressible or compressible flow generation (not shown), such as a cramper, may be provided. The compressible and / or incompressible feeder may be any compressible and / or incompressible loader known in the art. For example, an incompressible flow-excitation feeder can be an incompressible feeder or various types of live bottom-bin flow inducers, followed by various types of flow measuring conveyors such as drag chains, bucket elevators, or rotating helices. In its simplest form, an incompressible feeder can refer to manually loading biomass into the open first end of a cylindrical barrel. A compressible feeder can include mechanical compression. Mechanical compression can be achieved by providing a mechanical compression device such as a reciprocating plunger or screw feeder.

[0066]

[0072] A key embodiment of the present invention is the bore diameter of the input injector. While input injectors typically have larger bore diameters, the high pressures within the barrel and the small particle size of the material, which can cause clogging, necessitate construction with much smaller bore diameters than in conventional designs. When injecting water or acid, these bore diameters range from 2–3 mm, and for extruder barrels larger than 113 mm, steam injectors have bore diameters ranging from 2 mm to 4.5 or 5 mm. The angle of the injector relative to the barrel is generally perpendicular to the barrel, but it can also be angled to the upstream or downstream flow. Furthermore, conventional extruders with steam or liquid injection are generally designed to inject 3–15% steam per dry weight of the material. In embodiments of the present invention, the steam injector is pre-configured to inject 30–50% steam per dry weight of the material, processing volumes exceeding 100 dry megatons per day. The pressures generated in the extruder barrel lead to nozzle clogging and are therefore unattainable in conventional designs with larger bore diameters. Alternatively, to generate additional steam or liquid, an additional injector must be added to the system, or the flow rate must be increased.

[0067]

[0073] In one embodiment, as shown in Figure 1, the extruder barrel 45 is equipped with arrays of injectors 29, 32, 34, and 36 within a plurality of ports 55 (Figure 2), and these injectors are arranged in a spiral or circular pattern around the extruder barrel 45 and valve body 10 for a flow path designed to process biomass. In Figure 1, the injectors are grouped into four assemblies, as shown more clearly in Figure 6 as assemblies S1, S2, S3, and S4. The first assembly S1 consists of injector 29 and is located before plug formation, which is initiated by the mixing element 52. These injectors provide an addition of water upstream of the plug to maintain a specific minimum moisture (maximum solid) within the plug (not shown) for torque, flow rate, and heat control.

[0068]

[0074] This upstream portion of the extruder barrel 45 is equipped with a series of ports 55 (longitudinal and transverse sections in Figures 3A and 3B, respectively) for injecting water to hydrate the incoming material, with each barrel port housing an elongated water injector 29. The series of ports 55 are positioned to penetrate the outer wall of the extruder and communicate with the barrel holes 30. The ports can be arranged in a spiral pattern along conduits around the flow path, as shown in Figures 2, 3, and 4.

[0069]

[0075] The second assembly S2 of the injector 32 is located downstream of the mixing element 52 within the reaction section R. Depending on the required degree of processing and pressure / temperature, this assembly S2 can be positioned within the barrel section to deliver steam uniformly over substantially the entire reaction section immediately after plug formation, or to the end of the reaction section. In another embodiment, a combination of these arrangements can be used. Figures 3C (longitudinal section) and 3D (cross section) show one embodiment of a barrel section having a port 55 designed to house an injector positioned to deliver steam immediately after plug formation.

[0070]

[0076] The third assembly S3 of the injector 34 is also located downstream of the mixing element 52 within the reaction section R. Depending on the required degree of processing, this assembly S3 can be positioned within the barrel section to uniformly supply acid to the end of the extruder barrel 45 over substantially the entire reaction section after plug formation. In other embodiments, different combinations of these injectors 34 can be used. Figures 3E (longitudinal section) and 3F (cross section) show one embodiment of a barrel section having a port 55 designed to house an injector positioned to supply acid immediately after plug formation and before the material enters the valve body.

[0071]

[0077] The fourth assembly S4 of the injector 36 is organized immediately after the extruder barrel 45 but before the needle 11 in the valve body 10 (Figures 1 and 4). The injector 36 is used to inject water as the biomass material exits the extruder and is located behind the end of the screw element 51, although an optional shaft cap 39 can also protrude into this space 21. 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.

[0072]

[0078] The injectors are connected to port 55 so that the injector assembly is positioned at a desired angle with respect to the material flow path or screw element. Thus, as shown in Figure 1, injector 29 (the first set of injector combinations) can be connected to port 55 (Figures 2 and 3B) so that it is positioned at an angle of approximately 90° with respect to the extruder barrel and flow path. Similarly, injector 32 (the second set of injector assemblies) can be connected to port 55 (Figures 2 and 3D) so that it is positioned at an angle of approximately 90° with respect to the extruder barrel 45 and material flow path.

[0073]

[0079] In the system shown in Figure 1, the injector assemblies are positioned at a specific angle, but the angle used can be changed as long as the injector assemblies do not physically interfere with each other or with the movement of the screw elements. Thus, the angle between injector assemblies can be decreased, for example, as the physical dimensions of the injector assemblies decrease, or increased, for example, as the physical dimensions of the injector assemblies increase. The ports are arranged in a spiral or helical pattern along the length of the extruder or valve body at separate locations around the material flow path to provide both angular and longitudinal separation between individual ports.

[0074]

[0080] Figures 5A and 5B show individual injectors. Each injector comprises a distal end with a hole 73 opening into the inner chamber of the extruder, a proximal end 70, and a duct 71 connecting the distal and proximal ends of the injector. An adjustable valve (not shown) is housed within the manifold (Figure 6) before the conduits connecting the injectors to the manifold are attached. The nozzle 72 of the injector tube can protrude into the flow path of the extruder by any suitable distance, as long as it does not interfere with the movement of the screw elements or other moving parts. Thus, the nozzle 72 is substantially flush with the inner wall 45 of the extruder and hardly protrudes into the inner wall 45 of the extruder, but can extend further into the valve body 10 without hindering mechanical movement.

[0075]

[0081] Each injector nozzle 72 is supplied from its own unique manifold / header by piping attached to the nozzle. Therefore, when water is injected into the barrel, it is supplied from its own pump into the manifold to which all nozzles in use are connected. The flow can be controlled by the pump settings. There are no restrictions on the injector tubing. The same applies to acids and other fluids, each having its own pump and manifold / header. Steam is supplied from a steam supply unit operating at a pressure of 69 barg at the source and reduced to 49 barg by the extruder's pressure reduction system. The steam flow is regulated by opening a flow control valve (not shown).

[0076]

[0082] The valves exiting the manifold are individually adjustable for each line leading to the injector nozzles. Therefore, the specific flow to each nozzle of each injector is similarly adjustable. If fewer injectors are required in any particular set, the injectors can be removed, and the holes are closed after the valves are switched off, so that no material flows from the manifold to its nozzles, and therefore no material exits the extruder through those holes.

[0077]

[0083] The valve is provided with at least one inlet for supplying additives to the valve and may be any suitable valve, such as a manually or automatically operated bidirectional valve. Suitable valves include, but are not limited to, those described in U.S. Patent Nos. 6,220,296 (Ragsdale et al.), 6,247,839 (Kochanowicz et al.), 6,316,053 (Ragsdale et al.), and 6,541,531 (Ragsdale), which are incorporated herein by reference, respectively.

[0078]

[0084] The conduits of a manifold can be constructed from any suitable material. For example, the conduits can be constructed from metals such as aluminum, steel, stainless steel, and corrosion-resistant alloys, or from plastic materials such as polyvinyl chloride (PVC) and polycarbonate (when using lower pressures).

[0079]

[0085] The manifold may be provided with any suitable means for attachment to a suitable system, such as a system used in the manufacture of polymer foams (e.g., polyurethane foams). For example, threads may be provided at the ends of the conduits to provide a means for connecting the manifold to a suitable system. Alternatively, flanged fittings may be provided at the ends of the conduits to provide a means for connecting the manifold to a system.

[0080]

[0086] Preferred embodiments of the present invention 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 modifications, changes, and substitutions will be conceivable to those skilled in the art without departing from the present invention. It should be understood that various alternative means to the embodiments of the present invention described herein may be used when carrying out the present invention. The following claims define the scope of the present invention and are intended to encompass methods and structures within the scope of these claims and their equivalents.

[0081]

[0087] Exemplary Embodiments

[0088] Embodiment 1. A system for introducing one or more additives into a material, a. At least one assembly of an injector having an internal bore in the range of 2 to 6 mm in diameter, b. A manifold for controlling the flow of material within the assembly, c. Valves incorporated into the manifold so that each injector independently controls the flow of material within the injector, d. A system comprising at least one additive supply unit.

[0082]

[0089] Embodiment 2. The system according to Embodiment 1, wherein the additive is a liquid or vapor.

[0083]

[0090] Embodiment 3. The system according to Embodiment 1, wherein the additive is water.

[0084]

[0091] Embodiment 4. The system according to Embodiment 1, wherein the additive is an acid.

[0085]

[0092] Embodiment 5. Additives are 5.625 to 42.19 kgf / cm³ 2 The system according to Embodiment 1, wherein the steam is at a pressure of (80-600 psi).

[0086]

[0093] Embodiment 6. Additives with a concentration of 10.55 kgf / cm³ 2The system according to Embodiment 1, wherein the steam is at a pressure of (150 psi).

[0087]

[0094] Embodiment 7. The additive is 14.06 kgf / cm³. 2 The system according to Embodiment 1, wherein the steam is at a pressure of (200 psi).

[0088]

[0095] Embodiment 8. Additives with a concentration of 17.58 kgf / cm³ 2 The system according to Embodiment 1, wherein the steam is at a pressure of (250 psi).

[0089]

[0096] Embodiment 9. Additives with a concentration of 21.09 kgf / cm³ 2 The system according to Embodiment 1, wherein the steam is at a pressure of (300 psi).

[0090]

[0097] Embodiment 10. The system according to Embodiment 1, wherein the material consists of biomass.

[0091]

[0098] Embodiment 11. The system according to Embodiment 1, wherein the material consists of biomass in the conduit.

[0092]

[0099] Embodiment 12. The system according to Embodiment 11, wherein the conduit is an extruder.

[0093] [000100] Embodiment 13. The system according to Embodiment 12, wherein the conduit comprises an extruder and a discharge valve.

[0094] [000101] Embodiment 14. The system according to Embodiment 1, wherein the diameter of the inner bore of the injector is 2 mm.

[0095] [000102] Embodiment 15. The system according to Embodiment 1, wherein the diameter of the inner bore of the injector is 2.5 mm.

[0096] [000103] Embodiment 16. The system according to Embodiment 1, wherein the diameter of the inner bore of the injector is 3 mm.

[0097] [000104] Embodiment 17. The system according to Embodiment 1, wherein the diameter of the inner bore of the injector is 3.5 mm.

[0098] [000105] Embodiment 18. The system according to Embodiment 1, wherein the diameter of the inner bore of the injector is 4 mm.

[0099] [000106] Embodiment 19. The system according to Embodiment 1, wherein the diameter of the inner bore of the injector is 4.5 mm.

[0100] [000107] Embodiment 20. The system according to Embodiment 1, wherein the diameter of the inner bore of the injector is 5 mm.

[0101] [000108] Embodiment 21. The system according to Embodiment 1, wherein the diameter of the inner bore of the injector is 5.5 mm.

[0102] [000109] Embodiment 22. The system according to Embodiment 1, wherein the diameter of the inner bore of the injector is 6 mm.

[0103] [000110] Embodiment 23. The system according to Embodiment 1, wherein the assembly comprises two or more injectors.

[0104] [000111] Embodiment 24. The system according to Embodiment 1, wherein the assembly comprises four or more injectors.

[0105] [000112] Embodiment 25. The system according to Embodiment 1, wherein the assembly comprises six or more injectors.

[0106] [000113] Embodiment 26. The system according to Embodiment 1, wherein the assembly comprises eight or more injectors.

[0107] [000114] Embodiment 27. The system according to Embodiment 1, wherein the assembly comprises 10 or more injectors.

[0108] [000115] Embodiment 28. The system according to Embodiment 1, wherein the assembly comprises 12 or more injectors.

[0109] [000116] Embodiment 29. The system according to Embodiment 1, wherein the assembly comprises 14 or more injectors.

[0110] [000117] Embodiment 30. The system according to Embodiment 1, wherein the assembly comprises 16 or more injectors.

[0111] [000118] Embodiment 31. The system according to Embodiment 1, wherein the material consists of biomass within the reaction zone.

[0112] [000119] Embodiment 32. A method for injecting liquid or vapor into an extruder barrel or valve body, a. The step of passing multiple injection ports through the outer wall or outer valve wall of the extruder barrel to the holes thereof, b. A step including an injector in the injection port, c. Inject steam into the extruder barrel or valve to create a conduit with a steam flow rate of 10.55 to 56.25 kgf / cm². 2 The steps include maintaining a pressure of (150-800 psi) and d. A method comprising the step of injecting liquid into the extruder barrel or valve.

[0113] [000120] Embodiment 33. A method for injecting liquid and vapor into an extruder barrel or valve body, a. The step of passing multiple injection ports through the extruder barrel or valve body to the holes, b. A step including an injector in the injection port, c. Inject liquid and steam into the extruder barrel or valve to produce a pressure of 10.55 to 56.25 kgf / cm² inside the section. 2 A method comprising the step of maintaining a pressure of (150-800 psi).

[0114] [000121] Embodiment 34. The method according to Embodiment 32, wherein the diameter of the injector nozzle hole is 2 to 6 mm.

[0115] [000122] Embodiment 35. The method according to Embodiment 32, wherein the diameter of the injector nozzle hole is 2 to 4 mm.

[0116] [000123] Embodiment 36. The method according to Embodiment 32, wherein the diameter of the injector nozzle hole is 2 to 3 mm.

[0117] [000124] Embodiment 37. The method according to Embodiment 32, wherein the diameter of the injector nozzle hole is 2 mm.

[0118] [000125] Embodiment 38. To pre-treat at least 1 dry ton of biomass per day, (a) The step of supplying biomass to an extrusion system equipped with a barrel at a rate of at least 1 dry metric ton (MT) of biomass per day, wherein the barrel defines an inner chamber including a supply section and a reaction section, and the extrusion system (i) By compressing the biomass in a high-pressure section that separates the supply section and the reaction section, a vapor-impermeable plug is formed. (ii) The method according to Embodiment 32, wherein at least one assembly of a steam injector having an internal nozzle bore diameter of 6 mm or less is constructed and positioned to provide pressure and high temperature to the reaction section.

[0119] [000126] Embodiment 3 An extrusion system having at least one assembly of one or more injectors having an internal nozzle hole diameter of 9.6 mm or less.

[0120] [000127] Embodiment 40. The injector has a capacity of 10.55 to 56.25 kgf / cm². 2 The system according to embodiment 38, which supplies steam to the extruder bore at a pressure of (150-800 psi).

[0121] [000128] Embodiment 41. The system according to Embodiment 39, wherein the inner diameter of the injector is 4 mm or less.

[0122] [000129] Embodiment 42. The system according to Embodiment 39, wherein the inner diameter of the injector is 2 mm or less.

[0123] [000130] Embodiment 43. The system according to Embodiment 38, wherein the system comprises at least two injector assemblies, at least three injector assemblies, or at least four injector assemblies.

[0124] [000131] Embodiment 44. The system according to Embodiment 43, wherein the diameter of the inner bore of the injector is 2 mm.

[0125] [000132] Embodiment 45. The system according to Embodiment 43, wherein the diameter of the inner bore of the injector is 2.5 mm.

[0126] [000133] Embodiment 46. The system according to Embodiment 43, wherein the diameter of the inner bore of the injector is 3 mm.

[0127] [000134] Embodiment 47. The system according to Embodiment 43, wherein the diameter of the inner bore of the injector is 3.5 mm.

[0128] [000135] Embodiment 48. The system according to Embodiment 43, wherein the diameter of the inner bore of the injector is 4 mm.

[0129] [000136] Embodiment 49. The system according to Embodiment 43, wherein the diameter of the inner bore of the injector is 4.5 mm.

[0130] [000137] Embodiment 50. The system according to Embodiment 43, wherein the diameter of the inner bore of the injector is 5 mm.

[0131] [000138] Embodiment 51. The system according to Embodiment 43, wherein the diameter of the inner bore of the injector is 5.5 mm.

[0132] [000139] Embodiment 52. The system according to Embodiment 43, wherein the diameter of the inner bore of the injector is 6 mm.

[0133] [000140] Embodiment 53. The system according to Embodiment 43, wherein the assembly comprises two or more injectors.

[0134] [000141] Embodiment 54. The system according to Embodiment 43, wherein the assembly comprises four or more injectors.

[0135] [000142] Embodiment 55. The system according to Embodiment 43, wherein the assembly comprises six or more injectors.

[0136] [000143] Embodiment 56. The system according to Embodiment 43, wherein the assembly comprises eight or more injectors.

[0137] [000144] Embodiment 57. The system according to Embodiment 43, wherein the assembly comprises 10 or more injectors.

[0138] [000145] Embodiment 58. The system according to Embodiment 43, wherein the assembly comprises 12 or more injectors.

[0139] [000146] Embodiment 59. The system according to Embodiment 43, wherein the assembly comprises 14 or more injectors.

[0140] [000147] Embodiment 60. The system according to Embodiment 43, wherein the assembly comprises 16 or more injectors.

[0141] [000148] Embodiment 61. An extrusion system comprising at least one barrel portion having a helical or concentric port for the assembly of an injector nozzle.

[0142] [000149] Embodiment 62. The extrusion system according to Embodiment 61, wherein the barrel portion has at least four ports.

[0143] [000150] Embodiment 63. The extrusion system according to Embodiment 61, wherein the barrel portion has at least six ports.

[0144] [000151] Embodiment 64. The extrusion system according to Embodiment 61, wherein the barrel portion has at least eight ports.

[0145] [000152] Embodiment 65. The extrusion system according to Embodiment 61, wherein the barrel portion has at least 10 ports.

[0146] [000153] Embodiment 66. The extrusion system according to Embodiment 61, wherein the barrel portion has at least 12 ports.

[0147] [000154] Embodiment 67. The extrusion system according to Embodiment 61, wherein the barrel portion has at least 14 ports.

[0148] [000155] Embodiment 68. The extrusion system according to Embodiment 61, wherein the barrel portion has at least 16 ports.

[0149] [000156] Embodiment 69. The extrusion system according to Embodiment 61, comprising at least two barrel portions.

[0150] [000157] Embodiment 70. The extrusion system according to Embodiment 61, wherein the barrel portion is interchangeable with other barrel portions.

[0151] [000158] Embodiment 71. The extrusion system according to Embodiment 61, wherein a spiral or concentric port is perpendicular to the barrel portion.

[0152] [000159] Embodiment 72. The extrusion system according to Embodiment 61, wherein the injector is pre-configured to inject 30-50% steam per dry weight of the material.

Claims

1. An extruder, wherein the extruder is (1) A barrel comprising an inner chamber including a feed section and a reaction section, wherein the extruder is constructed and positioned such that a vapor-impermeable plug is formed by compressing biomass in a high-pressure section separating the feed section and the reaction section, (2) A discharge valve body at the discharge end of the barrel, wherein the discharge valve body has a plurality of injection ports, and the plurality of injection ports penetrate the outer wall of the discharge valve body, (3) A system for introducing one or more additives into a material, a. An assembly of an injector, wherein the injector includes an internal bore in the range of 2 to 6 mm in diameter, b. A manifold for controlling the flow of material within the injector assembly, c. Valves incorporated into the manifold such that each injector independently controls the flow of the substance within the injector, d. A system comprising an additive supply unit, Equipped with, An extruder in which the injector is located in the plurality of injection ports within the outer wall of the discharge valve body.

2. The extruder according to claim 1, wherein the additive is a liquid or vapor.

3. The extruder according to claim 1, wherein the additive is water.

4. The extruder according to claim 1, wherein the additive is an acid.

5. The additive is vapor, and the pressure of the vapor is 80 to 600 psi (approximately 5.625 to 42.19 kgf / cm²). ２ The extruder according to claim 1, wherein the extruder is as described in claim 1.

6. The additive is vapor, and the pressure of the vapor is 150 psi (approximately 10.55 kgf / cm²). ２ ) to 300 psi (approximately 21.09 kgf / cm²) ２ The extruder according to claim 1, wherein the extruder is as described in claim 1.

7. The extruder according to claim 1, wherein the material includes biomass.

8. The extruder according to claim 1, wherein the diameter of the inner bore of the injector is 2 mm to 4 mm.

9. The extruder according to claim 1, wherein the diameter of the inner bore of the injector is 2 mm.

10. The extruder according to claim 1, wherein the injector assembly includes two or more injectors.

11. The extruder according to claim 1, wherein the injector assembly includes eight or more injectors.

12. The extruder according to claim 1, wherein the injector assembly includes 16 or more injectors.

13. An extruder according to claim 1, wherein the barrel comprises the injector arranged in a spiral or circular pattern around the barrel.

14. An extruder according to claim 13, wherein the injector is perpendicular to the barrel.

15. An extruder according to claim 13, wherein one or more of the injectors are pre-configured to inject steam at a rate of 30 to 50% per dry weight of the material in the barrel.

16. A method for injecting a liquid or vapor into a discharge valve body of an extrusion system, wherein the extrusion system comprises an extruder barrel, the extruder barrel comprises an inner chamber including a feed section and a reaction section, and the extrusion system is constructed and arranged such that a vapor-impermeable plug is formed by compressing biomass in a high-pressure section separating the feed section and the reaction section. a. A step of providing multiple injection ports, wherein the injection ports penetrate the outer wall of the discharge valve body, b. A step of introducing an injector into the plurality of injection ports, wherein the injector has a lumen with a diameter of 6 mm or less, c. Inject steam into the extruder barrel or the discharge valve body to achieve a pressure of 10.55 to 56.25 kgf / cm² within the extruder barrel or the discharge valve body. ２ The steps include maintaining a pressure of (150-800 psi) and d. A method comprising the step of injecting liquid into the discharge valve body.

17. The method according to claim 16, The plurality of injection ports penetrate the outer wall of the extruder barrel and the outer wall of the discharge valve body. e. A method further comprising the step of injecting liquid into the extruder barrel or the discharge valve body via the injector.

18. A method according to claim 16, wherein the plurality of injection ports are arranged in a spiral or circular pattern around the extruder barrel.

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