High Consistency Cellulosic Feedstock Processing with Silica Removal
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Solution Overview
Problem
Current cellulosic conversion processes face challenges with high water content requirements, leading to increased equipment size, energy consumption, and capital costs, as well as equipment erosion due to silica content in sugar cane-derived feedstocks, which necessitates frequent repairs and downtime.
Innovation Solution
A process involving silica removal from sugar cane-derived cellulosic feedstocks through methods like sieving, screening, or cyclone separation, followed by pretreatment and enzymatic hydrolysis, reduces equipment erosion and enhances process efficiency by operating at higher solids consistency and lower water content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If water is added to form a slurry to facilitate transportation and mechanical handling, then ease of operation is improved, but water content increases leading to increased equipment size and energy consumption
Solution Approach 1:
The patent changes the consistency parameter from conventional low consistency (1-10% dry solids) to high consistency (15-50% dry solids) by reducing water content. This parameter change enables operation at higher solids concentration, reducing equipment size and energy consumption for pumping, heating, cooling and evaporating while maintaining processability through appropriate equipment design
2Ease of operation
If water is added to form a slurry to facilitate transportation and mechanical handling, then ease of operation is improved, but equipment size increases leading to increased capital cost
Solution Approach 1:
The patent changes the consistency parameter from conventional low consistency (1-10% dry solids) to high consistency (15-50% dry solids) by reducing water content. This parameter change enables operation at higher solids concentration, reducing equipment size for the same throughput capacity and thereby reducing capital costs
3Stability of the object's composition
If silica is present in the feedstock, then feedstock composition is maintained, but equipment erosion increases requiring frequent repairs
Solution Approach 1:
The patent extracts and removes silica from the sugar cane-derived cellulosic feedstock before processing. This removal eliminates the erosive effect of silica on equipment surfaces, reducing wear and extending equipment life while maintaining the cellulosic composition necessary for fermentation product production
4Stability of the object's composition
If silica is present in the feedstock, then feedstock composition is maintained, but chemical consumption increases due to buffering effect
Solution Approach 1:
The patent extracts and removes silica from the sugar cane-derived cellulosic feedstock before processing. This removal eliminates the buffering effect of silica, which reduces the chemical demand for pretreatment and hydrolysis steps, thereby reducing chemical consumption and costs
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces equipment wear, lowers operational and capital costs, and improves the economic viability of cellulosic conversion processes by minimizing water usage and energy consumption while maintaining process efficiency.
Implementation Method 1
separating at least silica from the feedstock by size or density differences
Implementation Method 2
silica removal selected from processes comprising separating at least silica from the feedstock by size or density differences
Implementation Method 3
at least partially de-pressurizing the pretreated feedstock comprising passing the pretreated feedstock through an orifice
Implementation Method 4
enzymatic hydrolysis of the cellulose to glucose
Implementation Method 5
hydrolyzing the depressurized, pretreated feedstock with cellulase enzymes to produce glucose
Implementation Method 6
fermenting the glucose to produce the fermentation product
Data Source
AI summary
Provided herein is a process for producing an alcohol from a sugar cane derived cellulosic feedstock comprising: subjecting the sugar cane derived cellulosic feedstock comprising bagasse, leaves, tops, or any combination thereof, to silica removal selected from processes comprising sieving, screening, washing, cyclone separation or any combination thereof. The bagasse, leaves or tops, or any combination thereof, from which at least a portion of the silica has been removed is treated in one or more processing stages to produce sugar, wherein the undissolved solids content of a slurry during said processing stages reaches a weight percent of at least 15%. Thereafter the sugar is fermented with yeast or bacteria to produce the alcohol and the alcohol is concentrated and recovered.