Lignin Slurry Pressurization for Continuous Conversion
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Solution Overview
Problem
Current technologies face challenges in implementing a continuous process for converting lignin, particularly due to issues with high-pressure feeding and charging of biomass slurries, which are not effectively addressed in existing disclosures, leading to inefficiencies and low yields in lignin conversion.
Innovation Solution
A process involving a pump with adjustable inlet and outlet valves to pressurize a lignin slurry, allowing for unrestricted flow and unobstructed passage, enabling continuous introduction into a lignin conversion reactor, where the slurry is pressurized to a discharge pressure and then discharged into the reactor, facilitating efficient lignin conversion with high yields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a continuous process is implemented for lignin conversion, then productivity is improved, but high-pressure feeding and charging of biomass slurries becomes problematic due to bridging and plugging of orifices and valves
Solution Approach 1:
The patent applies preliminary action by pre-processing the biomass feedstock through grinding and sizing before slurry formation, ensuring particles are small enough to pass through high-pressure feeding systems without bridging or plugging. The system also pre-mixes the biomass with liquid to create a homogeneous slurry that flows more easily through valves and orifices at high pressure
Solution Approach 2:
The patent changes physical parameters by controlling slurry viscosity, particle size distribution, and liquid-to-solid ratios to optimize flow characteristics. By adjusting these parameters, the slurry maintains pumpability and valve compatibility at high pressures required for continuous lignin conversion processes
2Productivity
If high-pressure feeding systems are used for biomass slurries, then productivity is improved, but ball check valves and orifices are prone to bridging and plugging
Solution Approach 1:
The patent applies local quality by designing specific valve and orifice geometries in critical feeding zones that prevent particle accumulation. The system uses specially shaped passages and surfaces in high-pressure feeding components that reduce turbulence and minimize points where particles could bridge or plug, maintaining reliable flow at high pressures
Solution Approach 2:
The system performs preliminary particle size reduction and slurry homogenization before the slurry enters high-pressure feeding zones, ensuring particles are sufficiently small and evenly distributed to prevent bridging and plugging of valves and orifices during high-rate feeding operations
3Duration of action of moving object
If batch autoclave processes are used for lignin conversion, then catalyst contact time is sufficient, but the process cannot be continuously operated
Solution Approach 1:
The patent implements continuity of useful action by designing a continuous flow reactor system where biomass slurry and catalyst are continuously fed, reacted, and separated. The system maintains constant catalyst contact time through controlled residence times in the reactor while operating in continuous mode rather than batch mode, enabling sustained high-rate lignin conversion
Solution Approach 2:
The patent applies segmentation by dividing the continuous conversion process into distinct stages: slurry preparation, catalytic reaction zone, and product separation. This segmentation allows each stage to be optimized independently, ensuring sufficient catalyst contact time in the reaction zone while maintaining overall continuous operation for high productivity
4Ease of manufacture
If solid lignin is processed, then feedstock handling is simple, but significant handling problems occur in continuous processes
Solution Approach 1:
The patent applies hydraulics by using liquid carriers to form slurries from solid biomass feedstock. The slurry can be pumped and transported through the continuous processing system using hydraulic principles, avoiding the mechanical handling problems of dry solids while maintaining ease of feedstock preparation
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
The process achieves high lignin recovery rates, with approximately 80% of available lignin being converted to usable products, overcoming previous inefficiencies and enabling a continuous, high-yield conversion of lignin from biomass feedstocks.
Implementation Method 1
Increasing the pressure of the pump cavity to a discharge pressure
Implementation Method 2
Passing the slurry comprised of lignin through the inlet valve which is in the inlet valve position selected from the group consisting of at least partially open and open into the pump cavity
Implementation Method 3
an inlet valve which can be present in an inlet valve position selected from the group consisting of open, closed and at least partially open, an outlet valve which can be present in an outlet valve position selected from the group consisting of open, closed and at least partially open
Data Source
AI summary
This specification discloses an operational continuous process to convert lignin as found in ligno-cellulosic biomass before or after converting at least some of the carbohydrates. The continuous process has been demonstrated to create a slurry comprised of lignin, raise the slurry comprised of lignin to ultra-high pressure, deoxygenate the lignin in a lignin conversion reactor over a catalyst which is not a fixed bed without producing char. The conversion products of the carbohydrates or lignin can be further processed into polyester intermediates for use in polyester preforms and bottles.