Processes, methods, and systems for processing of biomass materials

Abstract

Disclosed herein is a system comprising, a first chamber configured to receive a biomass material, a first threaded shaft configured to convey the biomass material through the first chamber and to apply a first force to the biomass material to cause a first amount of liquid to be extracted from the biomass material to generate a reduced moisture content biomass material, a second chamber configured to receive the reduced moisture content biomass material, and a second threaded shaft configured to convey the biomass material through the second chamber and to apply a second force to the reduced moisture content biomass material to cause a second amount of liquid to be extracted from the reduced moisture content biomass material.

Description

PROCESSES, METHODS, AND SYSTEMS FOR PROCESSING OF BIOMASS MATERIALSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application Serial No. 63 / 663,248, filed on 24 June 2024, which is incorporated herein by reference in its entirety as if fully set forth below.FIELD OF THE DISCLOSURE

[0002] The present disclosure relates generally to biomass processing. Particularly, embodiments of the present disclosure relate to mechanical processing of biomass materials, and systems and methods of making and using the same.BACKGROUND

[0003] Processing raw materials into useable and value-added products is a constant area of human innovation that is consistently developing. Wood or other lignocellulosic materials, for example, can be processed into useable and value-added products such as paper, packaging, biofuel, pellets and the like. A current problem with such processes, as with all processes, is high energy inputs and the addition of harsh chemicals required to obtain valuable products. In conventional methods for processing lignocellulosic materials, large amounts of shaft work are required to mill the materials to desirable sizes, and large amounts of added energy (e.g., heat and / or pressure) and chemicals (e.g., strong acids or bases) can be necessary to remove excess water content and inhibiting constituents. Producing useful products in an energy-efficient manner is desirable to expand the design space of a number of industries, such as construction / infrastructure, building, energy, energy production, packaging, lawn / garden products, farming, food production, antipollution, and the like. Additionally, preserving the content of the raw organic materials, such as VOCs, nutrients, organic acids, and the like, is desirable to obtain other useful co-products during processing. Such co-products present attractive opportunities to produce value-added products and improve margins of processing.

[0004] What is needed, therefore, are processes, methods, and systems for producing solid and liquid products from lignocellulosic (or other) feedstocks in an energy-efficient manner. Embodiments of the present disclosure address this need as well as other needs that will become apparent upon reading the description below in conjunction with the drawings.BRIEF SUMMARY OF THE INVENTION

[0005] The present disclosure relates generally to biomass processing. Particularly, embodiments of the present disclosure relate to mechanical processing of biomass materials, and systems and methods of making and using the same. There is provided, in accordance with an example of the disclosed technology, a system. The system can include a first chamber configured to receive a biomass material. The system can include a first threaded shaft. The first threaded shaft can be configured to convey the biomass material through the first chamber and to apply a first force to the biomass material to cause a first amount of liquid to be extracted from the biomass material to generate a reduced moisture content biomass material. The system can include a second chamber. The second chamber can be configured to receive the reduced moisture content biomass material. The system can include a second threaded shaft. The second threaded shaft can be configured to convey the biomass material through the second chamber and to apply a second force to the reduced moisture content biomass material to cause a second amount of liquid to be extracted from the reduced moisture content biomass material.

[0006] The disclosed technology can include a system. The system can include a plurality of chambers. The plurality of chambers can be configured to receive a biomass material. At least one chamber of the plurality of chambers can include a plurality of apertures. The system can include a plurality of threaded shafts. Each threaded shaft of the plurality of threaded shafts can be disposed at least partially in a respective chamber of the plurality of chambers and configured to apply a force to the biomass material and to convey the biomass material through the respective chamber. The system can include a plurality of motors. Each motor of the plurality of motors can be in mechanical communication with a respective threaded shaft of the plurality of threaded shafts and configured to cause the respective threaded shaft to rotate independent of the other threaded shafts of the plurality of threaded shafts.

[0007] The disclosed technology can include a method of generating a fibrous pulp from a lignocellulosic feedstock. The method can include feeding the lignocellulosic feedstock to a first chamber. The method can include applying, with a first threaded shaft in the first chamber, a first force to the lignocellulosic material. The first force can cause a first amount of moisture to be extracted from the lignocellulosic feedstock to generate a reduced moisture content lignocellulosic feedstock. The method can include feeding the reduced moisture content lignocellulosic feedstock to a second chamber. The method can include applying, with a second threaded shaft in the second chamber, a second force to the lignocellulosic material. The secondforce can cause a second amount of moisture to be extracted from the reduced moisture content lignocellulosic material to generate a further reduced moisture content lignocellulosic material. The method can include exposing the further reduced moisture content lignocellulosic material to an environment having a pressure lower than a pressure inside the second chamber to induce a cellular explosion in a plurality of cells of the further reduced moisture content lignocellulosic material to generate the fibrous pulp.

[0008] These and other aspects of the present invention are described in the Detailed Description of the Invention below and the accompanying figures. Other aspects and features of embodiments of the present invention will become apparent to those of ordinary skill in the art upon reviewing the following description of specific, exemplary embodiments of the present invention in concert with the figures. While features of the present invention may be discussed relative to certain embodiments and figures, all embodiments of the present invention can include one or more of the features discussed herein. Further, while one or more embodiments may be discussed as having certain advantageous features, one or more of such features may also be used with the various embodiments of the invention discussed herein. In similar fashion, while exemplary embodiments may be discussed below as device, system, or method embodiments, it is to be understood that such exemplary embodiments can be implemented in various devices, systems, and methods of the present invention.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate multiple embodiments of the presently disclosed subject matter and serve to explain the principles of the presently disclosed subject matter. The drawings are not intended to limit the scope of the presently disclosed subject matter in any manner.

[0010] Fig. 1 A illustrates a machine used for some processes according to some embodiments of the present disclosure.

[0011] Fig. IB illustrates a machine used for some processes according to some embodiments of the present disclosure.

[0012] Fig. 1C illustrates an exemplary process according to some embodiments of the present disclosure.

[0013] Figs. 2A-B illustrate a portion of a threaded shaft for a machine used for some processes according to some embodiments of the present disclosure.DETAILED DESCRIPTION

[0014] Disclosed herein is a solution for a compressive explosion-based process that can concurrently dewater, dry, fractionate, extract and separate cell-based (biological or biomass) materials and particularly those that (a) are viewed as recalcitrant in terms of their reluctance to be industrially processed and (b) have liquid co-products that have market value. The presently disclosed technology can be agnostic to the state of the biomass material. For example, in addition to processing lignocellulosic feedstock, the presently disclosed technology can apply very well to processing cellulosic spent materials, such as coffee grains, waste paper, woody construction waste, poultry litter, poultry residuals such as feathers, biosolids, compost production, and the like.

[0015] By way of another example, the liquid extract from orchard grass, when applied to a test lawn, removed the dandelions and rapidly grew the grass. This result would enable a municipality or lawn service to process the cut grass and then reapply the extract back on the lawn. The water savings as well as the avoidance of harsh fertilizers would have broad appeal. The grass extract has additional potential also. In another test, the orchard grass extracts were processed by heating. The proteins coagulated, thereby making this process suitable for the much-pursued leaf protein concentrate applications and a very viable alternative to the Pro- Xan process. Such advancements can greatly expand the design space of, for example, the “meatless protein” market.

[0016] The presently disclosed technology not only can concurrently dewater, dry, fractionate, extract and separate plant material, but it also can fundamentally transform the resulting fiber with the plant cells completely exposed. All this renders the byproducts, e.g., fiber and liquid extract, ready for the follow-up processing for many industry applications such as bioenergy feedstock, advanced materials production, absorbents manufacture, soil amendments, water filtration systems, strengthening agents for the construction industry, inputs for Biopharma, fungus and yeast substrates, and many more, some examples of which will be outlined below.

[0017] The presently disclosed technology can condition wood fiber to an extent that it is optimized for inputs for industries that utilize pulp, such as paper-making industries, fiber board manufacturing, and the like. The tremendous reduction in particle size can allow for quicker conversion. Many products are now feasible, most notably carbonized products such as graphene and the like. In terms of graphene, such a process can enable lower-cost production, allowing it to be added to fabrics for better aesthetics and performance, such as in terms ofmoisture wicking and pest barriers (e.g., mosquitoes.) Graphene is also perfectly suited as an input for degradable electronics, renewable carbon materials for electrochemical energy storage, and circuit substrates, thereby replacing millions of tons of hazardous material placed in landfills around the world every year.

[0018] Additionally, advanced processes are being developed that utilize organic phenol- based chemistries such as humic acid to serve as building blocks for advanced materials used in green energy systems such as supercapacitors. The liquid extract produced by processes of the present disclosure can be rich in humic and fiilvic acids, as well as other organic acids.

[0019] The environmental challenges imposed by an oversupply of plastics in the world necessitate solutions for recycling. By utilizing products of the present disclosure, less plastic can be used. Such materials are often referred to as wood-plastic composites. In combination with products of the present disclosure, better cross-linking can occur with a plastic feedstock. This improved effect can enable improved consumer goods, such as composite decking. Moreover, the products disclosed herein provide a small particle size necessary to simulate the appearance of real wood and achieve improve material properties.

[0020] Research is also advancing that produces sustainable polymers made from carboxylic acid that prevents misting of jet fuel in the event of crash. Certain products of the present disclosure are rich in organic carboxylic acids.

[0021] 3D printing is now mainstream, but the preponderance of materials utilized is largely synthetic. Products of the present disclosure can be used as a filament for 3D printing, due to improved form-factor and small particle size.

[0022] Cellulose nanomaterials such as nanocrystals and nanofibrils are very small, cylinder shaped particles that are produced from lignocellulosic materials. The present technology can accelerate its production and reduce its associated cost. Cellulose nanomaterials are currently being used in many industries, fields and disciplines around the globe, in various applications such as chemical manufacturing, pulp and paper, composites, food packaging and cosmetics.

[0023] Cellulose nanocrystals are unique nanomaterials derived from the most abundant and almost inexhaustible natural polymers, such as cellulose. The material has a wide and exciting potential in many industries. The exposed cellulose once viewed as cost-prohibitive to obtain from trees and the like can now be converted into nanocrystals for use in medical, material sciences, and electronics. The presently disclosed technology can condition the wood fiber by consolidating the lignin into exposed “drops” on the cellulose surface, which consequently lays the cellulose barer. This effect then can allow developing industrial processes to produce thecellulose nanocrystals by removing the lignin in more-cost effective and more environmentally friendly way.

[0024] Processes and products of the present disclosure can serve as feedstock to allow for the production of sustainable polymers from fragrant molecules often contained in aromatic species such as pine, witch hazel, eucalyptus, and the like. Given the struggles evidenced in the world today from polymers and plastics produced by conventional petroleum feedstocks, such processes of the present disclosure can provide an improvement in polymer production.

[0025] Recent advances in electrochemistry have occurred that simplify the creation of valuable and coveted molecules that are used for drugs, electronics, and the like. Processes of the present disclosure can generate important reactive intermediate molecules known as a carbocation needed for ether synthesis from inexpensive carboxylic acids. Products of the presently disclosed technology is rich in carboxylic acids, thereby providing even less- expensive feedstocks for this critical process.

[0026] The unique and cost-effective manner in which raw, green lignocellulosic feedstock can be conditioned according to the technology of the present disclosure makes available many applications in horticulture. These applications range from replacing non-sustainable growing substrates such as peat and other nonrecyclables, to producing very effective and organic soil amendments to applying the liquid extract as organic fertilizers.

[0027] It is found that products of the present disclosure produced by the chemo-mechanical cellular explosion of lignocellulosic material can preserve freshly cut plants such as industrial hemps, tomato stem, and / or succulents for extended periods of time before putting into soil for rooting. Applying the products to vegetables can also preserve them for extended shelf life.

[0028] Typical greenhouse substrates consist of peat and perlite. Peat is a hydrocarbon and non-renewable. Processes of the present disclosure can produce a wood feedstock in a formfactor conducive to growing mediums. A portion of products from the present technology can be substituted for a portion of the peat, thus reducing the dependence on hydrocarbons. Additionally, products of the present disclosure can inherently serve as an inoculated mushroom growing media. Due to its expanded form-factor, the products can also compress into a growing and erosion control mats and does so at significantly reduced cost.

[0029] Hydro mulch is a mix of fiber / grass seed / fertilizer that is applied to steep inclines where erosion could occur. Presently, mechanically treated wood fiber is used as a base material. In contrast, products of the present disclosure can offer a superior product produced with substantially less energy and emissions at a much lower price. The consequence of this isless top soil erosion and cleaner waterways. Hydroseeding is a mixture of grass seed, fertilizer and wood fiber. Products of the present disclosure can provide greater moisture absorbency, thus helping to accelerate seed germination.

[0030] Demand for natural and organic food is rapidly increasing. Conversely, continuous farming drains the soil of its vitality. Due to its nature produced by organic acids, sugars, humic / fulvic acids and a very diverse amount of amino acids, products of the present disclosure can create a soil environment that attracts the necessary microbial activity that is vital for the fixation of nitrogen and other nutrients in the soil.

[0031] The presently disclosed technology can allow for the extraction of bio-stimulants found in willows and other water-laden feedstocks that were once considered ineffective for processing due to the cost associated. Additionally, the characteristics of products of the present disclosure can provide for very specialized gene expression and controls once considered not possible by organics. The unadulterated nature and quantities of contained organic chemicals such as the various glutamine concentrations found in different species provides for very powerful horticultural methodologies. For example, a liquid extract produced from processes of the present disclosure utilizing hardwood species can be used as a cloning agent for pecans. Pecan trees can be started from seed or cloned from stems of live trees. The process of cloning presents challenges in the survival of the clone. The quicker that the clone is able to add healthy roots, the chances of its survival increase dramatically. The numerous organic acids found in products of the present disclosure are the building blocks for producing growth hormones that stimulate healthy and rapid root growth.

[0032] In another example, for certain species of feedstocks and particularly for that of the bark components, the presently disclosed technology can extract a considerable amount of tannin. Research is proving that remarkable changes in soluble nitrogen manifests in soils after regular applications of tannin and related phenolic compounds. These tannins are utilized by soil microorganisms as substrates, thereby increasing microbial demand for nitrogen and immobilization in microbial biomass. This increase translates to more nitrogen is being fixed by the microbes, making more nitrogen available to plants.

[0033] Products of the present disclosure can also offer pest control and defensive mechanisms to the horticultural markets once considered the monopolized domains of synthetic chemicals. Allelopathic effects made possible by products disclosed herein can serve as an example: the liquid extracts can enable new but sustainable approaches to weed control. The liquid extracts from hardwood can be very effective for nematode control also, which isimperative to preserve millions of dollars in produce. Various combinations of phenols and over-applications of other bio-stimulants and amino acids are very effective growth control options to that of synthetic chemicals.

[0034] The presently disclosed technology, such as fiber and liquid extracts produced from it, offers the construction markets inputs never available. The availability of the fiber can catalyze the development of newly engineered lumber, concrete, and asphalt formulations, resins, and preservatives.

[0035] Wood fiber is a very good sound insulator. Such products are popular in Europe and are gaining ground in the United States. Products of the present disclosure can provide even better insulation, due to improved densification of the smaller particle sizes. Such products of the present disclosure can also enable improved fiber-based or particle-based boards such as Medium Density Fiber (MDF). For such applications as fiber cement siding, the expanded format of the products disclosed herein can provide additional support to concrete based siding. The presently disclosed technology also allows the use of alternative board material such as giant reed and the like, thereby improving the carbon cycling for the environment. The format of the products of the present disclosure can also allow for less binder to be utilized in the board construction, thereby granting another environmental advantage.

[0036] Products of the present disclosure can also be used in the advancement of engineering boards and siding. Lignin is a major component of wood fiber and is composed of various phenol groups. Using the phenol groups contained in the extract, sustainable foam boards may now be constructed. This is made possible by the ability of the present technology to produce a portion of the lignin contained in the wood fiber as solubilized in a liquid extract. These extracted phenols can then be utilized in the formulation of foam boards.

[0037] Products (e.g., fiber) disclosed herein can also help to reinforce concrete. In order for concrete to support high loading, it must be reinforced. Typically, rebar steel is used to reinforce concrete. The products of the present disclosure can be a very good reinforcement mechanism for concrete.

[0038] The technology disclosed herein can be used to make engineered bamboo articles, such as flooring. Before bamboo can be converted into value added products, it has to be broken down. The processes of the present disclosure can allow for the bamboo fiber to be broken down into a material that can easily be converted to valuable products such as bamboo composite boards and bamboo flooring.

[0039] The technology disclosed herein can allow for the partial removal of lignin from lignocellulosic fiber. This lignin can be collected in a liquid extract. From this extract, the lignin can be isolated and then utilized as a component for natural asphalt.

[0040] Certain species of wood such as teak, red oak, and the like produce liquid extracts via the presently disclosed technology that can act as natural wood preservative. Such processes are generally expressed as acetylation. Acetic acid contained in the extract can create an environment where mold cannot grow. Once considered not scalable to a sufficient and cost- effective industry magnitude, the presently disclosed technology can make acetylation possible.

[0041] The presently disclosed technology can contribute significantly to environmental and remediation markets. Products of the present disclosure can create various adsorbents and filter medias, as well as accelerate the composting of biosolids. Adsorbents are utilized in nearly every industrial application, where spills can be a problem. The products disclosed herein can show much higher absorbency rates than commonly used material such as clay or sawdust.

[0042] Filtration is a part of many industrial processes. Wood fiber is used in many applications. Filtration effectiveness has a direct correlation to the surface area of the filter media. Products of the present technology can provide significantly greater surface area than typical machined wood fiber. The processes disclosed herein can also be very scalable thereby allowing large issues to be addressed, such as the control of red-tide and algae issues caused by fertilizer run-off.

[0043] Bio-solids are becoming a very large problem in the world. Disposal via land applications is now proving to be a less-than-optimal mechanism due to metals and other materials contained. Composting is quickly becoming the preferred approach to disposal. The products produced by the present technology can contain sugars and other molecules that rapidly accelerate the growth of necessary bacteria needed. Subsequently, the metabolites of these bacteria build upon the already-rich nutrient concentration contained in the composted bio-solids.

[0044] Additionally, the products produced by the present disclosed technology can be rich in amino acids that are proving to be very valuable phytopharmaceutical inputs to combat cancer and other diseases. Diethyl ether extracts and alkaloids can make possible anticancer medications for the treatment of breast cancer and dysfunctional maladies to human health. Additionally, it has been found that quantitative reductions in short-chain fatty acids, especially butyrate, contribute to the progression of chronic kidney disease and gastrological issues. Theproducts disclosed herein can be rich in such short-chain fatty acids when fermented and processed. The products can also contain berbeine depending on feedstock species, which assists the lowering of sugar and leads to a maintenance of healthy cholesterol levels; this serves as a powerful tool for the treatment of diabetes.

[0045] Additionally, various plant-based and non-plant -based feedstocks can be extracted for specific medicinal purposes. The present technology can be very effective in hemp and cannabis processing. The liquid extracts render valuable cannabinoids and other nutraceuticals that offer new treatments. Various antibacterial properties of flavonoids from kino (sap) of the eucalyptus tree are also made possible by our technology.

[0046] The present technology can contribute significantly to human health applications. Various components of the products of the present disclosure can be used to produce insecticides and pesticides from such obstinate and exotic feedstock as oak and bloodroot. The technology also makes possible very low-cost products for aromatherapy and other terpenes for engineered aroma inputs to cannabis and specialized / engineered wines.

[0047] Exper imentation is also underway to use the present technology for the production of insoluble dietary fiber and its inclusion as a food additive. Numerous studies have revealed increased physiological and psychological improvements when good bacteria utilize this type of insoluble fiber as substrates during their gastrological migration through the body.

[0048] Aside from the gastrological benefits, the short- and medium-chain fatty acids made available via products of the present disclosure can exhibit antimicrobial activity for oral microorganisms. This type of treatment will contribute to the prevention of tooth and gum diseases.

[0049] Mold and mildew have been a growing problem with residential housing for decades. Harsh chemicals and sprays are the conventional approach to eradicating the issue. However, by using the presently disclosed products produced from hardwoods other phenol-rich feedstocks, the present technology can enable an organic mold control mechanism for mold- infested basements and the like.

[0050] The presently disclosed technology can have immediate and direct applications to agricultural markets. The disclosed products can enhance litter and bedding applications, as well as improve animal health when added to feed and drinking water. The disclosed products can also have direct applications to the prevention and the treatment of certain animal disease and illness. Additionally, the present technology can also contribute to forestry and thereby participate in a circular economy when applied to wood fiber that is specifically farmed.

[0051] The products disclosed herein, such as fibrous materials, due to having very large surface area, can create animal bedding that is extremely adsorbent. This attribute allows harmful moisture and degassing (e.g., ammonia) to be managed. The products can also be very effective for use in drying and warming certain species of livestock. For example, when pigs are bom, they are covered in moisture and their skin sensitivities are often high. By applying such fibrous materials to the pigs’ skin after birth, the moisture can be rapidly wicked and the skin dried thereby allowing their body temperature to rise more quickly.

[0052] The large surface area can also allow bio-char to be produced more efficiently than conventional methods today. Bio-char is also a very effective adsorbent and particularly in sequestering ammonia. Blending biochar with products of the present disclosure can serve as a healthier environment for livestock, and particularly poultry where moisture and ammonia are problematic.

[0053] In terms of animal feed, the present technology can contribute to the growth and care of many species and including fish. The organic acids in products of the present disclosure can serve as an alternative to antibiotics. Studies indicate that pigs fed with a diet inclusive of organic acids show improved average daily feed consumption and average daily weight gain. Some products of the present disclosure can contain tryptophan and a substrate of very small particle-sized fibers that have a form-factor similar to a digestate. Tryptophan is an essential amino acid in swine diets that is important for stimulating feed intake and subsequently, growth performance. Monogastric organisms such as pigs do not produce tryptophan, so it must be included as part of their dietary supplement.

[0054] Products of the present disclosure can also serve as a very effective substrate for various yeasts, such as Candida Utilis, that create proteins. These proteins have potential for fish feed alternatives. Additionally, for some exotic fish species that have ruminant-like digestive systems, the exposed cellulose exhibited in products of the present disclosure can be more quickly digested as a food source. Lastly, feedstocks such as seaweed and other high- protein herbaceous feedstocks can be processed by the present technology for alternative, plantbased proteins as well. Substituting plant-based proteins for conventional fishmeal returns significant environmental dividends.

[0055] For ruminants such as cattle, sheep, and goats, the present technology can offer a number of advantages. Ruminant digestive systems have the potential to digest lignocellulosic materials if the contained lignin is conditioned sufficiently to expose the cellulose. The presently disclosed technology can aggregate the lignin into “droplet” forms, thereforerendering the cellulose more accessible to the cellulases in the animal gut and thereby improving digestion and nourishment. Certain species of wood (e.g., larch) are also proven to boost cattle liver health, being that they are high in arabinogalactans, lignin, flavonoids, and diterpenes. Making available these types of feedstocks to ruminants, particularly those feedstocks once viewed as too recalcitrant would make a world-wide impact relative to human nutrition and well-being.

[0056] Certain sizes and specifically engineered form-factors of lignocellulosic fiber can enable a targeted activation of organic acids such as butyrate-2 that consequently produces specific microbiota in the animal gut. The ability of the present technology to process different fiber form-factors, for different species, is critical to the commercialization of this process. Beneficial modulation of the gut microbiome is also “butterflied” into numerous metabolic changes and interdependent pathways that produce short chain fatty acids. These types of prebiotic products are vital for the livestock industry to meet the demand for natural food products.

[0057] The presently disclosed technology can benefit poultry also. Recent consumers are shying away from poultry that are fed antibiotics. As antibiotics do improve the health and survivability of poultry, a possibility exists that traces of these antibiotics remain in the bird after slaughter. Tannins, due to their antimicrobial nature as well as fatty acids, have been proven to combat the growth of pathogens in poultry rearing. Products disclosed herein, such as a liquid extract, can contain and create the valuable fatty acids and tannins. As such, products of the present disclosure can be included in poultry feed and water systems to improve bird health without the addition of synthetic antibiotics.

[0058] In a recent finding, the butyric acid produced by the fermentation of certain products of the present disclosure when mixed with zinc has proven to reduce the occurrence of woody breast in commercial broilers in the poultry industry. Woody breast describes a quality issue stemming from a muscle abnormality in a small percentage of chicken meat. Although this does not pose a health risk to consumers, it causes the meat to be deemed undesirable.

[0059] The present technology can also have applications in agroforestry, commonly referred to as tree farming. Agroforestry is a type of agriculture that involves the planting, care, and sustainment of trees or other woody plants. Being that the products of the present disclosure can be originally derived from the xylem and phloem of a tree, once extracted and processed, they can provide a formulation of nutrients and care products for this industry. Prior to thepresent technology, the liquids in trees were evaporated off the fiber and converted to volatile organic compounds that created emission control challenges.

[0060] The presently disclosed technology can contribute directly to production of sustainable and clean energy. Applications can range from biofuels and bio-refineries, wood pellets, and even hydraulic fracturing industries for conventional fuels.

[0061] The present technology can utilize green (wet) feedstock to produce a conditioned and fractionated fiber that directly creates a highly-durable, low-moisture, and high-energy wood pellet. It can do so without the use of conventional sizing machinery such as hammer mills and without the need for enormously expensive indirect drying systems. The avoidance of these systems and their consequent capital and recurring costs offers the wood pellet industry a transformative paradigm shift; one that will eliminate the dependence on subsidies and create worldwide industry processing alternative and very available feedstocks once viewed as too wet to process such as forestry and farm residue, bamboo, waterborne biomass (e.g., algae, seaweed, kelp, etc.) and other high-moisture species.

[0062] The presently disclosed technology can also contribute to the value of conventional pelleting methods. Producing quality wood pellets with conventional means is a difficult challenge. With improved pellet durability as the goal, producers have searched extensively for an effective binder to improve pellet durability. When products of the present disclosure, such as dry pulp product, are mixed with conventionally-dried wood fiber, it can allow for greater densification of the pellet and better utilization of the lignin for binding.

[0063] The cellulosic component of lignocellulosic fiber has always been eyed as a potential base stock for cellulosic ethanol production. However, in order to be a viable feed stock, the lignin must be removed to some degree by the biorefineries to allow sufficient exposure of the cellulose to specific cellulases. The processes of the present disclosure can allow for the exposure and partial removal of lignin. Further processing can allow for the easy removal of the remaining lignin. Furthermore, the use of a low operating temperature can prevent the formation of inhibitors, which can have a negative impact on the effectiveness of the cellulases. The processes offer greater exposure of the cellulose, increasing enzymatic effectiveness. Such products can also be applied to the production of biobutanol and other bioenergy products. The format of certain products rendered from the presently disclosed technology can also now be suitable to make cleaner biorefining approaches effective. These include, but are not limited to, the organosolv and Simultaneous Saccharification and Fermentation (SSF) processes.

[0064] In terms of drilling industries such as natural gas and petroleum, the present technology can be applied also. For example, lost circulation material is used extensively in the drilling industry. It helps to retard mud loss into fractures or highly permeable zones. The smaller particle sizes produced by the presently disclosed technology allows for a product with better flowability and permeability to seal cracks and crevices inherent in drilling for oil. In another example, tannates from products of the present technology have proven to be a very good, environmentally-safe drilling fluid.

[0065] The presently disclosed technology can also contribute directly to the food and beverage market. Products of the present technology can be used to better a number of the associated senses, including but not limited flavor enhancements, palate sensations, and smell augmentation. The products can also participate in nutrient upgrades and the production of sweetening aids and as supporting ingredients for foods containing flour.

[0066] Utilizing the tannins in products of the present disclosure and specifically the ellagitannins contained therein, wine producers can engineer the “dryness” of their product and emulate that effect conventionally produced in the oxidation process via time as made available by the oak barrels.

[0067] Similarly, some of the phenolic compounds found in products of the present disclosure can be supplemented into food products as a nutritional value; the anthocyanin in certain lignocellulosic species has been proven to improve cognitive functioning.

[0068] In another example, utilizing the SSF process subsequent to pulping, the acetoin produced can be used as a food flavoring in baked goods. The present technology can also participate very actively in the production of torula yeast, scientifically known as Candida utilis. Products of the present disclosure can serve as a substrate for its growth. It is widely used as a flavoring in processed foods and pet foods. The form-factor of other products of the present disclosure can also accelerate the production of food-grade cellulose. This product is regularly found in as a thickener and bulker for tomato sauces, salad dressings, ice creams, energy bars, pasta, bread, and many other products.

[0069] The present technology can also contribute very effectively to the production of xylitol, a naturally occurring alcohol found in certain lignocellulosic feedstocks. It is widely used as a sugar substitute and in "sugar-free" chewing gums, mints, and other candies. The presently disclosed processes can condition the feedstock, such as birch, far more cost- effectively, lowering the overall cost. It also allows markets such as pulp-and-paper and biorefineries to establish co-product streams where conventionally that opportunity was lost.

[0070] Pulp is the fibrous material produced either chemically or mechanically (or by some combination of chemical and mechanical means) from wood or other cellulosic raw material. The wood cell has a nonliving cell wall, made of cellulose fibers, hemicellulose, and lignin which gives strength and support to the cell wall. Lignin holds the cellulose fibers together in the cell wall. Therefore, lignin must be removed to separate the individual cellulose fibers, which eventually become paper.

[0071] Conventional pulping processes inflict very difficult environmental issues. In fact, the industry is traditionally one of the largest contributors of industrial air, water, and land emissions in the world primarily due to the harsh chemicals used. Thousands of tons of pollutants are released each year. The industry is also one of the largest consumers of energy and water in the world, using more water to produce one ton of product than any other industry.

[0072] The industry is experiencing tremendous pressure from society to address these challenges. Research is being applied to the development of sustainable pulping mechanisms, including the use of environmentally-friendly chemicals and lower-energy approaches to mechanical conditioning of the feedstock.

[0073] Steam explosion is a process of great promise for the industry. However, in a conventional form, it has shown many economic problems which include the insufficient destruction of lignin-carbohydrate complex and, in the case of biorefinery and paper application, possible generation of fermentation inhibitors. Additionally, for the engineered lumber segment, the fiber also requires drying before it can be processed further.

[0074] In terms of bio-refineries and paper production, as a result of the effectiveness of processes of the present disclosure, cost-effective pulping processes such as organosolv pulping are now possible. This method uses organic solvents to break down the lignin and hemicellulose. This method is considered to be the cleanest of contemporary methods in use today.

[0075] In terms of products, the present technology can substantially reduce the cost necessary to produce cardboard, molded pulp, and fluff pulp as well. Most of the feedstock required to make these products today is obtained from the recycling industry. The feedstock requires much processing to render it clean and useful again, consequently creating additional environment issues.

[0076] Engineered lumber includes manufactured wood products which are produced by binding fiber together with adhesives, or other methods of fixation to form composite materials. The present technology can contribute directly to the production of densified wood, MediumDensity Fiberboard (MDF), and particle board. The present technology can also contribute directly to the developing transparent wood markets as well.

[0077] All the aforementioned engineered lumber products are manufactured from wood chips, sawmill shavings, or even sawdust, and a synthetic resin or other suitable binder, which is pressed and extruded. Conventionally, the feedstock necessary for this production must be dried; the presently disclosed technology can inherently dry the feedstock and avoid this costly step in the process. Emissions are also consequently avoided, and the fractionated form-factor of the fiber produced from processes of the present disclosure can be conducive to creating a strong product. The products when produced conventionally also require binders, most of which are not sustainable and cause additional environment challenges, both in production and in disposal / rccycling. The presently disclosed technology can require less or no binder. Additionally, the liquid extract produced by the presently disclosed technology can be developed into a sustainable binding product to serve other market interests as discussed previously.

[0078] For example, the presently disclosed technology can process spent coffee grains very efficiently and make them available for pellet production. The pellets can then be incinerated as solid fuel for heat or electricity production or utilized in the rapidly-increasing grilling industry as a flavored smoke product. In another example, the present technology can process poultry feather quills for the production of keratin that provides a never-available form-factor for thin film applications as well as many others. In another example, the present technology can process citrus peels into a very unique form that allows it to be more- efficiently used a number of industrial applications. The extracted liquid from processes of the present disclosure also has much potential, particularly in the pursuit of organic chemical synthesis.

[0079] Although certain embodiments of the disclosure are explained in detail, it is to be understood that other embodiments are contemplated. Accordingly, it is not intended that the disclosure is limited in its scope to the details of construction and arrangement of components set forth in the following description or illustrated in the drawings. Other embodiments of the disclosure are capable of being practiced or carried out in various ways. Also, in describing the embodiments, specific terminology will be resorted to for the sake of clarity. It is intended that each term contemplates its broadest meaning as understood by those skilled in the art and includes all technical equivalents which operate in a similar manner to accomplish a similar purpose.

[0080] Herein, the use of terms such as “having,” “has,” “including,” or “includes” are open- ended and are intended to have the same meaning as terms such as “comprising” or “comprises” and not preclude the presence of other structure, material, or acts. Similarly, though the use of terms such as “can” or “may” are intended to be open-ended and to reflect that structure, material, or acts are not necessary, the failure to use such terms is not intended to reflect that structure, material, or acts are essential. To the extent that structure, material, or acts are presently considered to be essential, they are identified as such.

[0081] By “comprising” or “containing” or “including” is meant that at least the named compound, element, particle, or method step is present in the composition or article or method, but does not exclude the presence of other compounds, materials, particles, method steps, even if the other such compounds, material, particles, method steps have the same function as what is named.

[0082] It is also to be understood that the mention of one or more method steps does not preclude the presence of additional method steps or intervening method steps between those steps expressly identified.

[0083] The components described hereinafter as making up various elements of the disclosure are intended to be illustrative and not restrictive. Many suitable components that would perform the same or similar functions as the components described herein are intended to be embraced within the scope of the disclosure. Such other components not described herein can include, but are not limited to, for example, similar components that are developed after development of the presently disclosed subject matter.

[0084] As used herein, the term “pulp” is understood to include lignocellulosic materials of varying moisture content, physical characteristics, bulk density, or species having been dewatered, dried, fractionated, and expanded.

[0085] Disclosed herein are processes, machines, and methods for use in conjunction with the aforementioned processes.

[0086] Also disclosed herein are a liquid product made by the aforementioned processes, a solid product and / or dry pulp product and / or fibrous pulp material made by the aforementioned processes.

[0087] Disclosed herein are processes, systems, and methods for processing and / or producing materials comprising a fibrous material. The fibrous material can comprise natural fibers, such as cellulosic fibers. For instance, the fibrous material can comprise wood fibers. The wood fibers can be provided in the form of a wood pulp or other lignocellulosic fibrous source. Forinstance, the wood fibers can be provided in the form of southern bleached softwood Kraft pulp. Suitable examples of fibrous sources can include, but are not limited to, fluff pulp, dissolving pulp, mechanical pulp, chemical pulp, chemo-mechanical pulp, recovered paper pulp, semi-mechanical pulp, semi-chemical pulp, soft cook fully chemical pulp, consumer waste products such as clothes, viscose, rayon, lyocell, or any combination thereof. Additionally, the fibrous material can be any material that comprises lignin and hemicellulose.

[0088] The fibrous material can also be in the form of wood chips, wood fibers, or other wood sources. Other suitable examples of wood sources include hardwood, softwood, aspen, balsa, beech, birch, mahogany, hickory, maple, oak, teak, eucalyptus, pine, cedar, juniper, spruce, redwood, or any combination thereof. It is understood that any other known sources of wood fibers and lignocellulosic materials can be used. Alternatively, the fibrous material can be provided in the form of natural non-wood or alternative fibers. Suitable examples of natural non-wood alternative fibers that can make up the fibrous material can include, for example, barley, bagasse, bamboo, wheat and wheat straw, flax, hemp, kenaf, arundo donax, com stalk, jute, ramie, cotton, wool, rye, rice, papyrus, esparto, sisal, grass, abaca, shrubs, miscanthus, giant reed, alfalfa, woody vines, flowers, wisteria, honeysuckle, clematis, kudzu, coffee and other beans / legumes, stevia and other functional plants, other lignocellulosic species, fastgrowing grasses, or any combination thereof. It is understood that the fibrous material can include any other natural fibers from any source or any combination of natural fibers. In some embodiments, the fibrous material can be provided from cellulosic fibers that can be prepared from the wood pulp or otherwise provided fiber source by means of a mechanical process such as hammer-milling or other comminution processes.

[0089] The fibrous material can comprise fibers having an average length from approximately 0.01 mm to 12 mm. For example, the fibrous material can comprise fibers having an average length of 0.01 mm or greater (e.g., 0.05 mm or greater, 0.10 mm or greater, 0.15 mm or greater, 0.20 mm or greater, 0.25 mm or greater, 0.30 mm or greater, 0.35 mm or greater, 0.40 mm or greater, 0.45 mm or greater, 0.50 mm or greater, 0.55 mm or greater, 0.60 mm or greater, 0.65 mm or greater, 0.70 mm or greater, 0.75 mm or greater, 0.80 mm or greater, 0.85 mm or greater, 0.90 mm or greater, 0.95 mm or greater, 1.0 mm or greater, 1.1 mm or greater, 1.2 mm or greater, 1.3 mm or greater, 1.4 mm or greater, 1.5 mm or greater, 1.6 mm or greater, 1.7 mm or greater, 1.8 mm or greater, 1.9 mm or greater, 2.0 mm or greater, 2.1 mm or greater, 2.2 mm or greater, 2.3 mm or greater, 2.4 mm or greater, 2.5 mm or greater, 2.6 mm or greater, 2.7 mm or greater, 2.8 mm or greater, 2.9 mm or greater, 3.0 mm or greater, 3.5 mmor greater, 4.0 mm or greater, 4.5 mm or greater, 5.0 mm or greater, 5.5 mm or greater, 6.0 mm or greater, 6.5 mm or greater, 7.0 mm or greater, 7.5 mm or greater, 8.0 mm or greater, 8.5 mm or greater, 9.0 mm or greater, 9.5 mm or greater, 10 mm or greater, 10.5 mm or greater, 11 mm or greater, or 11.5 mm or greater).

[0090] In some embodiments, the fibrous material can comprise fibers having an average length of 12 mm or less (e.g., 11.5 mm or less, 11 mm or less, 10.5 mm or less, 10 mm or less,9.5 mm or less, 9.0 mm or less, 8.5 mm or less, 8.0 mm or less, 7.5 mm or less, 7.0 mm or less,6.5 mm or less, 6.0 mm or less, 5.5 mm or less, 5.0 mm or less, 4.5 mm or less, 4.0 mm or less,3.5 mm or less, 3.0 mm or less, 2.9 mm or less, 2.8 mm or less, 2.7 mm or less, 2.6 mm or less,2.5 mm or less, 2.4 mm or less, 2.3 mm or less, 2.2 mm or less, 2.1 mm or less, 2.0 mm or less,1.9 mm or less, 1.8 mm or less, 1.7 mm or less, 1.6 mm or less, 1.5 mm or less 1.4 mm or less, 1.3 mm or less, 1.2 mm or less, 1.1 mm or less, 1.0 mm or less, 0.95 mm or less, 0.90 mm or less, 0.85 mm or less, 0.80 mm or less, 0.75 mm or less, 0.70 mm or less, 0.65 mm or less, 0.60 mm or less, 0.55 mm or less, 0.50 mm or less, 0.45 mm or less, 0.40 mm or less, 0.35 mm or less, 0.30 mm or less, 0.25 mm or less, 0.20 mm or less, 0.15 mm or less, 0.10 mm or less, 0.05 mm or less).

[0091] In some embodiments, the fibrous material has a length of 0.01 mm to 12 mm (e.g., 0.3 mm to 7 mm, 0.5 mm to 5 mm, 0.7 mm to 2.8 mm, 2.9 mm to 8 mm, 8 mm to 12 mm, 0.01 mm to 1 mm). In some embodiments, the fibrous material comprises a blend of one or more fibers that are of different average fiber lengths. In other words, in some embodiments, the fibrous material has bimodal (or trimodal, etc.) average fiber length. The fibrous material can, in some examples, have an average length of fibers from about 1 angstrom to about 5000 microns.

[0092] The fibrous material can comprise fibers having various cross-sectional shapes (e.g., round, scalloped oval, cruciform, hexagonal, etc.). The fibrous material can have a cross- sectional size based on the cross-sectional shapes. As used herein, the term “cross-sectional size” is understood to refer to the greatest dimension of a plane perpendicular to the length of the fibers (i.e., the diameter in a cylindrical fiber, the diagonal in a rectangular fiber). In some embodiments, the average maximum cross-sectional size of the fibers in the fibrous material (i.e., the average diameter for a round fiber) is from 100 nanometers to 1000 microns. In some embodiments, the fibrous material can have an average maximum cross-sectional size of 100 nanometers or greater (e.g., 150 nanometers or greater, 250 nanometers or greater, 350 nanometers or greater, 450 nanometers or greater, 550 nanometers or greater, 650 nanometersor greater, 750 nanometers or greater, 850 nanometers or greater, 950 nanometers or greater, 1 micron or greater, 5 microns or greater, 10 microns or greater, 15 microns or greater, 20 microns or greater, 25 microns or greater, 30 microns or greater, 35 microns or greater, 40 microns or greater, 45 microns or greater, 50 microns or greater, 55 microns or greater, 60 microns or greater, 65 microns or greater, 70 microns or greater, 75 microns or greater, 80 microns or greater, 85 microns or greater, 90 microns or greater, 95 microns or greater, 100 microns or greater, 200 microns or greater, 300 microns or greater, 400 microns or greater, 500 microns or greater, 600 microns or greater, 700 microns or greater, 800 microns or greater, or 900 microns or greater).

[0093] In some embodiments, the fibrous material can have an average maximum cross- sectional size of 1000 microns or less (e.g., 900 microns or less, 800 microns or less, 700 microns or less, 600 microns or less, 500 microns or less, 400 microns or less, 300 microns or less, 200 microns or less, 100 microns or less, 95 microns or less, 90 microns or less, 85 microns or less, 80 microns or less, 75 microns or less, 70 microns or less, 65 microns or less, 60 microns or less, 55 microns or less, 50 microns or less, 45 microns or less, 40 microns or less, 35 microns or less, 30 microns or less, 25 microns or less, 20 microns or less, 15 microns or less, 10 microns or less, 5 microns or less, 1 micron or less, 900 nanometers or less, 800 nanometers or less, 700 nanometers or less, 600 nanometers or less, 500 nanometers or less, 400 nanometers or less, 300 nanometers or less, 200 nanometers or less).

[0094] In some embodiments, the fibrous material can have an average maximum cross- sectional size of about 100 nanometers to about 1000 microns (e.g., 100 nanometers to 1 micron, 1 micron to 10 microns, 10 microns to 25 microns, 25 microns to 50 microns, 50 microns to 75 microns, 75 microns to 100 microns, 25 microns to 75 microns, 25 microns to 100 microns, 100 nanometers to 10 microns, 100 nanometers to 25 microns, 1 micron to 25 microns, 10 microns to 75 microns, from 1 micron to 1000 microns, from 1 micron to 900 microns, from 1 micron to 800 microns, from 1 micron to 700 microns, from 1 micron to 600 microns, from 1 micron to 500 microns, from 100 microns to 1000 microns, from 100 microns to 900 microns, from 100 microns to 800 microns, from 100 microns to 700 microns, from 100 microns to 600 microns, or from 100 microns to 500 microns). In some embodiments, the fibrous material comprises a blend of one or more fibers that are of different average maximum cross-sectional size. In other words, in some embodiments, the fibrous material has bimodal (or trimodal, etc.) average maximum cross-sectional size. In some embodiments, the fibers ofthe fibrous material can be present in the nanoscale, having an average cross section size of from 1 nanometer to 100 nanometers, or from 1 nanometer to 1000 microns.

[0095] Also disclosed herein is an additive material, though some embodiments can process feedstocks without the use of an additive. The additive material can comprise, for example, a small molecule material, a surfactant, or a polymer. Without wishing to be bound by any particular scientific theory, the additive material can interact with lignin in the fibrous material to weaken the cellular structure of the fibrous material. The additive material can also act in a catalytic manner and / or as a drag-reducing agent during processing.

[0096] The additive can be a water-soluble material capable of interacting with lignin. The additive can be a surfactant, for example. A variety of surfactants can be included in the present disclosure to interact with the fibrous material (e.g., weakening the lignin), act in a catalytic manner, and act as a drag-reducing or dewatering agent during processing. The surfactants used in the present invention can contain a lipophilic nonpolar hydrocarbon group and a polar or ionic (e.g., cationic, anionic, zwitterionic, etc.) functional hydrophilic group. The anionic or polar functional group can be a carboxylate, ester, amine, amide, imide, hydroxyl, ether, nitrile, phosphate, sulfate, or sulfonate. The cationic functional group may be a primary amine, secondary amine, tertiary amine or quandary amine. The surfactants that are useful in the present invention may be used alone or in combination. Accordingly, any combination of surfactants may include anionic, cationic, nonionic, zwitterionic, amphoteric and ampholytic surfactants.

[0097] Accordingly, the surfactants for use in the present invention may be anionic, including, but not limited to, sulfonates such as alkyl sulfonates, alkylbenzene sulfonates, alpha olefin sulfonates, paraffin sulfonates, and alkyl ester sulfonates; sulfates such as alkyl sulfates, alkyl alkoxy sulfates, and alkyl alkoxylated sulfates; phosphates such as monoalkyl phosphates and dialkyl phosphates; phosphonates; carboxylates such as fatty acids, alkyl alkoxy carboxylates, sarcosinates, isethionates, and taurates. Specific examples of carboxylates are sodium cocoyl isethionate, sodium methyl oleoyl taurate, sodium stearate, sodium laureth carboxylate, sodium polyacrylate, sodium trideceth carboxylate, sodium lauryl sarcosinate, sodium carboxymethyl cellulose, lauroyl sarcosine, and cocoyl sarcosinate. Specific examples of sulfates include sodium dodecyl sulfate (SDS), sodium lauryl sulfate, sodium lauryl ether sulfate, cationsodium laureth sulfate, sodium trideceth sulfate, sodium tridecyl sulfate, sodium cocyl sulfate, and lauric monoglyceride sodium sulfate.

[0098] Suitable sulfonate surfactants include, but are not limited to, alkyl sulfonates, aryl sulfonates, lignosulfonate, linear alkylbenzene sulfonates, monoalkyl and dialkyl sulfosuccinates, and monoalkyl and dialkyl sulfosuccinamates. Each alkyl group independently contains about two to twenty carbons and can also be ethoxylated with up to about 8 units, preferably up to about 6 units, on average, e.g., 2, 3, or 4 units, of ethylene oxide, per each alkyl group. Illustrative examples of alky and aryl sulfonates are sodium tridecyl benzene sulfonate (STBS) and sodium dodecylbenzene sulfonate (SDBS).

[0099] Illustrative examples of sulfosuccinates include, but are not limited to, dimethicone copolyol sulfosuccinate, diamyl sulfosuccinate, dicapryl sulfosuccinate, dicyclohexyl sulfosuccinate, diheptyl sulfosuccinate, dihexyl sulfosuccinate, diisobutyl sulfosuccinate, dioctyl sulfosuccinate, dioctyl sodium sulfosuccinate (DOSS), Cl 2- 15 pareth sulfosuccinate, cetearyl sulfosuccinate, cocopolyglucose sulfosuccinate, cocoyl butyl gluceth-10 sulfosuccinate, deceth-5 sulfosuccinate, deceth-6 sulfosuccinate, dihydroxyethyl sulfosuccinylundecylenate, hydrogenated cottonseed glyceride sulfosuccinate, isodecyl sulfosuccinate, isostearyl sulfosuccinate, laneth-5 sulfosuccinate, laureth sulfosuccinate, laureth-12 sulfosuccinate, laureth-6 sulfosuccinate, laureth-9 sulfosuccinate, lauryl sulfosuccinate, nonoxynol-10 sulfosuccinate, oleth-3 sulfosuccinate, oleyl sulfosuccinate, PEG- 10 laurylcitrate sulfosuccinate, sitosereth-14 sulfosuccinate, stearyl sulfosuccinate, tallow, tridecyl sulfosuccinate, ditridecyl sulfosuccinate, bisglycol ricinosulfosuccinate, di(l ,3- di-methylbutyl)sulfosuccinate, and silicone copolyol sulfosuccinates.

[0100] Illustrative examples of sulfosuccinamates include, but are not limited to, lauramido- MEA sulfosuccinate, oleamido PEG-2 sulfosuccinate, cocamido MIPA-sulfosuccinate, cocamido PEG-3 sulfosuccinate, isostearamido MEA-sulfosuccinate, isostearamido MIPA- sulfosuccinate, lauramido MEA-sulfosuccinate, lauramido PEG-2 sulfosuccinate, lauramido PEG-5 sulfosuccinate, myristamido MEA-sulfosuccinate, oleamido MEA-sulfosuccinate, oleamido PIPA-sulfosuccinate, oleamido PEG-2 sulfosuccinate, palmitamido PEG-2 sulfosuccinate, palmitoleamido PEG-2 sulfosuccinate, PEG-4 cocamido MIPA-sulfosuccinate, ricinoleamido MEA-sulfosuccinate, stearamido MEA-sulfosuccinate, stearyl sulfosuccinamate, tallamido MEA-sulfosuccinate, tallow sulfosuccinamate, tallowamido MEA-sulfosuccinate, undecylenamido MEA-sulfosuccinate, undecylenamido PEG-2 sulfosuccinate, wheat germamido MEA-sulfosuccinate, and wheat germamido PEG-2 sulfosuccinate.

[0101] For an anionic surfactant, the counter ion is typically sodium but may alternatively be potassium, lithium, calcium, magnesium, ammonium, amines (primary, secondary, tertiary or quandary) or other organic bases. Exemplary amines include isopropyl amine, ethanolamine, diethanolamine, and triethanolamine. Mixtures of the above cations may also be used.

[0102] In some embodiments, the surfactants for use in the present invention may also be cationic, so long as at least one surfactant bearing a net positive charge is also included. Such cationic surfactants include, but are not limited to, primarily organic amines, primary, secondary, tertiary or quaternary. For a cationic surfactant, the counter ion can be chloride, bromide, methosulfate, ethosulfate, lactate, saccharinate, phosphate, acetate, and other organic acid anions. Examples of cationic amines include polyethoxylated oleyl / stearyl amine, ethoxylated tallow amine, cocoalkylamine, oleylamine, and tallow alkyl amine.

[0103] Examples of quaternary amines with a single long alkyl group are cetyl trimethyl ammonium bromide (CETAB), cetyl trimethyl ammonium chloride (CETAC), dodecyltrimethylammonium bromide, myristyl trimethyl ammonium bromide, stearyl dimethyl benzyl ammonium chloride, oleyl dimethyl benzyl ammonium chloride, lauryl trimethyl ammonium methosulfate (also known as cocotrimonium methosulfate), cetyldimethyl hydroxyethyl ammonium dihydrogen phosphate, bassuamidopropylkonium chloride, cocotrimonium chloride, distearyldimonium chloride, wheat germ-amidopropalkonium chloride, benzalkonium chloride, stearyl octyidimonium methosulfate, isostearaminopropal- konium chloride, dihydroxypropyl PEG-5 linoleammonium chloride, PEG-2 stearmonium chloride, behentrimonium chloride, dicetyl dimonium chloride, tallow trimonium chloride and behenamidopropyl ethyl dimonium ethosulfate.

[0104] Examples of quaternary amines with two long alkyl groups are distearyldimonium chloride, dicetyl dimonium chloride, benzethonium chloride, stearyl octyidimonium methosulfate, dihydrogenated palmoylethyl hydroxyethylmonium methosulfate, dipalmitoylethyl hydroxyethylmonium methosulfate, dioleoylethyl hydroxyethylmonium methosulfate, and hydroxypropyl bisstearyldimonium chloride.

[0105] Quaternary ammonium compounds of imidazoline derivatives include, for example, isostearyl benzylimidonium chloride, cocoyl benzyl hydroxyethyl imidazolinium chloride, cocoyl hydroxyethylimidazolinium PG-chloride phosphate, and stearyl hydroxyethylimidonium chloride. Other heterocyclic quaternary ammonium compounds, such as dodecylpyridinium chloride and cetylpyridinium chloride, can also be used.

[0106] The surfactants for use in the present invention may be nonionic, including, but not limited to, polyalkylene oxide carboxylic acid esters, fatty acid esters, fatty alcohols, ethoxylated fatty alcohols, poloxamers, polyalkylene oxidesm alkanolamides, polyacrylamides, alkoxylated alkanolamides, polyethylene glycol monoalkyl ether, and alkyl polysaccharides. Polyalkylene oxide carboxylic acid esters have one or two carboxylic ester moieties each with about 8 to 20 carbons and a polyalkylene oxide moiety containing about 5 to 200 alkylene oxide units. An ethoxylated fatty alcohol contains an ethylene oxide moiety containing about 5 to 150 ethylene oxide units and a fatty alcohol moiety with about 6 to about 30 carbons. The fatty alcohol moiety can be cyclic, straight, or branched, and saturated or unsaturated. Some examples of ethoxylated fatty alcohols include ethylene glycol ethers of oleth alcohol, steareth alcohol, lauryl alcohol and isocetyl alcohol. Poloxamers are ethylene oxide and propylene oxide block copolymers, having from about 15 to about 100 moles of ethylene oxide. Alkyl polysaccharide ("APS") surfactants (e.g. alkyl polyglycosides) contain a hydrophobic group with about 6 to about 30 carbons and a polysaccharide (e.g., polyglycoside) as the hydrophilic group.

[0107] Specific examples of suitable nonionic surfactants include alkanolamides such as cocamide diethanolamide ("DEA"), cocamide monoethanolamide ("MEA"), cocamide monoisopropanolamide ("MIPA"), PEG-5 cocamide MEA, lauramide DEA, and lauramide MEA; alkyl amine oxides such as lauramine oxide, poly-N-vinyl formamide, cocamine oxide, cocamidopropylamine oxide, and lauramidopropylamine oxide; polyalkylene oxides such as polyethylene oxide (PEO), polypropylene oxide, and polybutylene oxide; polyethylene glycol (PEG) and polypropylene glycol and block copolymers thereof; polysorbates or Tweens such as polysorbate 20, polysorbate 40, polysorbate 60, and polysorbate 80; polyacrylamide-co- sodium acrylate (PAAM-co-NaA); polyacrylamide-co-(sodium2-(acrylamido)- 2methylpropanesulfonate) (PAAM-co-NaAMPS); polyacrylamide-co-(sodium3- (acrylamido)-3methylbutanoate) (PAAM-co-NaAMB); and polyacrylamide-co-diacetone acrylamide (PAAM-coDAAM); polyampholytes (containing both negative and positive charges in the same polymeric chain) based on acrylamide (AM), sodium 2-acrylamido-2- methylpropanesulfonate (NaAMPS), (2-acrylamido2-methylpropyl)trimethylammonium chloride (AMPTAC), sodium 3-acrylamido-3-methylbutanoate (NaAMB), and 3-((2- acrylamido-2-methylpropyl)dimethylammonio)- 1 -propanesulfonate (AMPDAPS); gums such as Guar gum, Xanthan gum, Lucas Bean gum, Gellan gum, and gum Arabic; sorbitan laurate, sorbitan distearate, fatty acids or fatty acid esters such as lauric acid, isostearic acid, and PEG-150 distearate; fatty alcohols or ethoxylated fatty alcohols such as lauryl alcohol, alkylpolyglucosides such as decyl glucoside, lauryl glucoside, and coco glucoside.

[0108] The surfactants for use in the present invention may be zwitterionic, meaning the same molecule has both a formal positive and negative charge. The positive charge group can be quaternary ammonium, phosphonium, or sulfonium, whereas the negative charge group can be carboxylate, sulfonate, sulfate, phosphate or phosphonate. Similar to other classes of surfactants, the hydrophobic moiety may contain one or more long, straight, cyclic, or branched, aliphatic chains of about 8 to 18 carbon atoms. Specific examples of zwitterionic surfactants include alkyl betaines such as cocodimethyl carboxymethyl betaine, coco betaine, lauryl dimethyl carboxymethyl betaine, lauryl dimethyl alpha-carboxyethyl betaine, cetyl dimethyl carboxymethyl betaine, lauryl bis-(2-hydroxyethyl)carboxy methyl betaine, stearyl bis-(2-hydroxypropyl)carboxymethyl betaine, oleyl dimethyl gamma-carboxypropyl betaine, and lauryl bis-(2-hydroxypropyl)alphacarboxy-ethyl betaine, amidopropyl betaines; lecithins (phosphatidylcholine), such as soy lecithin; and alkyl sultaines such as cocodimethyl sulfopropyl betaine, stearyidimethyl sulfopropyl betaine, lauryl dimethyl sulfoethyl betaine, lauryl bis-(2-hydroxyethyl)sulfopropyl betaine, and alkylamidopropylhydroxy sultaines.

[0109] The surfactants for use in the present invention may be amphoteric. Examples of suitable amphoteric surfactants include ammonium or substituted ammonium salts of alkyl amphocarboxy glycinates and alkyl amphocarboxypropionates, alkyl amphodipropionates, alkyl amphodiacetates, alkyl amphoglycinates, and alkyl amphopropionates, as well as alkyl iminopropionates, alkyl iminodipropionates, and alkyl amphopropylsulfonates. Specific examples are cocoamphoacetate, cocoamphopropionate, cocoamphodiacetate, lauroamphoacetate, lauroamphodiacetate, lauroamphodipropionate, lauroamphodiacetate, cocoamphopropyl sulfonate, caproamphodiacetate, caproamphoacetate, caproamphodipropionate, and stearoamphoacetate.

[0110] The surfactants for use in the present invention may also be a polymer such as N- substituted polyisobutenyl succinimides and succinates, alkyl methacrylate vinyl pyrrolidinone copolymers, polyvinylpyrrolidones, alkyl methacrylate-dialkylaminoethyl methacrylate copolymers, alkylmethacrylate polyethylene glycol methacrylate copolymers, and polystearamides.

[0111] Alternatively, the surfactant may be an oil-based dispersant, which includes alkylsuccinimide, succinate esters, high molecular weight amines, and Mannich base and phosphoric acid derivatives. Some specific examples are polyisobutenyl succinimide-polyethylenepolyamine, polyisobutenyl succinic ester, polyisobutenyl hydroxybenzylpolyethylenepolyamine, and bis-hydroxypropyl phosphorate.

[0112] The surfactant used in the present invention may also be a combination of two or more selected from the group consisting of anionic, cationic, nonionic, zwitterionic, amphoteric, and ampholytic surfactants. Suitable examples of a combination of two or more surfactants of the same type include, but are not limited to, a mixture of two anionic surfactants, a mixture of three anionic surfactants, a mixture of four anionic surfactants, a mixture of two cationic surfactants, a mixture of three cationic surfactants, a mixture of four cationic surfactants, a mixture of two nonionic surfactants, a mixture of three nonionic surfactants, a mixture of four nonionic surfactants, a mixture of two zwitterionic surfactants, a mixture of three zwitterionic surfactants, a mixture of four zwitterionic surfactants, a mixture of two amphoteric surfactants, a mixture of three amphoteric surfactants, a mixture of four amphoteric surfactants, a mixture of two ampholytic surfactants, a mixture of three ampholytic surfactants, and a mixture of four ampholytic surfactants.

[0113] Suitable examples of a combination of two surfactants of different types include, but are not limited to, a mixture of one anionic and one cationic surfactant, a mixture of one anionic and one nonionic surfactant, a mixture of one anionic and one zwitterionic surfactant, a mixture of one anionic and one amphoteric surfactant, a mixture of one anionic and one ampholytic surfactant, a mixture of one cationic and one nonionic surfactant, a mixture of one cationic and one zwitterionic surfactant, a mixture of one cationic and one amphoteric surfactant, a mixture of one cationic and one ampholytic surfactant, a mixture of one nonionic and one zwitterionic surfactant, a mixture of one nonionic and one amphoteric surfactant, a mixture of one nonionic and one ampholytic surfactant, a mixture of one zwitterionic and one amphoteric surfactant, a mixture of one zwitterionic and one ampholytic surfactant, and a mixture of one amphoteric and one ampholytic surfactant. A combination of two or more surfactants of the same type, e.g., a mixture of two anionic surfactants, is also included in the present invention.

[0114] The additive can have a molecular weight from about 30 g / mol to about 10,000,000 g / mol. The additive can have a molecular weight from about 500 g / mol to about 10,000,000 g / mol. The additive can have a molecular weight from about 50 g / mol to about 10,000,000 g / mol. The additive can have a molecular weight from about 100 g / mol to about 10,000,000 g / mol. The additive can have a molecular weight from about 250 g / mol to about 10,000,000 g / mol. The additive can have a molecular weight from about 1 ,000 g / mol to about 10,000,000 g / mol. The additive can have a molecular weight from about 1,000 g / mol to about 8,000,000g / mol. The additive can alternatively have a molecular weight from about 5,000 g / mol to about 10,000,000 g / mol, from about 100,000 g / mol to about 10,000,000 g / mol, from about 500 g / mol to about 1,000,000 g / mol, from about 1,000 g / mol to about 1,000,000 g / mol, from about 1,000 g / mol to about 2,000,000 g / mol, from about 1,000 g / mol to about 3,000,000 g / mol, or from about 500 g / mol to about 8,000,000 g / mol.

[0115] Embodiments of the present disclosure can provide a dry pulp product. The dry pulp product can be made from fibrous material using processes of the present disclosure and can have an exploded cellular structure. The dry pulp product can be further processed into pellets, briquettes, bales, or other value-added products. The dry pulp product can have a particle size (e.g., average particle diameter) from about 1 mm to about 10 mm (e.g., from 1.5 mm to 9.5 mm, from 2 mm to 9 mm, from 2.5 mm to 8.5 mm, from 3 mm to 8 mm, from 3.5 mm to 7.5 mm, from 4 mm to 7 mm, from 4.5 mm to 6.5 mm, or from 5 mm to 6 mm).

[0116] Embodiments of the present disclosure can provide a fibrous pellet, comprising a fibrous material comprising lignin and water. The fibrous pellets of the present disclosure can be substantially dewatered. In other words, the fibrous pellet can comprise water in an amount of about 20% or less (e.g., 19% or less, 18% or less, 17% or less, 16% or less, 15% or less, 14% or less, 13% or less, 12% or less, 11% or less, 10% or less, 9% or less, 8% or less, 7% or less, 6% or less, 5% or less, 4.5% or less, 4% or less, 3.5% or less, 3% or less, 2.5% or less, 2% or less, 1.5% or less, 1% or less, or 0.5% or less) by weight, based on the total weight of the fibrous pellet.

[0117] In some embodiments, the fibrous pellet can comprise water in an amount of about 0.1% or greater (e.g., 19% or greater, 18% or greater, 17% or greater, 16% or greater, 15% or greater, 14% or greater, 13% or greater, 12% or greater, 11% or greater, 10% or greater, 9% or greater, 8% or greater, 7% or greater, 6% or greater, 5% or greater, 4.5% or greater, 4% or greater, 3.5% or greater, 3% or greater, 2.5% or greater, 2% or greater, 1.5% or greater, 1% or greater, or 0.5% or greater) by weight, based on the total weight of the fibrous pellet.

[0118] In some embodiments, the fibrous pellet can comprise water in an amount from about 0.1% to about 20% (e.g., from 0.1% to 19%, from 0.5% to 18%, from 1% to 17%, from 1% to 20%, from 1% to 19%, from 1% to 18%, from 1% to 16%, from 2% to 18%, from 3% to 17%, from 4% to 16%, from 5% to 15%, from 6% to 14%, from 7% to 13%, from 8% to 12%, from 9% to 11%, from 0.5% to 4.5%, from 1% to 5%, from 1% to 4.5%, from 1% to 4%, from 1.5% to 3.5%, or from 2% to 3%) by weight, based on the total weight of the fibrous pellet.

[0119] The fibrous pellets of the present disclosure can present substantially improved mechanical properties and structural integrity over conventional fibrous pellets as well. For example, the fibrous pellet can have a pellet durability index (PDI) of 75 or greater (e.g., 76 or greater, 77 or greater, 78 or greater, 79 or greater, 80 or greater, 81 or greater, 82 or greater, 83 or greater, 84 or greater, 85 or greater, 86 or greater, 87 or greater, 88 or greater, 89 or greater, 90 or greater, 91 or greater, 92 or greater, 93 or greater, 94 or greater, 95 or greater, 96 or greater, 97 or greater, 98 or greater, 99 or greater, or 100). The PDI of the fibrous pellets can be measured using, for example, ASAE Standard S269.5 R2016. Additionally, the fibrous pellets of the present disclosure can have improved structural integrity. For example, the fibrous pellets can undergo substantially minimal degradation when submerged in water from about 1 minute to about 1 year. As used herein, “substantially minimal degradation” is defined by a bulk density of the fibrous pellets changing by an amount of 10% or less. In other words, the fibrous pellets undergo minimal swelling and / or water adsorption when submerged.

[0120] The fibrous pellet can also have a bulk density of about 15 kg / m3or greater (e.g., 20 kg / m3or greater, 25 kg / m3or greater, 30 kg / m3or greater, 35 kg / m3or greater, 40 kg / m3or greater, 45 kg / m3or greater, 50 kg / m3or greater, 60 kg / m3or greater, 70 kg / m3or greater, 80 kg / m3or greater, 90 kg / m3or greater, 100 kg / m3or greater, 150 kg / m3or greater, 200 kg / m3or greater, 250 kg / m3or greater, 300 kg / m3or greater, 350 kg / m3or greater, 400 kg / m3or greater, 450 kg / m3or greater, 500 kg / m3or greater, 550 kg / m3or greater, 600 kg / m3or greater, 650 kg / m3or greater, 700 kg / m3or greater, or 750 kg / m3or greater).

[0121] The fibrous pellet can have a bulk density of about 800 kg / m3or less (e.g., 20 kg / m3or less, 25 kg / m3or less, 30 kg / m3or less, 35 kg / m3or less, 40 kg / m3or less, 45 kg / m3or less, 50 kg / m3or less, 60 kg / m3or less, 70 kg / m3or less, 80 kg / m3or less, 90 kg / m3or less, 100 kg / m3or less, 150 kg / m3or less, 200 kg / m3or less, 250 kg / m3or less, 300 kg / m3or less, 350 kg / m3or less, 400 kg / m3or less, 450 kg / m3or less, 500 kg / m3or less, 550 kg / m3or less, 600 kg / m3or less, 650 kg / m3or less, 700 kg / m3or less, or 750 kg / m3or less).

[0122] The fibrous pellet can have a bulk density from about 15 kg / m3to about 800 kg / m3(e.g., from 20 kg / m3to 800 kg / m3, from 25 kg / m3to 800 kg / m3, from 30 kg / m3to 800 kg / m3, from 35 kg / m3to 800 kg / m3, from 40 kg / m3to 800 kg / m3, from 45 kg / m3to 800 kg / m3, from 50 kg / m3to 800 kg / m3, from 60 kg / m3to 800 kg / m3, from 70 kg / m3to 800 kg / m3, from 80 kg / m3to 800 kg / m3, from 90 kg / m3to 800 kg / m3, from 100 kg / m3to 800 kg / m3, from 150 kg / m3to 800 kg / m3, from 200 kg / m3to 800 kg / m3, from 250 kg / m3to 800 kg / m3, from 300 kg / m3to 800 kg / m3, from 350 kg / m3to 800 kg / m3, from 400 kg / m3to 800 kg / m3, from 450 kg / m3to 800kg / m3, from 500 kg / m3to 800 kg / m3, from 550 kg / m3to 800 kg / m3, from 600 kg / m3to 800 kg / m3, from 650 kg / m3to 800 kg / m3, from 700 kg / m3to 800 kg / m3, from 750 kg / m3to 800 kg / m3, from 100 kg / m3to 750 kg / m3, from 100 kg / m3to 700 kg / m3, from 150 kg / m3to 650 kg / m3, from 250 kg / m3to 750 kg / m3, from 300 kg / m3to 700 kg / m3, from 350 kg / m3to 650 kg / m3, from 400 kg / m3to 600 kg / m3, or from 450 kg / m3to 550 kg / m3).

[0123] The fibrous pellet can also comprise a plurality of exposed cellulose fibers in the fibrous material. Each of the plurality of exposed cellulose fibers can be entangled with at least one other exposed cellulose fiber, as shown in Fig. 5B. The exposed cellulose fibers can be present in the fibrous pellet in an amount of 2% or greater (e.g., 3% or greater, 4% or greater, 5% or greater, 6% or greater, 7% or greater, 8% or greater, 9% or greater, 10% or greater, 15% or greater, 20% or greater, 25% or greater, 30% or greater, 35% or greater, 40% or greater, 45% or greater, 50% or greater, 55% or greater, 60% or greater, 65% or greater, 70% or greater, 75% or greater, 80% or greater, 85% or greater, 90% or greater, or 95% or greater) by weight, based on the total weight of the pellet.

[0124] The exposed cellulose fibers can be present in the fibrous pellet in an amount of 99% or less (e.g., 3% or less, 4% or less, 5% or less, 6% or less, 7% or less, 8% or less, 9% or less, 10% or less, 15% or less, 20% or less, 25% or less, 30% or less, 35% or less, 40% or less, 45% or less, 50% or less, 55% or less, 60% or less, 65% or less, 70% or less, 75% or less, 80% or less, 85% or less, 90% or less, or 95% or less) by weight, based on the total weight of the pellet.

[0125] The exposed cellulose fibers can be present in the fibrous pellet in an amount from 2% to 99% (e.g., from 2% to 98%, from 2% to 95%, from 2% to 90%, from 2% to 85%, from 2% to 80%, from 2% to 75%, from 2% to 70%, from 2% to 65%, from 2% to 60%, from 2% to 55%, from 2% to 50%, from 2% to 45%, from 2% to 40%, from 2% to 35%, from 2% to 30%, from 2% to 25%, from 3% to 99%, from 4% to 99%, from 5% to 99%, from 5% to 95%, from 5% to 90%, from 5% to 85%, from 5% to 80%, from 5% to 75%, from 5% to 70%, from 5% to 65%, from 5% to 60%, from 5% to 55%, from 5% to 50%, from 5% to 45%, from 5% to 40%, from 5% to 35%, from 5% to 30%, or from 5% to 25%) by weight, based on the total weight of the fibrous pellet.

[0126] Embodiments of the present disclosure can also provide a liquid product derived from the fibrous material, the liquid product comprising solid or liquid particulates, bio-stimulant compounds, minerals, amino acids, organic acids, proteins, water, and lignin. The bio-stimulant compounds can include compounds such as humic acid, fidvic acid, or other organic acids. The liquid product can also comprise other bio-stimulant compounds including, but not limited to,humic acid derivates, humates, other organic acids, humic substances, humin, lignosulfonates, lactic acids, acetic acids, formic acids, citric acids, oxalic acids, uric acids, malic acids, other derivatives of soil organic matter, humic matter, other bioactive compounds and the like, or any combination thereof. The minerals can include potassium, phosphorus, nitrogen, calcium, magnesium, sulfur, sodium, iron, manganese, zinc, copper, other natural minerals and the like, or any combination thereof. The liquid product can further comprise amino acids, such as glutamic acid or tryptophan. The liquid product can further comprise other volatile and nonvolatile organic compounds.

[0127] The bio-stimulant compounds can be present in the liquid product in an amount of about 0.001% or greater (e.g., 0.005% or greater, 0.01% or greater, 0.05% or greater, 0.1% or greater, 0.2% or greater, 0.3% or greater, 0.4% or greater, 0.5% or greater, 0.6% or greater, 0.7% or greater, 0.8% or greater, 0.9% or greater, 1% or greater, 1.1% or greater, 1.2% or greater, 1.3% or greater, 1.4% or greater, 1.5% or greater, 2% or greater, 2.5% or greater, 3% or greater, 3.5% or greater, 4% or greater, 4.5% or greater, 5% or greater, 5.5% or greater, 6% or greater, 6.5% or greater, 7% or greater, 7.5% or greater, 8% or greater, 8.5% or greater, 9% or greater, or 9.5% or greater) by weight, based on the total weight of the liquid product.

[0128] In some embodiments, the bio-stimulant compounds can be present in the liquid product in an amount of about 10% or less (e.g., 0.005% or less, 0.01% or less, 0.05% or less, 0.1% or less, 0.2% or less, 0.3% or less, 0.4% or less, 0.5% or less, 0.6% or less, 0.7% or less, 0.8% or less, 0.9% or less, 1% or less, 1.1% or less, 1.2% or less, 1.3% or less, 1.4% or less, 1.5% or less, 2% or less, 2.5% or less, 3% or less, 3.5% or less, 4% or less, 4.5% or less, 5% or less, 5.5% or less, 6% or less, 6.5% or less, 7% or less, 7.5% or less, 8% or less, 8.5% or less, 9% or less, or 9.5% or less) by weight, based on the total weight of the liquid product.

[0129] In some embodiments, the bio-stimulant compounds can be present in the liquid product in an amount from about 0.001% to about 20% (e.g., from 0.005% to 10%, from 0.01% to 10%, from 0.05% to 10%, from 0.1% to 10%, from 0.2% to 10%, from 0.3% to 10%, from 0.4% to 10%, from 0.5% to 10%, from 0.6% to 10%, from 0.7% to 10%, from 0.8% to 10%, from 0.9% to 10% from 1% to 10%, from 1% to 9.5%, from 1% to 9%, from 1.5% to 8.5%, from 2% to 8%, from 2.5% to 7.5%, from 3% to 7%, from 3% to 6.5%, from 3% to 6%, from 3% to 5.5%, from 3% to 5%, from 2.5% to 5%, from 2% to 5%, from 1.5% to 5%, from 1.4% to 5%, from 1.3% to 5%, from 1.2% to 5%, from 1.1% to 5%, from 1% to 5%, from 0.9% to 5%, from 0.8% to 5%, from 0.7% to 5%, from 0.6% to 5%, from 0.5% to 5%, from 0.4% to5%, from 0.3% to 5%, from 0.2% to 5%, or from 0.1% to 5%) by weight, based on the total weight of the liquid product.

[0130] The liquid product can comprise water in an amount of about 50% or greater (e.g., 55% or greater, 60% or greater, 65% or greater, 70% or greater, 75% or greater, 80% or greater, or 85% or greater) by weight, based on the total weight of the liquid product. In some embodiments, the liquid product can comprise water in an amount of about 90% or less (e.g., 55% or less, 60% or less, 65% or less, 70% or less, 75% or less, 80% or less, or 85% or less) by weight, based on the total weight of the liquid product. In some embodiments, the liquid product can comprise water in an amount from about 50% to about 90% (e.g., from 55% to 85%, from 60% to 80%, or from 65% to 75%) by weight, based on the total weight of the liquid product.

[0131] The liquid product can also comprise lignin in an amount of about 0.01% or greater (e.g., 0.05% or greater, 0.1% or greater, 0.5% or greater, 1% or greater, 2% or greater, 3% or greater, 4% or greater, 5% or greater, 6% or greater, 7% or greater, 8% or greater, 9% or greater, 10% or greater, 15% or greater, 20% or greater, 25% or greater, 30% or greater, 35% or greater, 40% or greater, 45% or greater, 50% or greater, 55% or greater, 60% or greater, 65% or greater, or 70% or greater) by weight, based on the total weight of the liquid product.

[0132] In some embodiments, the liquid product can comprise lignin in an amount of about 75% or less (e.g., 0.05% or less, 0.1% or less, 0.5% or less, 1% or less, 2% or less, 3% or less, 4% or less, 5% or less, 6% or less, 7% or less, 8% or less, 9% or less, 10% or less, 15% or less, 20% or less, 25% or less, 30% or less, 35% or less, 40% or less, 45% or less, 50% or less, 55% or less, 60% or less, 65% or less, or 70% or less) by weight, based on the total weight of the liquid product.

[0133] In some embodiments, the liquid product can comprise lignin in an amount from about 0.01% to about 75% (e.g., from 0.05% to 75%, from 0.1% to 75%, from 0.5% to 75%, from 1% to 75%, from 2% to 75%, from 2% to 75%, from 3% to 75%, from 4% to 75%, from 5% to 75%, from 6% to 75%, from 7% to 75%, from 8% to 75%, from 9% to 75%, from 10% to 75%, from 15% to 75%, from 20% to 75%, from 25% to 75%, from 30% to 70%, from 35% to 65%, from 40% to 60%, or from 45% to 55%) by weight, based on the total weight of the liquid product.

[0134] The liquid product can also comprise various dry matter. In other words, the liquid product can have a solids content of about 0.0001% or greater (e.g., 0.0005% or greater, 0.001% or greater, 0.005% or greater, 0.01% or greater, 0.05% or greater, 0.1% or greater,0.5% or greater, 1% or greater, 1.5% or greater, 2% or greater, 2.5% or greater, 3% or greater, 3.5% or greater, 4% or greater, 4.5% or greater, 5% or greater, 6% or greater, 7% or greater, 8% or greater, 9% or greater, 10% or greater, 11% or greater, 12% or greater, 13% or greater, 14% or greater, 15% or greater, 16% or greater, 17% or greater, 18% or greater, 19% or greater, 20% or greater, 25% or greater, 30% or greater, 35% or greater, 40% or greater, or 45% or greater) by weight, based on the total weight of the liquid product.

[0135] In some embodiments, the liquid product can have a solids content of about 50% or less (e.g., 0.0005% or less, 0.001% or less, 0.005% or less, 0.01% or less, 0.05% or less, 0.1% or less, 0.5% or less, 1% or less, 1.5% or less, 2% or less, 2.5% or less, 3% or less, 3.5% or less, 4% or less, 4.5% or less, 5% or less, 6% or less, 7% or less, 8% or less, 9% or less, 10% or less, 11% or less, 12% or less, 13% or less, 14% or less, 15% or less, 16% or less, 17% or less, 18% or less, 19% or less, 20% or less, 25% or less, 30% or less, 35% or less, 40% or less, or 45% or less) by weight, based on the total weight of the liquid product.

[0136] In some embodiments, the liquid product can have a solids content from about 0.0001% to about 50% (e.g., from 0.0005% to 50%, from 0.001% to 50%, from 0.005% to 50%, from 0.01% to 50%, from 0.05% to 50%, from 0.1% to 50%, from 0.5% to 50%, from 1% to 50%, from 0.0005% to 20%, from 0.001% to 20%, from 0.005% to 20%, from 0.01% to 20%, from 0.05% to 20%, from 0.1% to 20%, from 0.5% to 20%, from 1% to 20%, from 0.0005% to 19%, from 0.001% to 18%, from 0.005% to 17%, from 0.01% to 16%, from 0.05% to 15%, from 0.1% to 14%, from 0.5% to 13%, from 1% to 12%, from 1.5% to 11%, from 2% to 10%, from 2% to 9%, from 2% to 8%, from 2% to 7%, from 2% to 6%, from 2% to 5%, from 2.5% to 4.5%, or from 3% to 4%) by weight, based on the total weight of the liquid product.

[0137] The liquid product can also be acidic. For instance, the liquid product can have a pH of about 7 or less (e.g., 6.5 or less, 6 or less, 5.5 or less, 5 or less, 4.5 or less, 4 or less, 3.5 or less, 3 or less, 2.5 or less, 2 or less, 1.5 or less, 1 or less or 0.5 or less). In some embodiments, the liquid product can have a pH of about 0 or greater (e.g., 6.5 or greater, 6 or greater, 5.5 or greater, 5 or greater, 4.5 or greater, 4 or greater, 3.5 or greater, 3 or greater, 2.5 or greater, 2 or greater, 1.5 or greater, 1 or greater, or 0.5 or greater). In some embodiments, the liquid product can have a pH from about 0 to about 7 (e.g., from 0.5 to 6.5, from 1 to 6, from 1.5 to 5.5, from 2 to 5, from 2.5 to 4.5, from 3 to 4, from 0 to 6.5, from 0 to 6, from 0 to 5.5, from 0 to 5, from 0 to 4.5, or from 0 to 4).

[0138] Additionally, the liquid product can entrain substantially all VOCs present in the feedstock in a liquid form. In other words, the process of making the liquid product can produce substantially trace amounts of VOCs in a vapor phase because the VOCs are substantially contained in the liquid product. As used herein, the term “substantially trace amounts of VOCs” refers to producing VOCs in an amount of about 10 ppm or less.

[0139] Also disclosed herein is a method of promoting growth in a plant using the liquid products described above. The method can comprise administering a liquid product to said plant. A variety of liquid products can be formulated as described above and are contemplated and understood to be within the scope of this disclosure.

[0140] Reference will now be made in detail to exemplary embodiments of the disclosed technology, examples of which are illustrated in the accompanying drawings and disclosed herein. Wherever convenient, the same references numbers will be used throughout the drawings to refer to the same or like parts.

[0141] Some embodiments of the present disclosure build upon certain embodiments disclosed in U.S. Patent App. No. 16 / 990,977, entitled “Processes, methods, and systems for chemo-mechanical cellular explosion and solid and liquid products made by the same,” which is incorporated herein in its entirety as if fully set forth below.

[0142] Disclosed herein is a machine 100 that can be used in the processes described herein. For example, a machine 100 for mechanical moisture reduction can be provided, as shown in Figs. 1A-1C. Machine 100 can include an inlet 130, and the biomass material 190 can enter machine 100 via inlet 130. The biomass material 190 can be any feedstock as described herein. For example, the biomass material 190 can be one or more materials comprising a fibrous material as described herein, including, but not limited to, tree bark, wood chips, saw dust, the like, and combinations thereof. The biomass material 190 can include a lignocellulosic material. The machine can include an outlet 140. The machine 100 can include an expeller 110 connected to the inlet 130. The expeller 110 can include a first chamber 114 configured to receive the biomass material 190 from the inlet 130. The expeller 110 can include a first threaded shaft. The first threaded shaft can be disposed at least partially in the first chamber 114. The first threaded shaft can include one or more threads circumferentially disposed around the shaft. The first threaded shaft can include an interrupted screw. Alternatively, or in addition, the first threaded shaft can include an uninterrupted screw. The first threaded shaft can include one or more threads having a pitch. Alternatively, or in addition, the first threaded shaft can include a first portion comprising one or more threads having a first pitch and a second portioncomprising one or more threads having a second pitch, the second pitch different than the first pitch. The first chamber 114 can include one or more teeth extending into the first chamber 114 and configured to contact the biomass material. The first threaded shaft can be configured to convey the biomass material 190 through the first chamber 114 and to apply a force to the biomass material 190 to cause liquid to be extracted from the biomass material 190. The force can be a force, a compression force, or combinations thereof. This process can be used to generate a reduced moisture content biomass material. The application of the force to the biomass material can cause the biomass material to increase in temperature and / or pressure. For example, the application of the force to the biomass material can cause the biomass material to increase to a first temperature and a first pressure. The force applied in the first chamber 114 (and second chamber discussed later) can vary along a length of the chamber 114. For example, the force may be less at the end of the chamber proximate the inlet 130 and increase along the length of the chamber as the biomass material progresses through the expeller (or expander as discussed later). The first chamber 114 can include one or more apertures in the wall thereof through which the liquid extracted from the biomass material can exit the first chamber 114. For example, the apertures can extend through the outer wall of the chamber to provide a path for the liquid extract to pass from inside the chamber 114 to be collected outside the chamber 114. The liquid extracted from the biomass material can be a liquid extract or liquid product as described herein. The machine 100 can include a first motor 112. The first motor 112 can be configured to rotate the first threaded shaft. For example, the first motor 112 can be in mechanical communication with the first threaded shaft. The first motor 112 can be a variable speed motor wherein the adjusting the speed of the first motor 112 can be used to adjust the speed in which the first threaded shaft rotates. As would be appreciated, increasing the rotational speed of the first threaded shaft can increase the throughput of biomass material through the first chamber 114.

[0143] The machine 100 can include an expander 120 connected to the outlet 140. The expander 120 can be disposed downstream of the expeller 110. In some embodiments, the expander can rotate in a different direction than the expeller 110. Alternatively, the expander 120 can be configured to run in the same direction as the expeller 110. Alternatively, the expander 120 can be configured to run in a reverse direction to receive biomass material from the expeller 110, which can be run in a reverse direction. Alternatively, the expander 120 can be configured to run in a normal direction to receive biomass material from the expeller 110, which can be run in a normal direction.

[0144] The expander 120 can include a second chamber 124 configured to receive the biomass material after it has passed through the expeller 110. The expander 120 can include a second threaded shaft. The second threaded shaft can be disposed at least partially in the second chamber 124. The second threaded shaft can include one or more threads circumferentially disposed around the shaft. The second threaded shaft can include an interrupted screw. Alternatively, or in addition, the second threaded shaft can include an uninterrupted screw. The second threaded shaft can include one or more threads having a pitch. For example, the second threaded shaft can include one or more threads having a second pitch, and the first threaded shaft can include one or more threads having a first pitch, the first pitch can be different from the second pitch. Alternatively, the first pitch can be the same as the second pitch. Alternatively, or in addition, the second threaded shaft can include a first portion comprising one or more threads having a first pitch and a second portion comprising one or more threads having a second pitch, the second pitch different than the first pitch. The second chamber 124 can include one or more teeth extending into the second chamber 124 and configured to contact the biomass material. The second threaded shaft can be configured to convey the biomass material through the second chamber 124 and to apply a force to the biomass material to cause liquid to be extracted from the biomass material. This process can be used to generate a reduced moisture content biomass material. The liquid extracted from the biomass material can be a liquid extract or liquid product as described herein. This process can be used to generate a reduced moisture content biomass material. For example, when inside second chamber 124, the biomass material can begin undergoing a force from the rotation of second threaded shaft. As the force begins acting on the biomass material, the frictional forces fractionating the biomass material can cause the internal pressure and temperature to begin to rise. For example, the application of the force to the biomass material can cause the biomass material to increase to a second temperature and a second pressure. The second temperature can be greater than the first temperature caused by the force in the expeller 110, and the second pressure can be greater than the first pressure caused by the force in the expeller 110. As the material continues to move through the second chamber 124 and undergo shearing, water can be removed from the biomass material as the temperature and pressure continues to rise. The weakened cell walls can begin to balloon due to the increased temperature and pressure. The biomass material can then pass through an outlet of the second chamber 124. The fibrous material can be rapidly exposed to a decreased pressure (e.g., atmospheric pressure) upon exiting the outlet, thus inducing a cellular explosion, as discussed further herein.

[0145] The machine 100 can include a second motor 122. The second motor 122 can be configured to rotate the second threaded shaft. For example, the second motor 122 can be in mechanical communication with the second threaded shaft. The second motor 124 can be a variable speed motor wherein the adjusting the speed of the second motor 122 can be used to adjust the speed in which the second threaded shaft rotates. As would be appreciated, increasing the rotational speed of the second threaded shaft can increase the throughput of biomass material through the second chamber 124. The first motor 112 can be configured to cause the first threaded shaft to rotate in a first direction and the second motor 122 can be configured to cause the second threaded shaft to rotate in a second direction, the second direction being opposite the first direction. Alternatively, the second direction can be the same as the first direction. Similarly, in some embodiments, the first motor 112 can be configured to cause the first threaded shaft to rotate at a first speed and the second motor 122 can be configured to cause the second threaded shaft to rotate as a second speed, wherein the second speed can be greater than, less than, or equal to, the first speed, in accordance with various embodiments.

[0146] In some embodiments, as discussed above, the expeller 110 can include one or more apertures extending through the outer wall defining the first chamber through which liquid extract can be removed from the feedstock as it traverses through the expeller. In some embodiments, additionally, the expander 120 may not include such apertures. Thus, liquid extract can be mechanically “squeezed” out of the feedstock in the expeller to produce a reduced moisture feedstock at the exit of the expeller 110. The reduced moisture feedstock can then enter the expander without such apertures where pressure and temperature are increased until the cellular explosion process disclosed herein is performed. Additionally, in some embodiments, in addition to the mechanical “squeezing” in the expeller to reduce moisture content, the feedstock can undergo a first / partial cellular explosion process in the expeller (when the feedstock in the expeller is introduced to a lower pressure environment, e.g., at the exit to the expeller) to create the reduced moisture content feedstock, which can then be passed through the expander to undergo a further cellular explosion process as disclosed herein.

[0147] The machine 100 can further include a conveyor 150. For example, the machine 100 can include a conveyor 150 disposed downstream of the expeller 110 and upstream of the expander 120 and configured to receive the biomass material (e.g., a biomass material having a reduced moisture content from biomass material entering the expeller 110) from the expeller 110 and move the biomass material along the conveyor 150 to the expander 120. The conveyor 120 can be any conveyor system for moving material, such as a belt conveyor, screw conveyor,chain conveyor, bucket conveyor, roller conveyor, gravity conveyor, chute conveyor, or any other type of conveyor known in the art, or any combination of these types of conveyors. For example, the conveyor 150 can include an uninterrupted screw configured to move the biomass material from the outlet of the expeller 110 to the inlet of the expander 120. The uninterrupted screw can be connected to the first threaded shaft, or the second threaded shaft, or both and driven by the one or more motors driving these shafts. Alternatively, the uninterrupted screw can be turned by a separate conveyor motor. The conveyor 150 can also be unpowered. For example, the conveyor 150 can include a channel, pipe, tunnel, or any similar structure to allow the biomass material being pushed out of the expeller 110 to traverse the conveyor 150 to the inlet of the expander 120. As would be appreciated, as more biomass material is discharged from the expeller, the biomass material in the conveyor 150 will be displaced and forced to move along the conveyor 150 towards the inlet of the expander 120.

[0148] The temperature of the biomass material can be changed as it traverses the conveyor 150. For example, the biomass material can be heated from an external heat source, such as heater. The heater can be any type of heater such as steam, electric, gas, waste heat, process heat, and the like, or any combination thereof. The heater can be configured to redirect heat generated by the expeller 110, expander 120, e.g., output steam 192 from the first 160 and / or second 170 vents, both to the biomass material as it traverses the conveyor 150. The biomass material can be heated to a predetermined temperature. Alternatively, or in addition, the biomass material can be cooled from a cooling system. For example, the biomass material can be passively cooled by controlling the exposure to ambient. Alternatively, or in addition, the biomass material can be actively cooled through an external cooling source, such as conditioned air, chilled water, coolant, and the like, or any combination thereof. The biomass material can be cooled to a predetermined temperature. The pressure of the biomass material can be changed as it traverses the conveyor 150. For example, the pressure of the biomass material can be reduced to atmospheric pressure.

[0149] The machine 100 can include a first vent 160. For example, the first vent 160 can be connected to the conveyor 150 and, in some embodiments, can be open to the atmosphere. The first vent 160 can allow output steam 192 from the biomass material to exit the machine 100. For example, biomass material exiting the expeller 110 can be at an elevated temperature such that some amount of moisture in the biomass material can be in the form of steam and can exit the machine 100 through the first vent 160. The output steam 192 can be further captured and condensed to form a liquid extract or liquid product as described herein. In addition, the firstvent 160 can allow solids to exit the machine 100. For example, fine particulates from the biomass material can be discharged along with the steam from the biomass material to the atmosphere through the first vent 160.

[0150] In some embodiments, the output steam 192 from the expeller 110 can exit the vent 160 and be redirected to preheat the biomass material 190 prior to entering the chamber 114 of the expeller 110. In some of such embodiments, the output steam can comprise one or more non-water components (such as any of those of the liquid extracts disclosed herein). By repurposing this output steam to preheat the biomass material 190 entering the chamber 114 of the expeller 110, some of these non-water components in the output steam can eventually be captured in the liquid extract in the expeller 110 because they can ultimately traverse through the apertures in the outer wall of the expeller 110 as disclosed above.

[0151] The machine 100 can include an outlet chamber 180. The outlet chamber 180 can be disposed downstream of the expander 120 and configured to receive the biomass material discharged from the expander 120. In the outlet chamber 180, the biomass material can be exposed to atmospheric pressure rapidly. Without wishing to be bound by any scientific theory, this rapid depressurization of the biomass material can cause the chemo-mechanical cellular explosion of the biomass material. In other words, the “ballooned” cells in the biomass material can rupture, releasing intracellular water and further fractionating the biomass material. As would be appreciated, the biomass material can undergo immense stress when moved through the expander 120 due to the increased pressure gradient, force, frictional force, and temperature to result in expanded cells containing vaporized water. The rapid return to atmospheric conditions of the biomass material can induce the chemo-mechanical cellular explosion process to release a final portion of water and obtain dry pulp product. It will also be appreciated that the liberated portions of water during extraction during the process described herein can contain other components and can be recovered as a liquid extract or liquid product.

[0152] The machine 100 can include a second vent 170. For example, the second vent 170 can be connected to the outlet chamber 180 and be open to the atmosphere. The second vent 170 can allow steam from the biomass material to exit the machine 100. For example, biomass material exiting the expander 120 can be at an elevated temperature such that moisture in the biomass material can be in the form of steam and can exit the machine 100 through the second vent 170. The output steam 192 can be further captured and condensed to form a liquid extract or liquid product as described herein. In addition, the second vent 170 can allow solids to exit the machine 100. For example, fine particulates from the biomass material can be dischargedalong with the steam from the biomass material to the atmosphere through the second vent 170. Additionally, in some embodiments, the output steam 192 from the second vent 170 can be directed to preheat the biomass material 190 input to the expeller 110 or the reduced moisture biomass material 190 input to the expander 120, as discussed above.

[0153] The outlet 140 can be disposed downstream of the expander 120. For example, the outlet 140 can be connected to the outlet chamber 180. As illustrated in FIG. IB, the outlet 140 can be disposed on the bottom of the outlet chamber 180 and allow the output biomass material 194 to exit the machine 100 after the biomass material has been subjected to the moisture reduction process described herein. As such, the output biomass material 194 can be a reduced moisture content biomass material. Alternatively, or in addition, the output biomass material 194 can be any biomass material product or solid product of the present disclosure as described herein. For example, the biomass material product can be any materials comprising a fibrous material as described herein, any dry pulp product as described herein, or any fibrous pulp from a lignocellulosic feedstock as described herein.

[0154] The machine 100 can include one or more controllers to control the expeller 110 and expander 120. For example, the one or more controllers can be used to adjust the throughput of the expeller 110 and expander 120 by adjusting the speeds of the first motor 112 and the second motor 122. The one or more controllers can be configured to receive information from one or more sensors in the expeller 110 and expander 120. For example, the expeller 110 and expander 120 can include one or more sensors such as temperature sensors, pressure sensors, and / or flow sensors. The expeller 110 and expander 120 can be in communication with one another through the one or more controllers. The controller can automatically control the expeller 110 and expander 120 based on the received sensor data. For example, the one or more controllers can automatically control the speed of one or more motors driving the expeller 110 and expander 120 in response to receiving temperature or pressure readings from the one or more sensors. Alternatively, or in addition, the controller can output the sensor readings to a user and allow for the user to adjust the operation of the expeller 110 and / or expander 120. The controller can be configured to control the output of the heater. Alternatively, or in addition, the controller can be configured to control the output of the cooling system. In some embodiments, the controller can be further configured to control one or more of choke settings at an output of the first chamber / expeller and / or second chamber / expander, feed rates to the first or second chambers, mixtures of the feedstock (e.g., combinations of bark, saw dust, woodchips, tree types, etc.), addition of processing aids / additives to the feedstock, and outputs of heaters (between first and second chambers or at output of the second chamber.

[0155] The expeller 110 and expander 120 can be axially aligned. For example, the first threaded shaft of the expeller 110 can be axially aligned with the second threaded shaft of the expander 120. The first threaded shaft of the expeller 110 and the second shaft of the expander 120 can be not connected and be driven by separate motors (e.g., the first motor 112 and second motor 122). Alternatively, the first threaded shaft of the expeller 110 and the second shaft of the expander 120 can be coupled. As such the first threaded shaft of the expeller 110 and the second shaft of the expander 120 can be driven by a single motor. Alternatively, the coupled first threaded shaft of the expeller 110 and the second shaft of the expander 120 can be driven by a plurality of motors.

[0156] The expeller 110 can include one or more zones capable of operating at different speeds. For example, the expeller 110 can include a plurality of threaded shafts capable of operating at different speeds. The expeller 110 can include a plurality of motors configured to drive the plurality of threaded shafts to allow each of the plurality of threaded shafts to operate at a different desired speed. Each of the threaded shafts can include a threaded portion along a different length of the expeller 110, each length forming a zone. When operated, the plurality of threaded shafts therefore form multiple zones capable of being operated at independent speeds.

[0157] The expander 120 can include one or more zones capable of operating at different speeds. For example, the expander 120 can include a plurality of threaded shaft capable of operating at different speeds. The expander 120 can include a plurality of motors configured to drive the plurality of threaded shafts to allow each of the plurality of threaded shafts to operate at a different desired speed. Each of the threaded shafts can include a threaded portion along a different length of the expander 120, each length forming a zone. When operated, the plurality of threaded shafts therefore form multiple zones capable of being operated at independent speeds.

[0158] The machine 100 can include one or more liquids injection ports. For example, the one or more liquids injection ports can be configured to allow a user to add one or more liquids to the biomass material being processed by the machine 100. The one or more liquids injection ports can be configured to control the flow of a liquid through the liquids injection port. For example, the one or more liquids injection ports can include a liquid metering system configured to control the flow of a liquid through the liquids injection port. Adding liquids,such as dyes, nutrients, or preconditioners, to the biomass material may be desirable to infuse the biomass material with these liquids to add value to the processed biomass material discharged by the machine 100 at the outlet 140. Alternatively, or in addition, the one or more liquids added to the biomass material being processed by the machine 100 can be an additive material as described herein. As discussed above, the additive material can comprise, for example, a small molecule material, a surfactant, or a polymer. Without wishing to be bound by any particular scientific theory, the additive material can interact with lignin in the biomass material to weaken the cellular structure of the biomass material. The additive material can also act in a catalytic manner and / or as a drag-reducing agent during processing. The one or more liquids injection ports can be disposed proximate the inlet to the expander 120. For example, a liquids injection ports can be disposed proximate the conveyor 150. The one or more liquids injection ports can be used to add liquids to the biomass material after it has had some liquid expelled from it during the expeller 110 process. Adding different liquids back to the biomass material after the expeller 110 process may be desirable. For example, adding liquids, such as dyes, to the biomass material can allow for the dyes to infuse with the biomass material during the subsequent expander 120 process. Alternatively, or in addition, the example dyes can be in form other than a conventional liquid form, such as paste or gel. This process may facilitate an intricate and long-lasting infusion of the dye color into the biomass material. For example, infusing dyes with biomass materials used to create mulch can be desirable. By way of another example, adding water-soluble plant-based polymers, such as natural gums, or engineered polymers, in the form of a liquid, can allow for increased flash evaporation of liquids during the expander 120 process. This can allow for improved evaporation at lower temperature, therefore increasing the efficiency of the overall moisture reduction process by requiring lower temperature, and thus, lower energy to achieve the desired moisture reduction.

[0159] The machine 100 can include one or more solids injection ports. For example, the one or more solids injection ports can be configured to allow a user to add one or more solids to the biomass material being processed by the machine 100. The one or more solids injection ports can be configured to control the amount of solids passing through the solids injection port. For example, the one or more solids injection ports can include a solids metering system configured to control the amount of solids passing through the solids injection port. Alternatively, or in addition, the one or more solids added to the biomass material being processed by the machine 100 can be an additive material. As discussed above, the additive material can comprise, for example, a small molecule material, a surfactant, or a polymer.Without wishing to be bound by any particular scientific theory, the additive material can interact with lignin in the biomass material to weaken the cellular structure of the biomass material. The additive material can also act in a catalytic manner and / or as a drag-reducing agent during processing. The one or more solids injection ports can be disposed proximate the inlet to the expander 120. For example, a solids injection port can be disposed proximate the conveyor 150. The one or more solids injection ports can be capable of operating simultaneously with the one or more liquids injection ports. Adding solids to the biomass material after the expeller 110 process may be desirable. For example, adding water-soluble plant-based polymers, such as natural gums, or engineered polymers, in the form of a solid, can allow for increased flash evaporation of liquids during the expander 120 process. This can allow for improved evaporation at lower temperature, therefore increasing the efficiency of the overall moisture reduction process by requiring lower temperature, and thus, lower energy to achieve the desired moisture reduction.

[0160] As biomass material traverses through the first and / or second chambers, the biomass can have a tendency to “clog” at certain locations, which can decrease the flow of the biomass material. Accordingly, as shown in FIGs. 2A-B, in some embodiments of the present disclosure, one or more lugs which can serve as “flow disrupters” can be disposed at one or more locations along the threaded shaft (any threaded shaft, e.g., expeller and / or expander shafts). In some embodiments, the lugs can extend radially outward from the shaft. The lugs can be configured to alter a flow of biomass material through the chamber.

[0161] The number of lugs can vary in accordance with various embodiments of the present disclosure. In some embodiments, a first location along a length of the shaft can comprise a plurality of lugs disposed circumferentially around the shaft. In some embodiments, the plurality of lugs can be equally spaced circumferentially around the shaft. For example, in some embodiments, two lugs can be spaced 180 degrees apart circumferentially around the shaft. In some embodiments, three lugs can be spaced 120 degrees apart circumferentially around the shaft at a first location. In some embodiments, four lugs can be spaced 90 degrees apart circumferentially around the shaft. The disclosure, however, is not limited to any particular number of lugs.

[0162] The lugs can have many different shapes, in accordance with various embodiments of the present disclosure, including, but not limited to, polyhedrons, rectangular prisms, triangular prisms, square prisms, trapezoidal prisms, and the like. Additionally, some embodiments have a plurality of lugs in which a first portion of the lugs have a first shape and a second portion ofthe lugs have a second shape. For example, as shown in FIGs. 2A-B, a first portion of lugs 220A-B can have a rectangular prism shape while a second portion of lugs 220G-H can have a triangular prism shape. Additionally, as shown in FIGs. 2A-B, the shape of lugs 220A-Hv can vary at different locations along the length of the shaft.

[0163] As biomass material traverses through the chamber, the material can have a greater tendency to clog in certain locations than in other locations. Thus, in some embodiments, lugs are positioned at locations along the shaft where the tendency for clogging is greater. One such location can be at locations proximate to where the pitch of threads decreases. For example, as shown in FIG. 2A, thread 210C can have a greater pitch than thread 210A. Thus, lugs 220A-D can be positioned in the area between thread 210C and 210A. Additionally, in some embodiments, clogging tendency can be exacerbated at a locations where a diameter of the shaft increases (i.e., volume of chamber where biomass material traverses decreases), as shown by arrow 208 in FIG. 2A. In some embodiments, this location can be in the center / middle third of the length of the shaft between the first 206 and second 207 ends. In some embodiments, as shown in FIG. 2A, it can be advantageous to place one or more lugs 220C-D at this location 208. In some embodiments, this section 208 of the shaft can be semi-cone shaped as the shaft transitions from the smaller diameter section to the larger diameter section, and the lugs 220C- D can be located on the semi-cone shaped section.

[0164] The tendency for clogging can also be higher proximate an exit of the chamber at a second end 207 of the shaft (the second end 207 opposite the first end 206). FIG. 2B depicts a portion 215 of the shaft proximate the second end 207. A shown, the portion 215 can have a first surface 218 having a first diameter, a second surface 219 having a second diameter greater than the first diameter, and a wall 217 perpendicular to the first 218 and second 219 surfaces. As biomass material traverses along the chamber from the first end 206 of the shaft 205 to the second end 207 of the shaft, the biomass material can become clogged in the space created by the first surface 218 and the wall 217. Accordingly, in some embodiments, lugs 220G-H can be disposed circumferentially in this space, as shown in FIG. 2B. The lugs can disrupt the flow of biomass material at this location to decrease clogging, thus allowing the biomass material to pass through the apertures 216 disposed on the second surface 219 and exit the chamber. As shown in FIG. 2B, lugs 220G-H can have a triangular prism shape, though other shapes are also contemplated withing the scope of the present disclosure.

[0165] The shaft 205 shown in FIGs. 2A-B (or portions thereof) can be employed in any of the embodiments disclosed above, e.g., in an expeller, expander, or both. The use of lugs 220A-H as disclosed herein can advantageously result in increased flow rate (quantity) of the biomass material traversing through the machine 100.

[0166] Though embodiments above are disclosed as having an expeller 110 and an expander 120, in some embodiments, a second expeller can be substituted for the expander 120, and, in some embodiments, a second expander can be substituted for the expeller 110. The second expander and second expeller can have the same components / features as the expeller 110 and expander 120 disclosed herein.

[0167] As disclosed herein, some embodiments of the present disclosure provide systems and methods of treating biomass material to obtain both a dry (or reduced moisture) pulp product and a liquid extract. This can be performed in multiple stages, e.g., an expeller stage and an expander stage, each powered by a separate motor. The combination of two stages can provide for increased ability to dewater / dry the biomass material over conventional systems, particularly without the need for greater horsepower inputs to the motors. For exampoe, in some embodiments, the system can receive an biomass with a moisture content of 50-60% (e.g., 55%) and produce a dry pulp product having a moisture content of 15-20% (e.g., 18%) with an expeller motor operating at 100 horsepower per ton of feedstock and an expander motor operating at 70 horsepower per ton of feedstock.

[0168] The disclosed technology described herein can be further understood according to the following clauses:

[0169] Clause 1 : A system comprising: a first chamber configured to receive a biomass material; a first threaded shaft configured to convey the biomass material through the first chamber and to apply a first force to the biomass material to cause a first amount of liquid to be extracted from the biomass material to generate a reduced moisture content biomass material; a second chamber configured to receive the reduced moisture content biomass material; and a second threaded shaft configured to convey the biomass material through the second chamber and to apply a second force to the reduced moisture content biomass material to cause a second amount of liquid to be extracted from the reduced moisture content biomass material.

[0170] Clause 2: The system of clause 1, wherein the first chamber comprises a plurality of apertures, and wherein at least a portion of the first amount of liquid exits the first chamber via the plurality of apertures.

[0171] Clause 3: The system of clause 1, wherein the first threaded shaft and the second threaded shaft are axially aligned.

[0172] Clause 4: The system of clause 1, wherein the biomass material comprises a lignocellulosic biomass.

[0173] Clause 5: The system of clause 4, wherein application of the second force to the reduced moisture content biomass material induces a cellular explosion in the lignocellulosic biomass.

[0174] Clause 6: The system of clause 1 or clause 2, wherein the first threaded shaft and second threaded shaft are configured to move independently of each other.

[0175] Clause 7 : The system of any of the preceding clauses further comprising: a first motor in mechanical communication with the first threaded shaft and configured to cause rotation of the first threaded shaft; and a second motor in mechanical communication with the second threaded shaft and configured to cause rotation of the second threaded shaft.

[0176] Clause 8: The system of clause 7, wherein the first motor is configured to cause the first threaded shaft to rotate at a first speed and the second motor is configured to cause the second threaded shaft to rotate at a second speed.

[0177] Clause 9: The system of clause 8, wherein the first speed is greater than the second speed.

[0178] Clause 10: The system of clause 8, wherein the first speed is less than the second speed.

[0179] Clause 11 : The system of any of clauses 7-10, wherein the first motor is disposed near a first end of the system and the second motor is disposed near an opposing second end of the system.

[0180] Clause 12: The system of any of clauses 7-11, wherein the first motor is configured to cause the first threaded shaft to rotate in a first direction and the second motor is configured to cause the second threaded shaft to rotate in a second direction, the second direction being opposite the first direction.

[0181] Clause 13: The system of any of clauses 1-12, wherein the first force applied by the first threaded shaft is configured to cause the biomass material to increase to a first temperature and a first pressure, and wherein the second force applied to the reduced moisture content biomass material is configured to cause the biomass material to increase to a second temperature and a second pressure, the second temperature being greater than the first temperature, and the second pressure being greater than the first pressure.

[0182] Clause 14: The system of any of clauses 1-13, wherein the first chamber and first threaded shaft defines an expeller and the second chamber and second threaded shaft defines an expander.

[0183] Clause 15: The system of any of clauses 1-14, wherein the first threaded shaft comprises an interrupted screw.

[0184] Clause 16: The system of any of clauses 1-15, wherein the first chamber comprises a plurality of teeth extending into the first chamber and configured to contact the biomass material.

[0185] Clause 17: The system of any of clauses 1-16, wherein the second threaded shaft comprises an interrupted screw.

[0186] Clause 18: The system of any of clauses 1-17, wherein the second chamber comprises a plurality of teeth extending into the second chamber and configured to contact the reduced moisture content biomass material.

[0187] Clause 19: The system of any of clauses 1-18, further comprising a conveyor disposed between the first chamber and the second chamber, the conveyor configured to receive the reduced moisture content biomass material from the first chamber and direct the reduced moisture content biomass material to the second chamber.

[0188] Clause 20: The system of clause 19, further comprising a heater configured to apply heat to the reduced moisture content biomass material in the conveyor.

[0189] Clause 21 : The system of clause 20, wherein the heater comprises a steam source.

[0190] Clause 22: The system of clause 21, wherein the heater is configured to redirect heat generated in at least one of the first and second chambers to the conveyor.

[0191] Clause 23: The system of any of clauses 1-22, further comprising: one or more temperature sensors; one or more pressure sensors; and a controller configured to receive temperature data from the one or more temperature sensors and pressure data from the one or more pressure sensors.

[0192] Clause 24: The system of clause 23, wherein: the one or more temperature sensors comprises a first temperature sensor configured to detect a temperature in the first chamber; and the one or more pressure sensors comprises a first pressure sensor configured to detect a pressure in the first chamber.

[0193] Clause 25 : The system of clause 24, wherein: the one or more temperature sensors comprises a second temperature sensor configured to detect a temperature in the secondchamber; and the one or more pressure sensors comprises a second pressure sensor configured to detect a pressure in the second chamber.

[0194] Clause 26: The system of any of clauses 23-25, wherein the controller is further configured to control, based on the temperature data and the pressure data, a speed of the first threaded shaft and a speed of the second threaded shaft.

[0195] Clause 27: The system of any of clauses 23-26, wherein the controller is further configured to control an output of a heater.

[0196] Clause 28: The system of any of clauses 1-27, wherein the first threaded shaft comprises one or more threads having a first pitch, and wherein the second threaded shaft comprises one or more threads having a second pitch, the second pitch different than the first pitch.

[0197] Clause 29: The system of any of clauses 1-28, wherein the first threaded shaft comprises a first portion comprising one or more threads having a first pitch and a second portion comprising one or more threads having a second pitch, the second pitch different than the first pitch.

[0198] Clause 30: The system of any of clauses 1-29 further comprising a liquids injection port.

[0199] Clause 31 : The system of clause 30, wherein the liquids injection port is disposed between the first chamber and the second chamber.

[0200] Clause 32: The system of clause 30 or clause 31, wherein the liquids injection port further comprises a liquid metering system configured to control a flow of liquid through the liquids injection port.

[0201] Clause 33: The system of any of clauses 1-32 further comprising a solids injection port.

[0202] Clause 34: The system of clause 33, wherein the solids injection port is disposed between the first chamber and the second chamber.

[0203] Clause 35: The system of clause 33 or clause 34, wherein the solids injection port further comprises a solids metering system configured to control an amount of solids passing through the solids injection port.

[0204] Clause 36: A system comprising: a plurality of chambers configured to receive a biomass material, at least one chamber of the plurality of chambers comprising a plurality of apertures; a plurality of threaded shafts, each threaded shaft of the plurality of threaded shafts disposed at least partially in a respective chamber of the plurality of chambers and configuredto apply a force to the biomass material and to convey the biomass material through the respective chamber; and a plurality of motors, each motor of the plurality of motors in mechanical communication with a respective threaded shaft of the plurality of threaded shafts and configured to cause the respective threaded shaft to rotate independent of the other threaded shafts of the plurality of threaded shafts.

[0205] Clause 37: The system of clause 36, wherein the biomass material comprises a lignocellulosic biomass.

[0206] Clause 38: The system of clause 36 or clause 37, wherein each motor of the plurality of motors is configured to cause each respective threaded shaft to rotate at a plurality of different speeds.

[0207] Clause 39: The system of any of clauses 36-38 further comprising: a temperature sensor; a pressure sensor; and a controller configured to receive temperature data from the temperature sensor and pressure data from the pressure sensor.

[0208] Clause 40: The system of clause 39, wherein: the temperature sensor is configured to detect a temperature in a chamber of the plurality of chambers; and the pressure sensor is configured to detect a pressure in the chamber of the plurality of chambers, and the controller is configured to control a speed of the plurality of threaded shafts based on the temperature data and the pressure data.

[0209] Clause 41 : The system of any of clauses 36-40, wherein at least one first chamber of the plurality of chambers defines an expeller and at least one second chamber of the plurality of chambers defines an expander.

[0210] Clause 42: The system of any of clauses 36-41 further comprising a liquids injection port.

[0211] Clause 43: The system of clause 42, wherein the liquids injection port is disposed between at least one first chamber of the plurality of chambers defining an expeller and at least one second chamber of the plurality of chambers defining an expander.

[0212] Clause 44: The system of clause 42 or clause 43, wherein the liquids injection port further comprises a liquid metering system configured to control a flow of liquid through the liquids injection port.

[0213] Clause 45: The system of any of clauses 36-44 further comprising a solids injection port.

[0214] Clause 46: The system of clause 45, wherein the solids injection port is disposed between at least one first chamber of the plurality of chambers defining an expeller and at least one second chamber of the plurality of chambers defining an expander.

[0215] Clause 47: The system of clause 45 or clause 46, wherein the solids injection port further comprises a solids metering system configured to control an amount of solids passing through the solids injection port.

[0216] Clause 48: A method of generating a fibrous pulp from a lignocellulosic feedstock, the method comprising: feeding the lignocellulosic feedstock to a first chamber; applying, with a first threaded shaft in the first chamber, a first force to the lignocellulosic material , the first force causing a first amount of moisture to be extracted from the lignocellulosic feedstock to generate a reduced moisture content lignocellulosic feedstock; feeding the reduced moisture content lignocellulosic feedstock to a second chamber applying, with a second threaded shaft in the second chamber, a second force to the lignocellulosic material, the second force causing a second amount of moisture to be extracted from the reduced moisture content lignocellulosic material to generate a further reduced moisture content lignocellulosic material; and exposing the further reduced moisture content lignocellulosic material to an environment having a pressure lower than a pressure inside the second chamber to induce a cellular explosion in a plurality of cells of the further reduced moisture content lignocellulosic material to generate the fibrous pulp.

[0217] Clause 49: The method of clause 48, wherein the first threaded shaft comprises one or more threads circumferentially disposed around the shaft, and wherein the second threaded shaft comprises one or more threads circumferentially disposed around the shaft.

[0218] Clause 50: The method of clause 48 or 49, wherein the first threaded shaft is in mechanical communication with a first motor and the second threaded shaft is in mechanical communication with a second motor.

[0219] Clause 51 : The method of clause 49, wherein the first motor is configured to cause the first threaded shaft to rotate at a first speed and the second motor is configured to cause the second threaded shaft to rotate at a second speed, the second speed being different from the first speed.

[0220] Clause 52: The method of any of clauses 48-51, further comprising transporting, with a conveyor, the reduced moisture content lignocellulosic feedstock from an outlet of the first chamber to an inlet of the second chamber.

[0221] Clause 53: The method of clause 52, further comprising heating the reduced moisture content lignocellulosic material in the conveyor to a predetermined temperature.

[0222] Clause 54: The method of any of clauses 48-53, further comprising collecting at least a portion of the first amount of moisture and / or at least a portion of the second amount of moisture to form a liquid extract.

[0223] Clause 55: The method of clause 54, wherein the liquid extract comprises lignin and one or more organic acids.

[0224] Clause 56: The method of clause 54 or 55, wherein the liquid extract comprises at least a portion of volatile organic compounds present in the lignocellulosic feedstock.

[0225] Clause 57: The method of clause 56, wherein the liquid extract comprises at least 50% of volatile organic compounds present in the lignocellulosic feedstock.

[0226] Clause 58: The method of clause 56, wherein the liquid extract comprises at least 75% of volatile organic compounds present in the lignocellulosic feedstock.

[0227] Clause 59: The method of any of clauses 48-58, wherein heat from an external source is not injected into the first chamber when the first force is applied.

[0228] Clause 60: The method of any of clauses 48-59, wherein heat from an external source is not injected into the second chamber when the second force is applied.

[0229] Clause 61 : The method of any of clauses 48-60, wherein the fibrous pulp has a moisture content of between about 10% and 30% by weight without undergoing further drying.

[0230] Clause 62: The method of any of clauses 48-61, wherein the lignocellulosic feedstock is derived from wood.

[0231] Clause 63: The method of any of clauses 48-62, wherein the lignocellulosic feedstock comprises wood chips.

[0232] Clause 64: The method of any of clauses 48-63, wherein the lignocellulosic feedstock comprises saw dust.

[0233] Clause 65: The method of any of clauses 48-64, wherein the lignocellulosic feedstock has a moisture content of between 35% and 65% by weight prior to entering the first chamber.

[0234] Clause 66: The method of any of clauses 48-64 further comprising feeding a liquid via a liquids injection port to the lignocellulosic feedstock.

[0235] Clause 67: The method of clause 66, wherein the liquids injection port is disposed between the first chamber and the second chamber.

[0236] Clause 68: The method of clause 66 or clause 67 further comprising metering, via a liquid metering system, the feed of the liquid.

[0237] Clause 69: The method of any of clauses 48-68 further comprising feeding a solid via a solids injection port to the lignocellulosic feedstock.

[0238] Clause 70: The method of clause 69, wherein the solids injection port is disposed between the first chamber and the second chamber.

[0239] Clause 71 : The method of clause 69 or clause 70, further comprising metering, via a solids metering system, the feed of the solid.

[0240] Clause 72: The method of any of clauses 48-71, wherein the method utilizes the system of any of clauses 1-47.

[0241] While the present disclosure has been described in connection with a plurality of exemplary aspects, as illustrated in the various figures and discussed above, it is understood that other similar aspects can be used, or modifications and additions can be made to the described aspects for performing the same function of the present disclosure without deviating therefrom. For example, in various aspects of the disclosure, methods and compositions were described according to aspects of the presently disclosed subject matter. However, other equivalent methods or composition to these described aspects are also contemplated by the teachings herein. Therefore, the present disclosure should not be limited to any single aspect, but rather construed in breadth and scope in accordance with the appended claims.

[0242] It is to be understood that the embodiments and claims disclosed herein are not limited in their application to the details of construction and arrangement of the components set forth in the description and illustrated in the drawings. Rather, the description and the drawings provide examples of the embodiments envisioned. The embodiments and claims disclosed herein are further capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purposes of description and should not be regarded as limiting the claims.

[0243] Accordingly, those skilled in the art will appreciate that the conception upon which the application and claims are based may be readily utilized as a basis for the design of other structures, methods, and systems for carrying out the several purposes of the embodiments and claims presented in this application. It is important, therefore, that the claims be regarded as including such equivalent constructions.

[0244] Furthermore, the purpose of the foregoing Abstract is to enable the various patent offices and the public generally, and especially including the practitioners in the art who are not familiar with patent and legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The Abstract isneither intended to define the claims of the application, nor is it intended to be limiting to the scope of the claims in any way. Instead, it is intended that the invention is defined by the claims appended hereto.

Claims

ClaimsWhat is claimed is:

1. A system comprising: a first chamber configured to receive a biomass material; a first threaded shaft configured to convey the biomass material through the first chamber and to apply a first force to the biomass material to cause a first amount of liquid to be extracted from the biomass material to generate a reduced moisture content biomass material; a second chamber configured to receive the reduced moisture content biomass material; and a second threaded shaft configured to convey the biomass material through the second chamber and to apply a second force to the reduced moisture content biomass material to cause a second amount of liquid to be extracted from the reduced moisture content biomass material.

2. The system of claim 1, wherein the first chamber comprises a plurality of apertures, and wherein at least a portion of the first amount of liquid exits the first chamber via the plurality of apertures.

3. The system of claims 1 or 2, wherein the first threaded shaft and the second threaded shaft are axially aligned.

4. The system of any of the preceding claims, wherein the biomass material comprises a lignocellulosic biomass.

5. The system of claim 4, wherein application of the first force to the biomass material induces a cellular explosion in the lignocellulosic biomass when the lignocellulosic biomass is exposed to a reduced pressure from a pressure inside the first chamber6. The system of claims 4 or 5, wherein application of the second force to the reduced moisture content biomass material induces a cellular explosion in the lignocellulosic biomass when the lignocellulosic biomass is exposed to a reduced pressure from a pressure inside the second chamber.

7. The system of any of the preceding claims, wherein the first threaded shaft and second threaded shaft are configured to move independently of each other.

8. The system of any of the preceding claims further comprising: a first motor in mechanical communication with the first threaded shaft and configured to cause rotation of the first threaded shaft; and a second motor in mechanical communication with the second threaded shaft and configured to cause rotation of the second threaded shaft.

9. The system of claim 8, wherein the first motor is configured to cause the first threaded shaft to rotate at a first speed and the second motor is configured to cause the second threaded shaft to rotate at a second speed.

10. The system of claim 9, wherein the first speed is greater than the second speed.

11. The system of claim 9, wherein the first speed is less than the second speed.

12. The system of any of claims 8-11, wherein the first motor is disposed near a first end of the system and the second motor is disposed near an opposing second end of the system.

13. The system of any of claims 8-12, wherein the first motor is configured to cause the first threaded shaft to rotate in a first direction and the second motor is configured to cause the second threaded shaft to rotate in a second direction, the second direction being opposite the first direction.

14. The system of any of the preceding claims, wherein the first force applied by the first threaded shaft is configured to cause the biomass material to increase to a first temperature and a first pressure, and wherein the second force applied to the reduced moisture content biomass material is configured to cause the biomass material to increase to a second temperature and a second pressure, the second temperature being greater than the first temperature, and the second pressure being greater than the first pressure.

15. The system of any of claims 1-13, wherein the first force applied by the first threaded shaft is configured to cause the biomass material to increase to a first temperature and a first pressure, and wherein the second force applied to the reduced moisture content biomass material is configured to cause the biomass material to increase to a second temperature and a second pressure, the second temperature being less than the first temperature, and the second pressure being less than the first pressure.

16. The system of any of the preceding claims, wherein the first chamber and first threaded shaft defines an expeller and the second chamber and second threaded shaft defines an expander.

17. The system of any of the preceding claims, wherein the first threaded shaft comprises an interrupted screw.

18. The system of any of the preceding claims, wherein the first chamber comprises a plurality of teeth extending into the first chamber and configured to contact the biomass material.

19. The system of any of the preceding claims, wherein the second threaded shaft comprises an interrupted screw.

20. The system of any of the preceding claims, wherein the second chamber comprises a plurality of teeth extending into the second chamber and configured to contact the reduced moisture content biomass material.

21. The system of any of the preceding claims, further comprising a conveyor disposed between the first chamber and the second chamber, the conveyor configured to receive the reduced moisture content biomass material from the first chamber and direct the reduced moisture content biomass material to the second chamber.

22. The system of claim 21, further comprising a heater configured to apply heat to the reduced moisture content biomass material in the conveyor.

23. The system of claim 22, wherein the heater comprises a steam source.

24. The system of claims 22 or 23, wherein the heater is configured to redirect heat generated in at least one of the first and second chambers to the conveyor.

25. The system of any of the preceding claims, further comprising: one or more temperature sensors; one or more pressure sensors; and a controller configured to receive temperature data from the one or more temperature sensors and pressure data from the one or more pressure sensors.

26. The system of claim 25, wherein: the one or more temperature sensors comprises a first temperature sensor configured to detect a temperature in the first chamber; and the one or more pressure sensors comprises a first pressure sensor configured to detect a pressure in the first chamber.

27. The system of claim 26, wherein: the one or more temperature sensors comprises a second temperature sensor configured to detect a temperature in the second chamber; and the one or more pressure sensors comprises a second pressure sensor configured to detect a pressure in the second chamber.

28. The system of any of claims 25-27, wherein the controller is further configured to control, based on the temperature data and the pressure data, a speed of the first threaded shaft and a speed of the second threaded shaft.

29. The system of any of claims 25-28, wherein the controller is further configured to control an output of a heater.

30. The system of any of the preceding claims, wherein the first threaded shaft comprises one or more threads having a first pitch, and wherein the second threaded shaft comprises one or more threads having a second pitch, the second pitch different than the first pitch.

31. The system of any of the preceding claims, wherein the first threaded shaft comprises a first portion comprising one or more threads having a first pitch and a second portion comprising one or more threads having a second pitch, the second pitch different than the first pitch.

32. The system of any of the preceding claims further comprising a liquids injection port.

33. The system of claim 32, wherein the liquids injection port is disposed between the first chamber and the second chamber.

34. The system of claim 32 or claim 33, wherein the liquids injection port further comprises a liquid metering system configured to control a flow of liquid through the liquids injection port.

35. The system of any of the preceding claims further comprising a solids injection port.

36. The system of claim 35, wherein the solids injection port is disposed between the first chamber and the second chamber.

37. The system of claim 35 or claim 36, wherein the solids injection port further comprises a solids metering system configured to control an amount of solids passing through the solids injection port.

38. A system comprising: a plurality of chambers configured to receive a biomass material, at least one chamber of the plurality of chambers comprising a plurality of apertures; a plurality of threaded shafts, each threaded shaft of the plurality of threaded shafts disposed at least partially in a respective chamber of the plurality of chambers and configuredto apply a force to the biomass material and to convey the biomass material through the respective chamber; and a plurality of motors, each motor of the plurality of motors in mechanical communication with a respective threaded shaft of the plurality of threaded shafts and configured to cause the respective threaded shaft to rotate independent of the other threaded shafts of the plurality of threaded shafts.

39. The system of claim 38, wherein the biomass material comprises a lignocellulosic biomass.

40. The system of claim 38 or claim 39, wherein each motor of the plurality of motors is configured to cause each respective threaded shaft to rotate at a plurality of different speeds.

41. The system of any of claims 38-40 further comprising: a temperature sensor; a pressure sensor; and a controller configured to receive temperature data from the temperature sensor and pressure data from the pressure sensor.

42. The system of claim 41, wherein: the temperature sensor is configured to detect a temperature in a chamber of the plurality of chambers; and the pressure sensor is configured to detect a pressure in the chamber of the plurality of chambers, and the controller is configured to control a speed of the plurality of threaded shafts based on the temperature data and the pressure data.

43. The system of any of claims 38-42, wherein at least one first chamber of the plurality of chambers defines an expeller and at least one second chamber of the plurality of chambers defines an expander.

44. The system of any of claims 38-43 further comprising a liquids injection port.

45. The system of claim 44, wherein the liquids injection port is disposed between at least one first chamber of the plurality of chambers defining an expeller and at least one second chamber of the plurality of chambers defining an expander.

46. The system of claim 44 or claim 45, wherein the liquids injection port further comprises a liquid metering system configured to control a flow of liquid through the liquids injection port.

47. The system of any of claims 38-46 further comprising a solids injection port.

48. The system of claim 47, wherein the solids injection port is disposed between at least one first chamber of the plurality of chambers defining an expeller and at least one second chamber of the plurality of chambers defining an expander.

49. The system of claim 47 or claim 48, wherein the solids injection port further comprises a solids metering system configured to control an amount of solids passing through the solids injection port.

50. A method of generating a fibrous pulp from a lignocellulosic feedstock, the method comprising: feeding the lignocellulosic feedstock to a first chamber; applying, with a first threaded shaft in the first chamber, a first force to the lignocellulosic material, the first force causing a first amount of moisture to be extracted from the lignocellulosic feedstock to generate a reduced moisture content lignocellulosic feedstock; feeding the reduced moisture content lignocellulosic feedstock to a second chamber; applying, with a second threaded shaft in the second chamber, a second force to the lignocellulosic material, the second force causing a second amount of moisture to be extracted from the reduced moisture content lignocellulosic material to generate a further reduced moisture content lignocellulosic material; and exposing the further reduced moisture content lignocellulosic material to an environment having a pressure lower than a pressure inside the second chamber to induce a cellular explosion in a plurality of cells of the further reduced moisture content lignocellulosic material to generate the fibrous pulp.

51. The method of claim 50, further comprising, prior to feeding the reduced moisture content lignocellulosic feedstock to a second chamber, exposing the lignocellulosic material to an environment having a pressure lower than a pressure inside the first chamber to induce a cellular explosion in a plurality of cells of the lignocellulosic material to generate, at least in part, the reduced moisture content lignocellulosic feedstock.

52. The method of claim 50 or claim 51, wherein the first threaded shaft comprises one or more threads circumferentially disposed around the shaft, and wherein the second threaded shaft comprises one or more threads circumferentially disposed around the shaft.

53. The method of any of claims 50-52, wherein the first threaded shaft is in mechanical communication with a first motor and the second threaded shaft is in mechanical communication with a second motor.

54. The method of claim 52, wherein the first motor is configured to cause the first threaded shaft to rotate at a first speed and the second motor is configured to cause the second threaded shaft to rotate at a second speed, the second speed being different from the first speed.

55. The method of any of claims 50-54, further comprising transporting, with a conveyor, the reduced moisture content lignocellulosic feedstock from an outlet of the first chamber to an inlet of the second chamber.

56. The method of claim 55, further comprising heating the reduced moisture content lignocellulosic material in the conveyor to a predetermined temperature.

57. The method of any of claims 50-56, further comprising collecting at least a portion of the first amount of moisture and / or at least a portion of the second amount of moisture to form a liquid extract.

58. The method of claim 57, wherein the liquid extract comprises lignin and one or more organic acids.

59. The method of claim 57 or 58, wherein the liquid extract comprises at least a portion of volatile organic compounds present in the lignocellulosic feedstock.

60. The method of claim 59, wherein the liquid extract comprises at least 50% of volatile organic compounds present in the lignocellulosic feedstock.

61. The method of claim 59, wherein the liquid extract comprises at least 75% of volatile organic compounds present in the lignocellulosic feedstock.

62. The method of any of claims 50-61, wherein heat from an external source is not injected into the first chamber when the first force is applied.

63. The method of any of claims 50-62, wherein heat from an external source is not injected into the second chamber when the second force is applied.

64. The method of any of claims 50-63, wherein the fibrous pulp has a moisture content of between about 10% and 30% by weight without undergoing further drying.

65. The method of any of claims 50-64, wherein the lignocellulosic feedstock is derived from wood.

66. The method of any of claims 50-65, wherein the lignocellulosic feedstock comprises wood chips.

67. The method of any of claims 50-66, wherein the lignocellulosic feedstock comprises saw dust.

68. The method of any of claims 50-67, wherein the lignocellulosic feedstock has a moisture content of between 35% and 65% by weight prior to entering the first chamber.

69. The method of any of claims 50-67 further comprising feeding a liquid via a liquids injection port to the lignocellulosic feedstock.

70. The method of claim 69, wherein the liquids injection port is disposed between the first chamber and the second chamber.

71. The method of claim 69 or claim 70 further comprising metering, via a liquid metering system, the feed of the liquid.

72. The method of any of claims 50-71 further comprising feeding a solid via a solids injection port to the lignocellulosic feedstock.

73. The method of claim 72, wherein the solids injection port is disposed between the first chamber and the second chamber.

74. The method of claim 72 or claim 73, further comprising metering, via a solids metering system, the feed of the solid.

75. The method of any of claims 50-74, wherein the method utilizes the system of any of claims 1-49.

76. The system of any of claims 1-37, wherein the first threaded shaft comprises one or more lugs extending radially outward from the shaft, the one or more lugs configured to alter a flow of the biomass material through the first chamber.

77. The system of claim 76, wherein a first portion of lugs in the one or more lugs have a polyhedron shape.

78. The system of claim 77, wherein the first portion of lugs have a rectangular prism shape.

79. The system of claim any of claims 76-78, wherein a second portion of lugs in the one or more lugs have a triangular prism shape.

80. The system of claim 76, wherein the one or more lugs comprise a first plurality of lugs, the first plurality of lugs disposed circumferentially around a first location along a length of the first threaded shaft.

81. The system of claim 80, wherein the first plurality of lugs have a polyhedron shape.

82. The system of claim 81 , wherein the first plurality of lugs have a rectangular prism shape.

83. The system of any of claims 80-82, wherein the first location is in a center third of a length of the first threaded shaft.

84. The system of any of claims 80-83, wherein the one or more lugs further comprise a second plurality of lugs, the second plurality of lugs disposed circumferentially around a second location along a length of the first threaded shaft.

85. The system of claim 84, wherein the second plurality of lugs have a polyhedron shape.

86. The system of claim 84, wherein the second plurality of lugs have a rectangular prism shape.

87. The system of claim 86, wherein the second location is at a position along the first threaded shaft where a diameter of the shaft transitions from a first diameter to a second diameter greater than the first diameter.

88. The system of any of claims 84-87, wherein the second location is proximate an end of the first threaded shaft.

89. The system of any of claims 84-87, wherein the second location is in a center third of a length of the first threaded shaft.

90. The system of any of claims 76-89, wherein the one or more lugs are configured to decrease the occurrence of the biomass material clogging the first chamber.

91. The system of any of claims 76-90, wherein the one or more lugs are configured to increase a flow rate of the biomass material through the first chamber.

92. A system for use in processing a biomass material, the system comprising: a chamber configured to receive a biomass material; a threaded shaft configured to convey the biomass material through the chamber and to apply a first force to the biomass material to cause a first amount of liquid to be extracted from the biomass material to generate a reduced moisture content biomass material; and one or more lugs extending radially outward from the shaft and configured to alter a flow of the biomass material through the chamber.

93. The system of claim 92, wherein a first portion of lugs in the one or more lugs have a polyhedron shape.

94. The system of claim 92, wherein the first portion of lugs have a rectangular prism shape.

95. The system of claim any of claims 92-94, wherein a second portion of lugs in the one or more lugs have a triangular prism shape.

96. The system of claim 92, wherein the one or more lugs comprise a first plurality of lugs, the first plurality of lugs disposed circumferentially around a first location along a length of the threaded shaft.

97. The system of claim 96, wherein the first plurality of lugs have a polyhedron shape.

98. The system of claim 96, wherein the first plurality of lugs have a rectangular prism shape.

99. The system of any of claims 96-98, wherein the first location is in a center third of a length of the first threaded shaft.

100. The system of any of claims 96-99, wherein the one or more lugs further comprise a second plurality of lugs, the second plurality of lugs disposed circumferentially around a second location along a length of the threaded shaft.

101. The system of claim 100, wherein the second plurality of lugs have a polyhedron shape.

102. The system of claim 100, wherein the second plurality of lugs have a rectangular prism shape.

103. The system of any of claims 100-102, wherein the second location is at a position along the threaded shaft where a diameter of the shaft transitions from a first diameter to a second diameter greater than the first diameter.

104. The system of any of claims 100-102, wherein the second location is proximate an end of the first threaded shaft.

105. The system of any of claims 100-102, wherein the second location is in a center third of a length of the first threaded shaft.

106. The system of any of claims 92-105, wherein the one or more lugs are configured to decrease the occurrence of the biomass material clogging the first chamber.

107. The system of any of claims 92-106, wherein the one or more lugs are configured to increase a flow rate of the biomass material through the first chamber.

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