Processes and systems for biomass impregnation to improve conversion to sugars, chemicals, fuels, and materials

Patent metadata

Field	Value
Publication number	US-12359371-B2
Application number	US-202017067662-A
Country	US
Kind code	B2
Filing date	Oct 10, 2020
Priority date	Oct 11, 2019
Publication date	Jul 15, 2025
Grant date	Jul 15, 2025

Abstract

Some variations provide a process for impregnating a biomass feedstock with a reaction solution, comprising: providing a biomass feedstock that contains non-condensable gases within biomass pores; introducing a condensable vapor into the biomass pores to remove non-condensable gases out of the biomass pores, thereby generating an intermediate biomass material, wherein at least a portion of the condensable vapor remains within the biomass pores; exposing the intermediate biomass material to a liquid solution to infiltrate the liquid solution into the biomass pores and condense the vapor to form a condensed liquid contained within the biomass pores, thereby generating an impregnated biomass material containing a reaction solution; and recovering or further processing the impregnated biomass material. The non-condensable gases may be oxygen, nitrogen, or carbon dioxide, for example. The condensable vapor may be steam, for example. The reaction solution may contain a pretreatment chemical, such as a catalyst and/or a solvent.

First claim

What is claimed is:

1. A process for impregnating an agricultural residue with a reaction solution, said process comprising:
(a) providing a biomass feedstock that contains non-condensable gases within biomass pores of said biomass feedstock, wherein said biomass feedstock consists of an agricultural residue;
(b) introducing a condensable vapor into said biomass pores to remove at least some of said non-condensable gases out of said biomass pores, thereby generating an intermediate biomass material, wherein at least a portion of said condensable vapor remains within said biomass pores;
(c) exposing said intermediate biomass material to a liquid solution to (i) infiltrate said liquid solution into said biomass pores and (ii) condense at least a portion of said condensable vapor to form a condensed liquid contained within said biomass pores, thereby generating an impregnated biomass material containing a reaction solution comprising said liquid solution and said condensed liquid; and
(d) recovering or further processing said impregnated biomass material,
wherein step (b) is conducted at a first absolute pressure selected from 0.05 mbar to 5 bar;
wherein said liquid solution is at a liquid initial temperature prior to said exposing said intermediate biomass material to said liquid solution, and wherein said liquid initial temperature is selected from 20° C. to 210° C.;
and wherein step (c) is conducted at a second absolute pressure, and wherein said liquid initial temperature is selected such that said liquid initial temperature is about 5° C. to about 20° C. less than the condensation temperature of said condensable vapor calculated at said second absolute pressure.

2. The process of claim 1 , wherein said non-condensable gases include one or more gases selected from the group consisting of air, oxygen, nitrogen, carbon dioxide, argon, hydrogen, carbon monoxide, and methane.

3. The process of claim 1 , wherein said condensable vapor is steam.

4. The process of claim 1 , wherein said liquid solution consists essentially of water.

5. The process of claim 1 , wherein said liquid solution contains water.

6. The process of claim 1 , wherein said liquid solution is an aqueous solution containing an acid, a salt of said acid, a base, a salt of said base, or a combination thereof.

7. The process of claim 1 , wherein said liquid solution contains a solvent for lignin.

8. The process of claim 1 , wherein during step (b), at least 50 vol % of said non-condensable gases are removed out of said biomass pores.

9. The process of claim 1 , wherein during step (c), at least 50 vol % of said condensable vapor that is contained within said biomass pores condenses.

10. The process of claim 1 , wherein step (b) takes places within a unit selected from a tank, a reactor, a column, and a pipe, and wherein during step (b), said condensable vapor flows, within said unit, countercurrent or cross-current relative to a flow, within said unit, of said biomass feedstock.

11. The process of claim 1 , wherein step (d) includes pretreatment and/or hydrolysis of said impregnated biomass material within a digestor, to form biomass sugars.

12. The process of claim 11 , wherein said process includes mechanical refining of said impregnated biomass material during or after said pretreatment and/or hydrolysis.

13. The process of claim 11 , said process further comprising fermenting said biomass sugars to at least one fermentation product, wherein said fermentation product is optionally purified.

14. The process of claim 1 , wherein step (d) includes pretreatment and/or hydrolysis of said impregnated biomass material within a digestor, to form a nanocellulose precursor pulp.

15. The process of claim 14 , said process further comprising mechanically treating said nanocellulose precursor pulp to generate cellulose nanofibrils and/or cellulose nanocrystals.

16. The process of claim 1 , wherein during step (b), at least 50 vol % of said non-condensable gases are removed out of said biomass pores; and wherein during step (c), at least 50 vol % of said condensable vapor that is contained within said biomass pores condenses.

17. The process of claim 1 , wherein during step (b), at least 90 vol % of said non-condensable gases are removed out of said biomass pores.

18. The process of claim 1 , wherein during step (c), at least 90 vol % of said condensable vapor that is contained within said biomass pores condenses.

19. The process of claim 1 , wherein during step (b), at least 90 vol % of said non-condensable gases are removed out of said biomass pores; and wherein during step (c), at least 90 vol % of said condensable vapor that is contained within said biomass pores condenses.

Assignees

• Granbio Intellectual Property Holdings Llc

Inventors

• Zebroski Ryan

Classifications

• Y02E50/10

  Biofuels, e.g. bio-diesel · CPC title

• D21H11/02

  Chemical or chemomechanical {or chemothermomechanical} pulp · CPC title

• C12P19/14

  produced by the action of a carbohydrase {(EC 3.2.x)}, e.g. by alpha-amylase {, e.g. by cellulase, hemicellulase} · CPC title

• D21C1/02

  with water or steam · CPC title

• C12P19/02

  Monosaccharides (2-ketogulonic acid C12P7/60) · CPC title