METHOD FOR PRODUCING VOLATILE ORGANIC COMPOUNDS FROM BIOMASS MATERIAL

专利摘要:
Method for producing volatile organic compounds from biomass material modalities of the present invention provide for the efficient and economical production and recovery of ethanol or other volatile organic compounds, such as acetic acid, from solid biomass material, particularly in a large scale, such as in commercialization or on an industrial scale. according to one aspect of the invention, the method comprises (a) generating at least about 10,160 kg (10 tons) of prepared biomass material by adding a microbe, optionally an acid, and optionally, an enzyme to a solid biomass. ; (b) storing the prepared biomass material for at least about 24 hours in a storage facility to allow production of at least one volatile organic compound from at least a portion of the sugar in the solid biomass; and (c) capturing the at least one volatile organic compound through the use of a solvent-free recovery system.
公开号:BR112014028021B1
申请号:R112014028021-5
申请日:2013-05-16
公开日:2021-08-03
发明作者:Phillip Guy Hamilton；Corey William Radtke；Keith Michael Kreitman
申请人:Shell Internationale Research Maatschappij B.V.；
IPC主号:

专利说明:

field of invention
[001] Modalities of this invention refer in general to a process for producing volatile organic compounds, such as ethanol, from biomass material, and more particularly for the fermentation and recovery of such volatile organic compounds from biomass material . Particularly, the invention provides a method for producing volatile organic compounds from biomass material. Fundamentals of Invention
[002] This section is intended to introduce various aspects of the technique, which may be associated with example embodiments of the present invention. It is believed that this discussion will assist in providing a framework to facilitate a better understanding of particular aspects of the present invention. Appropriately, it should be understood that this section is to be read in this sense, and not necessarily as an admission of any prior art.
[003] As the world's petroleum sources continue to decline there is a growing need for alternative materials that can be substituted for various petroleum products, particularly transport fuels. US environmental regulations, such as the Clean Air Act of 1990, provide incentives for the use of oxygenated fuels in automobiles. Ethanol or methyl tertiary butyl ether (MTBE) increases the oxygen content of gasoline and reduces carbon monoxide emissions. A main advantage to using ethanol is that the fuel is produced from renewable sources. Atmospheric levels of carbon dioxide, a greenhouse gas, can be lowered by replacing fossil fuels with renewable fuels.
[004] Currently much effort is underway to produce bioethanol that is derived from renewable biomass materials such as corn, sugar crops, energy crops, and solid waste. The production of conventional ethanol from corn typically competes with valuable food resources, which can be increasingly amplified by the increase in more severe weather conditions, such as droughts and floods, which negatively impact the amount of crop harvested at every year. Competition from conventional ethanol production can increase food prices. While other crops have served as the biomass material for ethanol production, they are commonly not suitable for global deployments due to the climate requirements for such crops. For example, ethanol can also be efficiently produced from sugarcane, but only in certain areas of the world, such as Brazil, which have a climate that can support harvesting almost year-round.
[005] While other approaches to ethanol production that do not use corn are available, they are still few. For example, Henk and Linden at Colorado State University investigated solid-state ethanol production from sorghum (see Solid State Ethanol Production from Sorghum, Linda L. Henk and James C. Linden, Applied Biochemistry and Biotechnology, Vol. 57/ 58, 1996, pp. 489-501). They noted that for sweet sorghum to be used successfully for ethanol production, three problems need to be addressed: • Carbohydrate storage; • Accessibility of lignocellulosic fraction for enzymatic hydrolysis of hemicellulose and cellulose; and • A more cost-effective means of recovering ethanol from sweet sorghum.
[006] In their process, they highlighted that the seasonal availability and storage capacity of sweet sorghum are important factors in the US and this renewable biomass. Sugar extraction and storage capacity are two serious issues that have limited the use of sweet sorghum as a substrate for ethanol production. Traditional applications envision the use of juice containing about 10 to 15% sugar that has been extracted or pressed from sweet sorghum pulp. The juice is then either fermented directly into alcohol or evaporated into molasses for storage. Direct fermentation of juice into ethanol is a seasonal process, achieved for only a short time after collection. This presents challenges in scaling up solid state fermentation from an experimental stage to a more practical one, such as an industrial scale. For example, the short collection window requires substantial storage capital investment space and recovery facilities to process the peak amount for a short period of time while space and equipment can go dormant or be underutilized for the time. idle.
[007] Henk and Linden's strategy for some of the problems of making sweet sorghum for ethanol was to investigate the use of wet stored solid state fermentation integrated into an economical method for long-term storage of ethanol in sweet sorghum. While Henk and Linden show some improvements to the overall process, there are still a number of downsides, including the amount of ethanol they are capable of producing. Such proposed systems tend to make bioethanol production even more expensive, typically requiring expensive equipment that needs cost-effectiveness. In addition, Henk and Linden show the feasibility of solid state fermentation of sorghum on an experimental scale but do not provide details for scaling up the operation.
[008] For example, Henk and Linden do not provide any means to economically recover ethanol and other volatile organic compounds from solid material biomass. Henk and Linden and others have not addressed the obstacles that make ethanol production from solid-state sorghum fermentation economically viable when it is operated on a large scale, particularly an industrial scale.
[009] Others have also recognized challenges to economically recover ethanol and other volatile organic compounds from solid material biomass. For example, Webster et al. reported that the use of a forage harvester for sweet sorghum results in rapid juice spoilage and therefore not an attractive solution for bringing sweet sorghum to sugar mills (see Observations of the Harvesting, Transporting and Trial Crushing of Sweet Sorghum in a Sugar Mill , Webster, A., et al, 2004 Conference of the Australian Society of Sugar Cane Technologist, Brisbane, Queensland, Australia (May 2004)). Andrzejewski and Eggleston reported that the challenges in making US sweet sorghum for ethanol (or other uses) revolve around juice storage because of the relatively narrow harvest window for sweet sorghum in the United States of America (see Development of commercially viable processing technologies for sweet sorghum at USDA-ARS-Southem Regional Research Center in New Orleans, Andrzejewski and Eggleston, Sweet Sorghum Ethanol Conference, 26 Jan 2012). In particular, challenges include (i) clarification (removal of suspended and turbid particles) of raw juice to make it suitable for concentration and/or fermentation, (ii) stabilization of juice or partially concentrated juice for seasonal use with good cost-effectiveness (liquid feed charge), and (iii) the concentration of juice to syrup for storage, year-round supply, and efficient transport (liquid feed charge).
[0010] Bellmer wished to improve the process by optimizing conditions around the removal of juice from solids prior to processing (see The untapped potential of Sweet Sorghum as a Bioenergy feedstock., Bellmer, D., Sweet Sorghum Ethanol Conference, Jan 26, 2012 ). Wu et al. recognize the technical challenges to using sweet sorghum for biofuels, including a short collection period for higher sugar content, and rapid sugar degradation during storage (see Features of sweet sorghum juice and their performance in ethanol fermentation, X. Wu et al., Industrial Crops and Products 31:164-170, 2010). In particular, the study showed that as much as 20% of fermentable sugars could be lost in 3 days. Bennett and Annex noted the limitations of using sorghum for ethanol production that involve the cost of material transport and storage capacity (see Farm-gate productions costs of sweet sorghum as a bioethanol feedstock, Transactions of the American Society of Agricultural and Biological Engineers, Vol. 51(2):603-613, 2008). While Bennet and Annex were aware of direct ethanol production in yeast inoculated silage, they concluded that such a direct production method was not practical because of problems related to ethanol separation from silage, silage storage losses (even 40% in warehouse style silos), and the possible use of silage as an alternative feed load phennentation is yet to be examined for industrial scale applications.
[0011] Shen and Liu wish to address effective and longer time storage of fresh stem or juice by dry sweet sorghum first in order to preserve sugars, so they plan to use the material throughout the year for ethanol production, adding from this forms material costs that deal with drying by spreading the sweet sorghum for drying, as well as adding restrictions to the process by requiring suitable climatic conditions to achieve proper drying (see Research on Solid-State Ethanol Fermentation Using Dry Sweet Sorghum Stalk Particles with Active Dry Yeast, Shen, Fei and Liu, R., Energy & Fuels, 2009, Vol. 23, pp. 519-525). Imam and Capareda wish to process the juice before fermentation and to increase fermentation rates using a variety of options such as autoclaving (heat treating), freezing, and to increase sugar concentration (see Ethanol Fermentation from Sweet Sorghum Juice, Imam, T. and Capareda, S., AS ABE, 2010 AS ABE Annual International Meeting, Pittsburgh, PA (June 2010)).
[0012] Bellmer, Huhnke, and Godsey noted challenges to using sorghum in ethanol production such as: (i) carbohydrate storage capacity in sweet sorghum, (ii) rapid sugar/carbohydrate degradation in the stem after harvest, (iii) short shelf life of espresso juice, (iv) very expensive syrup production (dewatering) (see The untapped potential of sweet sorghum as a bioenergy feedstock, Bellmer, D., Huhnke, R., and Godsey, C, Biofuels 1(4) 563-573, 2010). They used solid-phase fermentors, which are metal containers including rotating drums and screw drills, which require equipment. Additionally, the use of a solid phase fermenter is also subject to the harvest window of the crop, eg sweet sorghum. Likewise, Noah and Linden noted inefficient sugar extraction and storage capacity as the biggest drawbacks to using sweet sorghum for fuels and chemicals.
[0013] In short, obstacles to using sorghum and other plants containing the fermentable sugars include the fact that they are only available seasonally and storage is expensive, which makes it a challenge to use infrastructure efficiently and to schedule work; Sugar extraction and storage capacity are two critical obstacles as conversion must start immediately after collection to avoid spillage.
[0014] Thus, there is a need for a process to produce ethanol and other volatile organic compounds on a large scale from biomass material that addresses at least these obstacles, such as preferably not competing with the world food source . summary
[0015] Modalities of the present invention provide a number of advantages over conventional processes. Modalities of the invention allow for the economical production of ethanol and other volatile organic compounds from plants containing fermentable sugar addressing the challenges, part of which was noted above, such as the needs of decentralized plants, small harvest windows, rapid degradation of sugars, and large investment in equipment.
[0016] In certain modalities, fermentation can be achieved by storing the prepared biomass material in one or more piles, thereby reducing or eliminating the need for expensive equipment compared to the prior art fermentation process which generally requires investment of significant capital. Embodiments of the invention allow fermentation in conjunction with product storage where prior art fermentable sugar fermentation crops generally need to be harvested on time to avoid spillage, which makes prior art operation time sensitive.
[0017] Modalities of the invention allow the recovery facility to run continuously throughout the year in a controlled manner independent of the harvest window, thereby extending the geological locations available to position a recovery facility, including areas with a harvest window. relatively short harvest. For example, sugarcane ethanol plants in Brazil typically for about nine months a year as this is the harvest window for sugarcane in Brazil. In the US, the same plant can only operate about three to five months a year because of the requirement to harvest on time coupled with the short time of harvest availability. Embodiments of the present invention eliminate or minimize the need for on-time harvesting which allows for year-round ethanol production regardless of the sugar harvest's harvest window.
[0018] Modalities of the invention provide control over the fermentation and storage period where there is minimal degradation of volatile organic compounds for up to 700 days, thus allowing a short harvest window where the crop is closer to its peak sugar potential and field yield. This allows harvesting in the optimum condition instead of conventional processes which may need to compromise the level of sugar production and field yield to obtain a longer harvest window.
[0019] Additionally, the embodiments of the invention allow for larger scale production of ethanol or other volatile organic compounds, including recovery of sufficient quantities for commercialization or other industrial applications.
[0020] In a particular embodiment, a method is provided for producing at least one volatile organic compound comprising: generating at least about 10,160 kg (10 tons) of prepared biomass material comprising at least one additive added to a solid biomass comprising a sugar, wherein said at least one additive comprises a microbe, and optionally, an acid and/or an enzyme; storing the prepared biomass material for at least about 24 hours in a storage facility to allow for the production of at least one volatile organic compound from at least a portion of the sugar; and capturing the at least one volatile organic compound by feeding the stored biomass material to a solvent-free recovery system to separate the stored biomass material into at least one gas component comprising the at least one volatile organic compound and a solid component.
[0021] In one embodiment, the capture step comprises: introducing the prepared biomass material into a closed compartment of a solvent-free recovery system, wherein the prepared biomass material contains one or more volatile organic compounds; contacting the prepared biomass material with a stream of superheated vapor in the closed compartment to vaporize at least a portion of an initial liquid content in the prepared biomass material, said stream of superheated vapor comprising at least one volatile organic compound; separating a gas component and a solid component from the prepared biomass material, said gas component comprising at least one volatile organic compound; and retaining at least a portion of the gas component for use as part of the superheated vapor stream.
[0022] In another embodiment, a method is provided for producing a moist biomass that can be stored containing the volatile organic compounds, said method comprising: adding at least one additive to at least about 10,160 kg (10 tons) of a biomass solid to generate a prepared biomass material, said solid biomass comprising a sugar production plant, wherein said at least one additive comprises a microbe, and optionally, an acid and/or an enzyme; and allowing the conversion of at least a portion of the sugar in the prepared biomass material to a volatile organic compound; wherein the biomass material is capable of being stored for about 700 days without significant degradation of the volatile organic compound.
[0023] In addition to the features described above, embodiments of the invention allow the economical production of alternative fuels, such as ethanol and other volatile organic compounds, from plants containing fermentable sugar, addressing challenges such as storage and storage costs. transport, small harvest windows, rapid degradation of sugars, and large investment in equipment. Aspects of the modalities described herein are applicable to any biomass material, such as plants containing the fermentable sugars. The functionalities of the embodiments of the present invention allow for the economical use of various plants to produce alternative fuels and chemicals and are not limited to sorghum and other plants that suffer from similar challenges. Such challenging crops are highlighted here as other methods and systems have not been able to economically use these challenging crops to produce fuels and chemicals. In this way, the specific movement of sorghum is not intended to be limiting, but rather illustrates a particular application of the embodiments of the invention.
[0024] Other features and advantages of the embodiments of the present invention will be apparent from the following detailed description. However, it is to be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, as various changes and modifications within the spirit and scope of the invention will be apparent to those skilled in the art. technique from this detailed description. Brief Description of Drawings
These drawings illustrate certain aspects of some of the embodiments of the invention, and are not to be used to limit or define the invention.
[0026] FIG. 1 is a diagram of an embodiment for processing biomass material in accordance with certain aspects of the present invention.
[0027] FIG. 2 is a diagram of another embodiment for processing biomass material in accordance with certain aspects of the present invention. Detailed Description of Preferred Modalities
[0028] Modalities of the present invention provide for the efficient and economical production and recovery of ethanol or other volatile organic compounds, such as acetic acid, from solid biomass material, particularly on a large scale, such as in commercialization or at scale industrial. According to one aspect of the invention, the method comprises (a) generating at least about 10,160 kg (10 tons) of prepared biomass material by adding a microbe, optionally an acid, and optionally, an enzyme to a solid biomass. ; (b) storing the prepared biomass material for at least about 24 hours in a storage facility to allow production of at least one volatile organic compound from at least a portion of the sugar in the solid biomass; and (c) capturing the at least one volatile organic compound through the use of a solvent-free recovery system.
[0029] As used herein, the term "solid biomass" or "biomass" refers to at least one biological matter from living or newly living organisms. Solid biomass includes plant or animal matter that can be converted to fibers or other products industrial chemicals, including biofuels. Solid biomass can be derived from various types of plants or trees, including miscanthus, grasses, hemp, corn, tropical aspen, willow, sorghum, sugar cane, sugar beet, and any energy cane, and a variety of tree species, ranging from eucalyptus to palm oil (palm oil). In one embodiment, solid biomass comprises at least one fermentable sugar producing plant. Solid biomass can comprise two or more types of plant different types, including fermentable sugar production plant. Different types of plant can have the same harvest season or different harvest seasons. In a preferred modality Not intended to limit the scope of the invention, sorghum is selected because of its high yield on less productive land and high sugar content.
[0030] The term "fermentable sugar" refers to oligosaccharides and monosaccharides that can be used as a carbon source (eg, pentoses and hexoses) by a microorganism to produce an organic product such as alcohols, organic acids, esters, and aldehydes, under anaerobic and/or aerobic conditions. Such production of an organic product can generally be referred to as fermentation. The at least one fermentable sugar production plant contains fermentable sugars dissolved in the water phase of the plant material at a point of time during its growth cycle. Non-limiting examples of fermentable sugar production plants include sorghum, sugar cane, sugar beet, and energy cane. In particular, sugarcane, energy cane, and sorghum typically contain from about 5% to about 25% soluble sugar w/w in the water phase and have a moisture content between about 60% and about 80% on a wet basis when they are close to their maximum potential fermentable sugar production or at their maximum potential fermentable sugar production (eg, maximum fermentable sugar concentration).
[0031] The term "wet base" refers at least to the percentage of mass that includes water as part of the mass. In a preferred embodiment, the sugar production plant is sorghum. Any species or variety of the sorghum genus that provides the microbial conversion of carbohydrates to volatile organic compounds (VOCs) can be used. For modalities using sorghum, the plant provides certain benefits, including being water efficient as well as heat and drought tolerant. These properties make the crop suitable for many locations, including various regions across the earth, such as China, Africa, Australia, and in the US, such as portions of the High Plains, the west and throughout southern Texas.
[0032] In modalities using sorghum, sorghum can include any variety or combination of varieties that can be collected with higher concentrations of fermentable sugar. Certain sorghum varieties with preferred properties are sometimes referred to as “sweet sorghum”. Sorghum can include a variety that may or may not contain enough moisture to support the juicing process in the sugarcane milling operation. In a preferred embodiment, the solid biomass includes a variety of T Sugar Sorghum commercially produced by Advanta and/or a male relative of T Sugar, which is also a commercially available product of Advanta. In a preferred embodiment, the culture used is from about 5 to about 25 brix, preferably from about 10 to about 20 brix, and more preferably from about 12 to about 18 brix. The term "brix" here refers at least to the content of glucose, fructose and sucrose in an aqueous solution where a brix degree is 1 gram of glucose, fructose and/or sucrose in 100 grams of solution and represents the strength of the solution as a percentage by weight (% w/w). In another preferred embodiment, the moisture content of the culture used is from about 50% to 80%, preferably at least 60%.
[0033] In one modality, the crop is a male relative of Sugar T with a brix value of about 18 and a moisture content of about 67%. In another modality, the crop is Sugar T with a brix value of about 12 at a moisture content of about 73%. In these particular modalities, the values of brix and moisture content were determined by a manual refractometer.
[0034] After at least one additive (a microbe, optionally an acid and/or enzyme) is added to solid biomass, a prepared biomass material is taken where the at least one additive facilitates the conversion of fermentable sugar to a VOC ( such as ethanol). As noted above and further described below, the prepared biomass material can be stored for a certain period of time to allow more VOCs to be generated by the conversion process. At least one volatile organic compound is then recovered from the prepared biomass material. Volatile organic compounds are known to those skilled in the art. The US EPA provides descriptions of volatile organic compounds (VOC), one which is any carbon compound, excluding carbon monoxide, carbon dioxide, carbonic acid, metallic carbides or carbonates, and ammonium carbonate, which participate in photochemical reactions atmospheric conditions, except those designated by EPA as having negligible photochemical reactivity (see http://www.epa.gOv/iaq/voc2.html#definition). Another description of volatile organic compounds, or VOCs, is any organic chemical compound in which the composition makes it possible for them to evaporate under normal indoor atmospheric conditions of temperature and pressure. This is the general definition of VOCs that is used in the scientific literature, and is consistent with the definition used for indoor air quality. Normal indoor atmospheric conditions of temperature and pressure refer to the range of conditions usually found in buildings occupied by people, and thus may vary depending on the type of building and its geographic location. An example normal indoor atmospheric condition is provided by the International Union of Pure and Applied Chemistry (lUPAC) and the National Institute of Standards and Technology (NIST). The lUPAC standard is a temperature of 0°C (273.15 K, 32°F) and an absolute pressure of 100 kPa (14.504 psi), and the NIST setting is a temperature of 20°C (293.15 K , 68°F) and an absolute pressure of 101.325 kPa (14.696 psi).
[0035] As the volatility of a compound in general is higher the lower is the boiling point temperature, the volatility of organic compounds is sometimes defined and classified by their boiling points. Appropriately, a VOC can be described by its boiling point. A VOC is any organic compound having a boiling point range of about 50 degrees C to 260 degrees C measured at a standard atmospheric pressure of about 101.3 kPa. Many volatile organic compounds that can be recovered and/or further processed from VOCs recovered in the embodiments of the present invention have applications in the flavor and perfume industries. Examples of such compounds can be esters, ketones, alcohols, aldehydes, hydrocarbons and terpenes. The following Table 1 further provides non-limiting examples of volatile organic compounds that can be recovered and/or further processed from VOCs recovered from the prepared biomass material. Table 1

[0036] Ethanol is a preferred volatile organic compound. Thus, many examples specifically mention ethanol. This specific mention, however, is intended to limit the invention. It should be understood that aspects of the invention also apply equally to other volatile organic compounds. Another preferred volatile organic compound is acetic acid.
[0037] Modalities of the present invention provide for long-term storage of solid biomass material without significant degradation to the volatile organic compounds contained in the prepared biomass material, and they provide sugar preservation to allow for the continued generation of VOCs. As used in this context, “Significant” refers to at least within the margin of error when measuring the amount or concentration of volatile organic compounds in the prepared biomass material. In one modality, the margin of error is around 0.5%.
[0038] Appropriately, embodiments of the present invention allow the continuous production of VOCs without dependence on the duration of the harvest, thereby eliminating or minimizing downtime of a recovery plant in traditional recovery and on-time harvest processes. Thus, embodiments of the present invention allow for harvesting the crop at its peak without compromises typically made to extend the harvest season, such as harvesting slightly earlier and later than the peak time. That is, embodiments of the invention allow for harvesting at high field yields and high sugar concentrations, such as when the selected crop has reached its peak sugar concentration or quantity of fermentable sugars that can be converted to a volatile organic compound, even if this results in a shorter harvest period. In one embodiment, solid biomass is harvested or prepared when it is at about 80%, about 85%, about 90%, about 95%, or about 100% of its maximum potential fermentable sugar concentration. In this way, embodiments of the present invention, particularly the recovery phase, can be operated continuously throughout the year without time pressure of fear of spoiling solid biomass and VOCs contained therein. While embodiments of the present invention allow for the collection of solid biomass near its maximum sugar production potential or its maximum sugar production potential, solid biomass material can be collected at any point when it is considered to contain an adequate amount of sugar. Additionally, the harvest window varies depending on the type of crop and geographic location. For example, the North American sorghum harvest window can range from about 1 to 7 months. However, in Brazil and in other equatorial and near-equatorial areas, the harvest window can be up to twelve months.
[0039] In the embodiments using plants as solid biomass, solid biomass can be collected or harvested from the field using any suitable means known to those skilled in the art. In one embodiment, the solid biomass comprises a stem component and a plant leaf component. In another embodiment, the solid biomass additionally comprises a grain component. In a preferred embodiment, solid biomass is harvested with a forage or silage harvester (a forage or silage cutter). A forage or silage harvester refers to agricultural equipment used to make silage, which is grass, corn, or other plant material that has been cut into small pieces, and compacted in a storage silo, silage bin, or silage bags. A forage or silage combine has a cutting mechanism, such as either a drum (cutting head) or a flywheel with a number of knives attached to it, which cuts and transfers the cut material to a receptacle that is either connected with the harvester or with another vehicle traveling alongside. A forage harvester is preferred as it provides benefits over the sugarcane harvester or dry bale system. For example, a forage harvester provides material with a higher density than a sugarcane harvester, thus allowing for more efficient transport of the harvested material. In one embodiment, using a forage harvester results in harvested sorghum with a volumetric density of about 400 kg/m3, compared to sugarcane harvested with a sugarcane harvester with a density of about 300 kg/m3, and to the sorghum harvested with a sugarcane harvester with a density of about 200 kg/m3. In general, material with higher volumetric density is cheaper to transport, which tends to limit the geographic area in which the harvested sugarcane crop can be collected.
[0040] Thus, a forage harvester is a generally cheaper way to collect selected biomass, such as sorghum, than a sugarcane harvester or dry baled system. Without being bound by theory, it is believed that cost savings are due in part to higher material yields and higher volumetric density of solid biomass harvested by a forage harvester. Solid biomass can be cut to any length. In one embodiment, combine cut lengths can be set to a range of from about 3mm to about 80mm, preferably about 3mm to about 20mm, with examples from about 3mm to about 13mm of cut lengths being most preferred. At these preferred cut lengths, there was no observable water discharge into the forage harvester, so losses were minimal. When a cut length is selected, the combine provides biomass with an average size or length distribution of about the selected cut length. In one embodiment, the average size distribution of the solid component leaving the recovery system can be adjusted as desired, which can be done by adjusting the cut length of the combine.
[0041] At least one additive is added to solid biomass to facilitate and/or accelerate the conversion of appropriate carbohydrates to volatile organic compounds. After selected additives have been added, solid biomass can be referred to as prepared biomass material. In one embodiment, the prepared biomass material may comprise at least one or any combination of fermentable sugar producing plants listed above. In a preferred embodiment, selected additives can be conveniently added using the combine during harvesting.
[0042] Modalities of the invention provide for increased scale operation to generate at least about 10,160 kg (10 tons) of the prepared biomass material in a particular harvest period. For modalities using a forage harvester, the forage harvester assists in achieving the scaled-up quantity. In one embodiment, at least about 711,232 kg (700 tons), preferably at least about 1,016,047 Mg (1 million tons), such as at least 1,219,256 Mg (1.2 million tons), or more preferably about at least 5,080,235 Mg (5 million tons) of prepared biomass material are generated in a particular harvest window based on the growing conditions of a specific region, such as about 1 to 7 months in North America. North to sorghum. In one modality, up to 101,604,700 Mg (100 million tons) of prepared biomass are generated in a particular harvest period.
[0043] The at least one additive can be added at any point during and/or after the harvesting process. In a preferred embodiment using a forage harvester, additives are added to the solid biomass during the harvesting process to generate a prepared biomass material. In particular, forage combines are designed to efficiently add both solid and liquid additives during harvesting. As mentioned above, the additives added include at least one microbe (for example a yeast), and optionally, an acid and/or an enzyme. In a preferred embodiment, selected additives are added as solutions. Further details of potential additives are further provided below.
[0044] For modalities using a forage harvester or similar equipment, selected additives can be added during harvesting at all stages, such as before the inlet feed rollers, during admission, at cutting, after cutting , through the blower, after the blower, in the accelerator, in the growth (or nozzle), and/or after the growth. In a modality where acid and enzyme are added, acid is added near the inlet feed rollers, and a microbe and enzyme are added in the growth. In one particular modality, a Krone Big X forage harvester with a VI2 engine with a collector almost 914.4 cm (30 ft) wide is used. In one embodiment using the Krone system, acid is added as a solution through flexible tubing that discharges the solution just in front of the feed rollers. In this way, the liquid flow could be monitored in a visual way, which showed the acid and solid biomass solution quickly mixed inside the cutting chamber. In another embodiment, the addition of acid has also been demonstrated as a viable practice using a Case New Holland FX 58 forage combine. In certain embodiments, the forage combine used may include an onboard rack to contain additives, at least those selected to be added during harvest. In another modality, selected additives to be added during harvesting can be towed behind the combine in a trailer. For example, in one embodiment, it has been demonstrated that a modified utility trailer equipped with tanks containing yeast additive solutions, enzymes, and acid can be employed with minimal interference with normal combine operations, thereby substantially maintaining expected cost and life. of the harvesting process. For example, a normal harvest and biomass yield setup that employs a silage combine that travels at about 4 miles per hour maintains a similar collection rate of about 4 miles per hour when equipped with certain additives as described above in a modality.
[0045] In the embodiments of the present invention, the prepared biomass material is eventually transported to a storage facility where it is stored for a period of time to allow the production of at least one volatile organic compound from at least a portion of the sugar fermentable from solid biomass. Details of the storage phase are additionally provided below. In certain embodiments, selected additives can also be added to the storage facility. For example, in one embodiment, selected additives can be added during offloading or after solid biomass has been unloaded into the storage facility. In one embodiment, a conveyor system is used to assist with the addition of selected additives in the storage facility. Additives added at the storage facility for solid biomass can be those that have not been added or additional amounts of those added previously. Appropriately, selected additives can therefore be added at any point from the beginning of the harvesting process to prior to storage of the prepared biomass material in the storage area or facility, such as at points where material is transferred.
[0046] As mentioned above, additives to embodiments of the present invention include at least one microbe and optionally, an acid and/or an enzyme. Selected additives can be added to solid biomass in any order. In a preferred embodiment, an acid is added to the solid biomass before adding a microbe to inoculate the material to provide an attractive growth environment for the microbe.
[0047] In a preferred embodiment, acid is added to reduce the pH of solid biomass to a range that facilitates and/or accelerates selected indigenous or added microbial growth, which increases ethanol production and/or volatile organic compounds. The acid can also stop or slow the plant's respiration, which consume fermentable sugars intended for subsequent VOC production. In one embodiment, acid is added until the pH of the solid biomass is between about 2.5 and about 5.0, preferably in a range of from about 3.7 to about 4.3, and more preferably about about 4.2. The acid used can include known acids such as sulfuric acid, formic acid, or phosphoric acid. The following Table 2 provides non-limiting examples of an acid that can be used singly or in combination. Table 2

[0048] In a preferred embodiment, after the solid biomass reaches the desired pH with the addition of acid, a microbe is added. A microbe in the additive context refers to at least one living organism added to solid biomass that is capable of impacting or affecting the prepared biomass material. An example effect or impact from the added microbes includes providing fermentation or other metabolism to convert fermentable sugars from various sources, including cellulosic material, to ethanol or other volatile organic compounds. Another example effect or impact might be the production of certain enzymes that help to deconstruct cellulose in the prepared biomass material to fermentable sugars that can be metabolized to ethanol or another VOC. One more example effect or impact provided by a microbe includes producing compounds such as vitamins, cofactors, and proteins that can enhance the quality, and thus the value, of an eventual by-product that can serve as animal feed. Additionally, microbial activity provides heat to the pile. Parts of the microbial cell walls or other catabolite or anabolite may also offer value-added chemicals that can be recovered by a recovery unit. These impacts and effects can also be provided by microbes indigenous to solid biomass.
[0049] Any microbe that is capable of impacting or affecting the prepared biomass material can be added. In a preferred embodiment, the microbes can include microbes used in silage, animal feed, wine and industrial ethanol fermentation applications. In one embodiment, the selected microbe includes yeast, fungi and bacteria according to the application and desired profile of the organic molecule to be made. In a preferred embodiment, yeast is the selected microbe. In another embodiment, the bacteria can be added to make lactic acid or acetic acid. Certain fungi can also be added to make these acids.
[0050] For example, Acetobacterium acetii can be added to generate acetic acid; Lactobacillus, Streptococcus thermophilus can be added to generate lactic acid; Actinobacillus succinogenes, Mannheimia succiniciproducens, and/or Anaerobiospirillum succiniciproducens can be added to generate succinic acid; Clostridium acetobutylicum can be added to generate acetone and butanol; and/or Aerobacter aerogenes can be added to generate butanediol.
[0051] The following Table 3 provides non-limiting examples of preferred microbes, which can be used singly or in combination. Table 3

Preferred microbes also include strains of Saccharomyces cerevisiae that can tolerate high concentrations of ethanol and are strong competitors in their respective microbial community. Microbes can be mesophilic or thermophilic. Thermophiles are organisms that grow best at temperatures above about 45°C, and are found in all three domains of life: Bacteria, Archaea, and Eukarya. Mesophiles in general are active between about 20 degrees C and 45 degrees C. In one embodiment using a strain of Saccharomyces cerevisiae, the strain may come from a commercially available source such as Biosaf from Lesaffre, Ethanol Red from Phibro, and yeast Lallamand activated liquid. If the microbe is obtained from a commercial source, the microbe can be added at the supplier's recommended rate, which is typically based on the expected sugar content per wet pound, where water is included in the mass calculation. The term "wet kilo" refers to at least the unit of mass including water. The recommended amount can be adjusted according to the reaction conditions. The added microbe can comprise one strain or multiple strains of a particular microbe. In one modality, microbes are added at a rate of up to 500 mL per wet kilogram of solid biomass. In a particular embodiment using commercially available yeast, about 300 mL of yeast preparation is added per wet kilogram of solid biomass. In another embodiment, an additional yeast strain can be added. For example, Ethanol Red can be added at a rate of between about 0.001 kg/wet kilo to about 0.5 kg/wet kilo, particularly about 0.1 kg/wet kilo. In a further modality, another strain of yeast can be added, eg Biosaf, at a rate of between about 0.001 kg/wet kilo and up to about 0.5 kg/wet kilo, particularly about 0.1 kg/kilo humid. It is understood that other amounts of any yeast strain can be added. For example, about 10%, about 20%, about 30%, about 40%, about 50%, about 60%, about 70%, about 80%, about 90%, about 1.5 times, about 2 times, about 2.5 times, or about 3 times of the provided amounts of microbes can be added.
[0053] In certain embodiments, an enzyme is additionally added. The enzyme may be one that aids in the generation of fermentable sugars from plant materials that are more difficult for the microbe to metabolize, such as different cellulosic materials, and/or to enhance the value of an eventual by-product that serves as animal feed, such as making food more digestible. The enzyme can also be an antibiotic, such as a lysozyme as discussed further below. The added enzyme can include one type of enzyme or many types of enzymes. The enzyme can come from commercially available enzyme preparations. Non-limiting examples of enzymes that aid in the conversion of certain difficult-to-metabolize plant materials to fermentable sugars include cellulases, hemicellulases, ferulic acid esterases, and/or proteases. Additional examples also include other enzymes that either provide or aid provision for the production of fermentable sugars from the feedstock, or increasing the value of the eventual feed by-product.
[0054] In certain embodiments, enzymes that aid in the conversion of certain difficult-to-metabolize plant materials into fermentable sugars can be produced by the plant itself, eg, inplantae. Examples of plants that can produce cellulases, hemicellulases, and other plant polymer-degrading enzymes can be produced within growing plants are described in patent and patent publications WO2011057159, WO2007100897, WO981 1235, and US6818803, which show which enzymes to depolymerize plant cell walls can be produced in plants. In another embodiment, ensiling can be used to activate such plant-produced enzymes as well as condition the biomass for further processing.
[0055] An example is described in patent publication WO201096510. If used, such transgenic plants can be included in the harvest in any quantity. For example, certain embodiments may employ in-plantae enzymes produced in plants using particular transgenic plants exclusively as a feedstock, or incorporating the transgenic plants in an intercalated manner within similar or different crops.
[0056] In certain embodiments that include such plant polymer-degrading enzymes, ethanol can be produced from cellulosic fractions of the plant. In a particular embodiment, when Novazymes CTEC2 enzyme was added to a sorghum storage system in excess of the recommended amount, about 100 times more than the recommended amount, about 152% of the theoretical ethanol conversion efficiency based on the Initial free sugar content was reached. While such a quantity of enzymes can be added using commercially available formulations, doing this can be costly. On the other hand, such amount of enzymes can be obtained in a more cost-effective way through the growth of transgenic plants that produce these enzymes at least interspersed among the biomass harvest.
[0057] The production of ethanol from cellulose occurred during the storage phase, for example, in silage and was stable for about 102 days of storage, after which the experiment was terminated. This demonstrates that, under the conditions of that particular experiment, an excess of such enzyme activity results in at least about 52% ethanol production using the fermentable sugars from cellulose. Not intended to be bound by theory, for certain modalities the immediate addition of acid during harvesting in the experiment may have lowered the pH, thereby potentially inducing enzyme activity, which could otherwise damage the plants if produced while the plants were still growing.
[0058] In a preferred embodiment, if an enzyme is added, the enzyme may be from any family of cellulase preparations. In one embodiment, the cellulose preparation used is Novozymes Cellic CTec 2 or CTec 3. In another embodiment, a fibrolytic enzyme preparation is used, particularly Liquicell 2500. If used, the amount of enzyme added to degrade plant polymer may be any amount that achieves the desired conversion of plant material to fermentable sugar, such as the recommended amount. In a particular embodiment, about 80,000 FPU to about 90,000,000 FPU, preferably about 400,000 FPU to about 45,000,000 FPU, more preferably about 800,000 FPU to about 10,000,000 FPU of enzyme is added per wet kilogram of biomass. The term "FPU" refers to the Filter Paper Unit, which refers to at least the amount of enzyme needed to release 2 mg of reducing sugar (eg glucose) from a 50 mg piece of Whatman No. 1 filter paper in 1 hour at 50°C at approximately pH 4.8.
[0059] In certain other embodiments, selected additives added may include other substances capable of slowing down or controlling microbial growth. Non-limiting examples of these other substances include antibiotics (including antibiotic enzymes), such as Lysovin (lysozyme) and Lactrol® (Virginiamycin, an inhibitor of bacteria). Controlling bacterial growth can allow the appropriate microbe to accelerate and/or provide for the production of volatile organic compounds. Antibiotic is a general term for something that suppresses or kills life. An example of an antibiotic is a bacteria inhibitor. In one embodiment, an antibiotic that is selective or intended to impact bacteria and not other microbes is used. An example of a selective antibiotic is Lactrol, which affects bacteria but does not affect yeast.
[0060] In a particular embodiment, if used, Lactrol can be added at rates of about 1 to 20 parts per million (ppm) w/v (by the amount of Lactrol per volume of liquid) as dissolved in the water phase of the material. biomass prepared, for example, at about at about 5 ppm w/v. In one embodiment using an enzyme to control bacterial growth, lysozyme is preferably used. Lysozyme can come from a commercial source. An example commercially available lysozyme preparation is Lysovin, which is a lysozyme enzyme preparation that has been declared permitted for use in food, such as wine.
[0061] The enzyme and/or other antibiotic material, if used, can be added independently or together with each other and/or with the microbe. In certain embodiments, other compounds that serve as nutrients to the microbes facilitating and/or providing for the production of the volatile organic compound may also be added as an additive. The following Table 4 provides non-limiting examples of other substances, including antibiotics, that can be added to solid biomass. Table 4

[0062] Yeasts and other microbes that are attached to solids individually, such as small aggregates, or biofilms have been shown to have increased tolerance for inhibitory compounds. Without intending to be bound by theory, part of long-term fermentation may be possible or enhanced by such microbe-to-solids binding. In this way, the prepared biomass material that includes the optimized microbe for microbial binding as well as additives that can bind microorganisms can undergo a higher degree of fermentation and/or fermentation efficiency. Substances that provide and/or facilitate long-term fermentation are different from substances that increase the rate of fermentation. In certain modalities, an increase in fermentation rate is not an important factor as long term fermentation, particularly over a period of many weeks or months,
[0063] The sequence provides particular amounts of additives applied to a specific modality. If used, the rate and amount of addition of an acid varies with the buffering capacity of the particular solid biomass to which the particular acid is added. In a particular embodiment using sulfuric acid, 9.3% w/w sulfuric acid is added at rates of up to about 10 liters/kg of wet biomass, for example, in about 3.8 liters/kg of wet biomass to achieve a pH of about 4.2. In other embodiments, the rate will vary depending on the concentration and type of acid, liquid and other content and buffering capacity of the particular solid biomass, and/or pH desired. In this particular modality, Lactrol is added at a rate of about 3.2 g/wet kilogram of solid biomass. Yeasts or other microbes are added at the rate recommended from the supplier, such as according to the expected sugar content per wet pound. In a particular embodiment, Lallemand stabilized liquid yeast is added at about 532 ml (18 fl oz) per wet kilogram, and Novozymes Cellic CTec2 is added at about 591 ml (20 fl oz) per wet kilo.
[0064] In a preferred embodiment, selected additives are added to the solid biomass stream during harvesting in accordance with aspects of the invention described above to generate the prepared biomass material. Preferably, the prepared biomass material is transported to a storage facility to allow for the conversion of carbohydrates from the prepared biomass material to volatile organic compounds of the desired amount and/or await recovery of the volatile organic compounds. Any suitable transport device and/or method can be used, such as vehicles, trains, etc., and any suitable method to position the prepared biomass material into the transport medium. Non-limiting examples of vehicles that can be used to transport the biomass material include final dump dump trucks, side dump dump trucks, and self-discharge silage trucks. In a preferred embodiment, a silage truck is used. In modalities using a forage harvester to collect biomass, transporting such solid biomass is more efficient than transporting materials collected by conventional means, such as sugar cane billets, since the bulk density is greater in solid biomass cut with a forage combine. That is, materials cut into smaller pieces pack more densely than billet materials. In one modality, the range of volumetric densities on a silage truck ranges from about 150 kg/m3 to about 350 kg/m3, eg about 256 kg/m3. As in certain embodiments, all selected additives are added during harvesting, preferably in the combine, the microbe can start to interact with the biomass during transport, and thus the transport is not detrimental to the overall process.
[0065] The biomass, whether prepared or not, is distributed to at least one storage area or facility. The storage facility can be located any distance from the collection site. Selected additives can be added if they have not yet been added or if additional amounts or types need to be added further to generate the prepared biomass material. In a preferred embodiment, the prepared biomass is stored in at least one pile on a prepared surface for a period of time. Installation can incorporate natural or man-made topography. Man-made structures may include on-site structures that were not initially designed for silage, such as canals and water treatment ponds. Non-limiting examples of a prepared surface include a surface of concrete, asphalt, fly ash or ground. The at least one stack may have any size or shape, which may depend on operating conditions such as available space, amount of biomass, desired storage duration, etc.
[0066] In a particular embodiment, at least one pile of prepared biomass material is formed having a height in a range of from about 304.8 cm (10 feet) to about 914.4 cm (30 feet) . In another embodiment, the height of the at least one stack is greater than 914.4 cm (30 feet). In one embodiment, at least one pile of prepared biomass material contains at least about 10,160 kg (10 tons) of prepared biomass material, which may be wet kilos. In another embodiment, at least one pile contains 25,401.1 Mg (25,000 tons) (or wet kilograms) of prepared biomass material. In another embodiment, the at least one pile of prepared biomass material contains at least about 101,604.7 Mg (100,000 tons) (or wet kilograms) of prepared biomass material. In a further embodiment, at least one pile of prepared biomass material contains at least about 1,016,047 Mg (1,000,000 tons) or (wet kilograms), such as 1,200,000 wet kilograms, of prepared biomass material. In one modality, the at least one pile contains up to about 10,000,000 tons, and in another modality, up to 101,604,700 Mg (100,000,000 tons) (or wet kilograms) of prepared biomass material.
[0067] The process of converting fermentable sugars is an exothermic reaction. Too much heat, however, can be detrimental to the conversion process if the temperature is in the lethal range for microbes in the prepared biomass material. However, in a modality using about 700 wet kilograms of biomass and accumulating up to about 365.8 cm (12 feet), ethanol production and stability were satisfactory. Therefore, larger stacks are unlikely to suffer from overheating. In one embodiment, an inner portion of the stack maintains a temperature in a range of from about 20 degrees C to about 60 degrees C for microbes of all types, including thermophiles. In an embodiment that does not employ thermophiles, an inner portion of the stack maintains a temperature in a range from about 35 degrees C to about 45 degrees C.
[0068J Prepared biomass material that is stored as at least one pile in the storage facility may also be referred to as a wet stored biomass aggregate. After the addition of selected additives, at least a portion of the solid biomass is converted to volatile organic compounds, such as sugar fermentation to ethanol. In one embodiment, the prepared biomass material is stored for a period of time sufficient to reach an anaerobic environment. In a preferred embodiment, the anaerobic environment is reached in about 24 hours. In another modality, the anaerobic environment is reached in more than about 4 hours. In yet another modality, the anaerobic environment is reached in up to about 72 hours.
[0069] The pile can stand freely or can be formed in another structure, such as a silage deposit, designed to accept silage, including provisions for collecting aqueous and leachate runoff, positioning a tarp over the biomass, and to facilitate both the efficient unloading of the initial silage truck to the warehouse and the removal of biomass throughout the year. Individual hoppers can be sized about the size to support annual feed load requirements of approximately 700 kilogram wet to 100,000,000 kilogram wet or more. For example, the storage facility may have 50 warehouses, where each individual warehouse can accept 100,000 wet kilograms of prepared biomass material for a total of a maximum of about 5,000,000 wet kilograms of stored material at any one time. Other sample inventory quantities of biomass material prepared in any storage facility include at least about 10 tons, about 25,401.1 Mg (25,000 tons), about 101,604.7 Mg (100,000 tons), about 1,016. 047 Mg (1,000,000 tons), about 1,219,256 Mg (1,200,000 tons), about 1,524,070 Mg (1,500,000 tons), about 10,160,470 Mg (10,000,000 tons), and even about 101,604,700 Mg (100,000,000 tons). In a preferred embodiment where ethanol is the volatile organic compound of choice, about 52.9 L (14 gallons) to about 60.5 L (16 gallons) of ethanol is recovered per one wet kilogram of prepared biomass material. The figures provided are exemplary and are not intended to limit the amount of prepared biomass material that a storage facility can accommodate.
[0070] In a particular embodiment, the storage stack additionally includes a leachate collection system. In one embodiment, the collection system is used to remove leachate collected from the storage pile. For example, the leachate collection system can be adapted to remove liquid from the pile at certain points during the storage period. In another embodiment, the leachate collection system is adapted to circulate liquid in the storage stack. For example, circulation may involve withdrawing at least a portion of the recovered liquid and routing it back to the stack, preferably in the top portion or near the top portion. Such recirculation allows longer retention times for certain portions of the liquids in the pile, even when the recovery phase of the prepared biomass material begins and portions of the non-liquid component of the prepared biomass material are sent to the recovery unit. The longer retention time results in longer microbial reaction times, and thus higher concentrations of volatile organic compounds such as ethanol.
[0071] Any suitable leachate collection system known to those skilled in the art can be employed as described. In a particular embodiment, the leachate collection system comprises at least one chute along the bottom of the pile, preferably positioned near the middle of the storage pile or the bin if one is used, where the storage pile is prepared in a grade designed to direct liquid from the prepared biomass material into the chute and out to a desired collection receptacle or routed for other applications.
[0072] In another embodiment, the leachate collection system comprises one or more perforated conduits, preferably tubes made of polyvinyl chloride (PVC), which run along the bottom of the stack to allow the liquid collected in the conduits to be directed to away from the stack.
[0073] In one embodiment, while the prepared biomass material is added to the deposit or deposited on top of the prepared surface, a tractor or other heavy implement is driven over the pile repeatedly to facilitate packaging. In one embodiment, the packaging ranges from about 112.1 kg/m3 (7 Ibs/ft3) to about 800.9 kg/m3 (50 Ibs/ft3) for the prepared biomass material. In a preferred embodiment, the packaging is from about 480.5 kg/m3 (30 Ibs/ft3) to about 800.9 kg/m3 (50 Ibs/ft3), particularly about 704.8 kg/m3 (44 Ibs/ft3). In one embodiment, compacting the prepared biomass material in a pile facilitates and/or allows an anaerobic environment to be achieved in the preferred time periods described above. In another embodiment, after packaging is carried out or during the time the packaging is being carried out, an air-impermeable membrane is positioned in the stack, typically a plastic sheet suitable for the purpose. In one particular modality, the tarpaulin is placed in the pile as soon as practical. For example, the canvas is placed in the pile within a 24-hour period.
[0074] In one embodiment, the prepared biomass material is stored for at least about 24 hours and preferably at least about 72 hours (or 3 days) to allow for the production of volatile organic compounds such as ethanol. In one embodiment, the prepared biomass material is stored for about three days, preferably ten days, more preferably longer than ten days. In one embodiment, the time period for storing the prepared biomass is from about 1 day to about 700 days, preferably about 10 to 700 days. In another modality, biomass material is stored for up to about three years. In one embodiment, the prepared biomass material is stored for a period of time sufficient to allow a conversion efficiency of sugar to at least one volatile organic compound of at least about 95% of the theoretical production efficiency as calculated through an evaluation stoichiometry of the relevant biochemical route. In another embodiment, the prepared biomass material is stored for a period of time sufficient to allow a calculated sugar conversion efficiency for at least one volatile organic compound of at least about 100%. In a further embodiment, the prepared biomass material is prepared with certain additives, such as enzymes, which allow a calculated sugar conversion efficiency for at least one volatile organic compound of up to about 150%) of the theoretical value based on the amount starting amount of fermentable sugars available. Without intending to be bound by theory, it is believed that, at 100% efficiency or close to 100% efficiency, volatile organic compounds are produced either from the initially available fermentable sugars or from the fermentable sugars from cellulosic material or another polymeric in the prepared biomass material, which can be achieved by enzymatic hydrolysis or acid hydrolysis facilitated by certain additives applied to the biomass.
[0075] The volatile organic products produced, such as ethanol, remain stable in the prepared stored biomass material for the duration of the storage period. In particular, the prepared biomass material can be stored for up to 700 days without significant degradation to volatile organic compounds. “Significant” in this context refers to at least within the margin of error when measuring the amount or concentration of volatile organic compounds in the prepared biomass material. In one modality, the margin of error is 0.5%. Ethanol has been shown to remain stable in the heap after at least about 330 days with no significant ethanol losses observed. This aspect of the embodiments of the present invention is important as it provides at least eight months of stable storage, which allows for year-round recovery and production of VOCs with a harvest window of only about four months. Embodiments of the invention provide significant advantages over conventional on-the-fly processing that may only be able to operate during the four-month-a-year harvest window. That is, embodiments of the invention allow a plant to operate year round using only a four month harvest window, thereby reducing the capital cost for a plant of the same size as the one currently being processed.
[0076] Still, in a modality that employs a tarpaulin, it is provided that the positioning of the ground or other means around the edges of the tarpaulin to 1) provide weight to retain the lowered tarpaulin; and also 2) to act as a biofilter of the exit gas from the stack. In such an embodiment, biofilters are efficient for detoxifying/degrading organic compounds and carbon monoxide. Prepared biomass material can also be stored as compressed modules, rollover piles, bins, silos, bags, tubes or rolled bales, or other anaerobic storage system.
[0077] In one embodiment, the outgoing gas stream from a pile of prepared biomass material was monitored and it was found that only small levels of organic compounds, and also very low levels of nitrogen oxides, were present. For example, Tables 5.1, 5.2, and 5.3 below show the analysis of various off-gas samples collected during the storage phase of an implementation of certain embodiments of the invention. The "BDL" designation refers to an amount below the threshold that can be detected. Summa and Tedlar refer to commercially available gas sampling vessels. Table 5.1


[0078] Modalities of the present invention, although relatively not contained in the deposit, must be environmentally benign. Still, certain aspects of the present invention do well with the use of soil or other means such as a biofilter positioned around and in the deposits as gas leakage from under the tarpaulin is radial in nature. In this way, the vapors have a greater amount of surface area in contact with the edges of the pile. In modalities using a biofilter, the vapor phase releases pass through the biofilter (such as soil or compost) positioned near the edge mass before entering the atmosphere. The biofilter traps many potential environmental pollutants and odors released by the storage stack, and it eliminates or greatly reduces potentially hazardous exhaust gases released from the storage stack.
[0079] In one embodiment, the prepared biomass material is stored until it contains no more than about 80% by weight of liquid. The prepared biomass material is stored until it contains at least about 4 to about 5% more than the initial content. At this stage, the stored wet biomass aggregate is not considered “beer” yet as it still contains about 20% solids. In one embodiment, the prepared biomass material is stored until it contains between about 2% by weight and about 50% by weight of ethanol, and preferably between about 4% by weight and about 10% by weight of ethanol. The liquid balance is primarily water but may contain many other organic compounds such as acetic acid, lactic acid, etc.
[0080] Modalities of the present invention allow solid biomass to be harvested in a much shorter harvest window than typical sugarcane juice operations, which allows 1) a much larger geographic area where facilities can be positioned, 2) harvesting the crop when the crop has its highest yield potential, 3) harvesting the crop at its highest sugar concentration potential, 4) smaller still economic harvest window, and 5) decoupling the need to harvest the juice from biomass for fermentation. In addition, aspects of the present invention allow for scaled-up operations, such as in the industrial or commercial range. In one embodiment, at least about 10,160 kg (10 tons) of prepared biomass material is generated by adding a microbe, an acid, and optionally an enzyme to the solid biomass. Other quantities are provided above.
[0081] The preparation of biomass material of the embodiments of the invention in general may also be referred to as solid state fermentation. Once the prepared biomass material has been stored for the desired amount of time and/or contains a desired concentration of volatile organic compounds, such as ethanol, it can be routed to the recovery system for the recovery of particular volatile organic compounds. The retrieval system and storage facility can be located at any distance from each other. System modalities and methods described here allow flexibility in the geographic location of both and their locations relative to each other. In a particular embodiment, the recovery system is located approximately 0.8 to approximately 3.21 kilometers (0.5 to approximately 2 miles) from the storage facility. Any suitable method and/or equipment can be used to transfer the prepared biomass material from the storage facility to the recovery system. In one modality, a feeding hopper is used. In one embodiment, a silage forage, front end loader or excavator, sweeping auger or other auger system can be used to position the prepared biomass material into the feed hopper. Material can be positioned directly into the feed hopper or it can be transferred by the conveyor system such as the belt system. The feed hopper containing the prepared biomass material can then be driven into the recovery system.
[0082] The recovery system is solvent free and uses a stream of superheated steam to vaporize the liquid in the prepared biomass material to a gas component, which can then be collected. A superheated steam is a steam that is heated above its saturation temperature at operating pressure. In a preferred embodiment, after the recovery system reaches steady state, the superheated steam stream comprises only steam previously evaporated from the prepared biomass material, so that no other gas is introduced, thus reducing the risk of combustion of the volatile organic compounds and/or the dilution of the product stream recovered from the volatile organic compounds. The remaining solid component is discharged from the system and can have several subsequent uses. A portion of the steam is removed as a product and the remainder is recycled back for use in transferring heat to prepared biomass material that arrives fresh. The superheated steam directly contacts the biomass, transferring energy and vaporizing the liquid present in it. The source of heat or thermal energy does not directly contact the prepared biomass material. Thus, the VOC recovery system can also be described as providing “indirect” heat contact.
[0083] To provide solvent-free recovery of volatile organic compounds, the recovery system comprises a compartment that allows the superheated steam to flow in a continuous manner, that is, as a stream. In one embodiment, the compartment has a cycle shape. In another embodiment, the compartment comprises a rotating drum. The compartment has an entrance through which the prepared biomass material can enter. In one embodiment, the inlet comprises a pressure-tight rotary valve, plug screw, or other similar device, which can assist in separating the prepared biomass material to increase the surface area exposed to the superheated steam stream.
[0084] In yet another embodiment, the system comprises a water removal mechanism to remove at least a portion of the liquid in the prepared biomass material before the liquid is vaporized. Liquid removal can take place before the prepared biomass material enters the compartment and/or while the prepared biomass material enters the compartment. The liquid from the prepared biomass material contains at least one volatile organic compound, which can be recovered by further processing the liquid, such as feeding the liquid to a distillation column. The liquid can be routed directly to an additional processing unit, such as a distillation column. Alternatively or in addition to, the system additionally includes a collection unit to collect the liquid removed from the prepared biomass material. Any portion of the collected liquid can then be further processed.
[0085] In one embodiment, the dewatering mechanism comprises a component adapted to squeeze liquid from the prepared biomass material. In such a modality, the act of squeezing can be performed while the prepared biomass material is being fed into the compartment. For example, the inlet may comprise a squeezing mechanism to squeeze liquid from the prepared biomass material as it is introduced into the compartment. Alternatively or in addition to, squeezing can be carried out separately before the prepared biomass material enters the compartment. A non-limiting example of such a tightening mechanism is a plug screw feeder.
[0086] In one embodiment, the liquid removal mechanism comprises a mechanical press. Non-limiting examples of mechanical press types include belt filter presses, V-type presses, ring presses, screw presses and drum presses. In a particular embodiment of a belt filter press, the prepared biomass material is sandwiched between two porous belts, which are passed over and under the rollers to squeeze the moisture out. In another particular embodiment, a drum press comprises a perforated drum with a revolving press roll within it that presses material against the perforated drum. In yet another modality, in a centrifuge bowl, the material enters a conical bowl rotating in which solids accumulate on the perimeter.
[0087] The compartment provides a space where the superheated steam stream can contact the prepared biomass material to vaporize the liquid from the prepared biomass material. The vaporization of at least a portion of the liquid provides a gas component and a solid component of the prepared biomass material. The system further comprises a separation unit where the solid component of the prepared biomass material can be separated from the gas component, then each component can be removed as desired for further processing. In one embodiment, the separation unit comprises a centrifugal collector. An example of such a centrifugal collector is a cyclone equipment with high efficiency. In a preferred embodiment, the separation unit also serves as an outlet for the solid component. For example, the separation unit can discharge the solid component from the solvent-free recovery system. There is a separate outlet for the gas component where it can exit the system for further processing such as distillation. In one embodiment, the separating unit is further coupled to a second pressure tight rotary valve or the like to extrude or discharge the solid component. In one embodiment, the superheated steam is maintained at a target or desired temperature above its saturation temperature through a heat exchange component coupled with a heat source where the superheated steam does not contact the heat source. Heat transfer between the heat source and the system takes place through convection to the superheated steam. In one embodiment, the heat source may include electrical elements or hot vapors through an appropriate heat exchanger. In one embodiment, the operating pressure is in a range from about 6.89 kPa man (1 psig) to about 827.3 kPa man (120 psig). In a preferred embodiment, the operating pressure is in a range from about 20.6 kPa man (3 psig) to about 275.7 kPa man (40 psig). In a particularly preferred embodiment, the system is pressurized to an operating pressure of about 413.6 kPa man (60 psig) to force the vapor component of the system.
[0088] In one embodiment, at startup of the recovery system, the prepared biomass material is introduced into the compartment through the inlet. The current is initially used as the superheated steam to initially vaporize the liquid into the prepared biomass material. The superheated steam moves continuously through the compartment. When the prepared biomass material enters the superheated vapor stream, it becomes fluidized where it flows through the compartment as a fluid. As the prepared biomass material is introduced, it comes into contact with the superheated steam stream. Heat from the superheated steam is transferred to the prepared biomass material and vaporizes at least a portion of the liquid in the prepared biomass material and is separated from the solid component, which may still contain moisture. The gas component contains volatile organic compounds produced in the prepared biomass material. In a preferred embodiment, when the liquid from the prepared biomass material begins to vaporize, at least a portion of the vaporized liquid can be recycled into the system as the superheated fluid. That is, during any given cycle, at least a portion of the vaporized liquid remains in the compartment to serve as superheated steam rather than being collected for further processing, until the next cycle where more prepared biomass material is fed into the system.
[0089] In a preferred embodiment, during the initial start-up procedure, the superheated fluid may be purged as necessary, preferably continuously (intermittently or constantly), until steady state is reached where the superheated vapor comprises only vaporized liquid of the prepared biomass material. Gas component and solid component can be collected through the respective outlet. Heat can be added continuously (intermittently or constantly) to the system through the heat exchanger coupled with the heat source to maintain the temperature of the superheated steam, to maintain a desired operating pressure in the system, or to maintain a rate of target vaporization. Various system conditions, such as superheated steam stream flow rate, pressure, and temperature, can be adjusted to achieve the desired rate of removal of liquid and/or volatile organic compounds.
[0090] In one embodiment, the collected gas component is condensed for further processing, such as being transferred to a purification process to obtain a higher concentration of the volatile organic compounds of choice. In a preferred embodiment, the collected gas component is fed directly to a distillation column, which provides savings on unused energy to condense the gas component. In another embodiment, the gas component is condensed and fed to the next purification step as a liquid.
[0091] In one embodiment, prior to entering the recovery phase, the prepared biomass material has an initial liquid content of about at least 10% by weight and up to about 80% by weight based on the biomass material. In a particular embodiment, the initial liquid content is at least about 50% by weight based on the biomass material. In one embodiment, the initial liquid content comprises from about 2 to 50% by weight, and preferably from about 4 to 10% by weight of ethanol based on the initial liquid content.
[0092] In one embodiment, the collected solid component contains from about 5% by weight to about 70% by weight, and preferably from about 30% by weight to about 50% by weight of liquid depending of the ethanol removal target. In another component, the collected gas component contains between about 1% by weight and about 50% by weight of ethanol, preferably between about 4% by weight and about 15% by weight of ethanol. In one embodiment, the recovery system recovers from about 50% to about 100% of the volatile organic compounds contained in the prepared biomass material. The residence time of the prepared biomass varies based on several factors, including the volatile organic compound removal target. In one embodiment, the residence time of the prepared biomass material in the compartment is in a range of from about 1 to about 10 seconds. In one embodiment, the recovery system can be operated between about 6 kPa man (0.06 barg) and about 1600 kPa man (16 barg). The term "barg" refers to bar meter as understood by one skilled in the art, and 1 bar equals 0.1 MegaPascal. In one embodiment, the gas in the recovery system has a temperature in a range of from about 100°C to about 375°C, particularly from about 104°C to about 372°C, and the solid component leaving the system has a temperature of less than about 50°C. The collected solid component can be used in other applications. Non-limiting examples include animal feed, feed to a biomass burner to supply process energy or generate electricity, or further converted to ethanol through a cellulosic ethanol process (either re-fermentation in a silage pile or feed to a plant pretreatment for any cellulosic ethanol process) or feed for any other biofuel process that requires lignocellulosic biomass.
[0093] The operating conditions of the solvent-free recovery system include at least one of temperature, pressure, flow rate and residence time. Any of these conditions or a combination of these conditions can be controlled to achieve a desired removal target or target, such as the amount of initial liquid content removed or the amount of liquid remaining in the separate liquid component exiting the recovery system. In one embodiment, at least one operating condition is controlled to achieve removal of about 10 to 90% by weight, preferably about 45 to 65% by weight, and more preferably about 50% by weight, of the liquid content. initial.
[0094] In a preferred modality, increasing the system temperature at constant pressure will cause the liquid in the biomass to be vaporized more quickly and so for a given residence time will cause a higher percentage of the liquid in the biomass is evaporated. The flow rate of vapor leaving the system needs to be controlled to match the rate of vaporization of liquid from the biomass in order to reach steady state and can also be used as a mechanism to control system pressure. Increasing system pressure will cause more energy to be stored in the vapor phase in the system which can then be used to assist with further processing or to help move the steam to the next downstream processing unit. Increasing the biomass residence time in the system causes more heat to be transferred from the vapor phase to the biomass which results in more liquid being vaporized.
[0095] In a specific example modality, the recovery system comprises a closed cycle pneumatic superheated steam dryer, which can be obtained from commercially available sources. In one embodiment, the closed loop pneumatic superheated steam dryer is a model SSD™ from GEA Barr-Rosin Inc. Other suitable commercially available equipment includes the Superheated Steam Processor, SSP™ from GEA Barr-Rosin Inc, the Steam Dryer Ring from several companies including GEA Barr-Rosin Inc. and Dupps; the Dupps Airless Dryer; the QuadPass™ Rotary Drum Dryer From DuppsEvactherm™, Eirich Vacuum Superheated Steam Drying; the rotary drum dryer using superheated steam from Swiss Combi Ecodry; and the Airless Dryer from Ceramic Drying Systems Ltd.
[0096] More other types of indirect dryers that can serve as the volatile organic compound recovery unit for this process are batch tray dryers, indirect contact rotary dryers, rotary batch vacuum dryers, and agitated dryers. The basic principle for these dryers is that they will be enclosed and attached to a vacuum system to remove vapors from the solids as they are generated (also lowering the pressure with vacuum as volatiles are removed more easily). Wet solids contact a hot surface such as trays or paddles, heat is transferred to the wet solids causing the liquids to evaporate and then they can be collected in the vacuum system and condensed.
[0097] FIG. 1 illustrates an example VOC recovery system and process that employs a superheated steam dryer, referred to as system 100. In a particular embodiment, dry superheated steam can be obtained from GEA Barr-Rosin Inc. In FIG. 1, prepared biomass material 1 containing ethanol and/or other VOCs following solid state fermentation in the silage stacks is fed to compartment 3 via inlet 2. In the particular embodiment shown, inlet 2 comprises a screw extruder. As shown in FIG. 1, at least a portion of the liquid from the prepared biomass material 1 is removed before entering compartment 3. The dewatering mechanism may be a plug screw feeder through which the prepared biomass material 1 passes. At least a portion of the liquid removed from the biomass material 1 can be routed directly to the distillation step 11 via stream 15 without passing through the recovery system 100. Optionally, an weir can be coupled with the output of the removal mechanism. water can be used to facilitate the introduction of dehydrated biomass material to compartment 3.
[0098] Referring to FIG. 1, the recovery system 100 comprises the pressurized compartment 3, shown as a conduit having a suitable diameter, length, and shape, adapted to provide the desired operating conditions, such as residence time of material. prepared biomass 1, heat transfer to superheated steam, and operating temperature and pressure. Upon entering compartment 3, during steady state operation, prepared biomass material 1 contacts superheated vapor which flows through system 100 at a target or desired temperature and becomes fluidized. As described above, in a preferred embodiment, the superheated steam, or at least a portion thereof, is the steam component obtained from previously prepared biomass materials fed to system 100 for VOC recovery. The fluidized biomass flows through compartment 3 at a target flow rate and remains in contact with the superheated vapor for a sufficient target residence time to evaporate the desired amount of liquid from the prepared biomass material 1. In the embodiment shown, the flow of superheated steam and prepared biomass material 1 through system 100 is facilitated by system fan 14. System 100 may have one or more fans. The flow rate or speed of the superheated steam and biomass material 1 can be controlled by the system fan 14. The biomass material 1 flows through compartment 3 and reaches separation unit 4, which is preferably a cyclone separator, where a vapor component and a solid component of biomass material 1 are separated from each other. As shown, the vapor component is routed away from the solid component through the overhead stream 5 and the remaining portion of the biomass material 1 is considered a solid component, which is discharged from the separation unit 4 as solid component 7, preferably by screw extruder 6. At least a portion of the discharged solid component 7 can be used as animal feed, burner fuel, or biomass feedstock for other biofuel processes.
[0099] Referring to FIG. 1, a portion of the steam component, referred to as stream 8, is retained and recycled as a portion of the superheated steam used to vaporize newly introduced prepared biomass material. In the embodiment shown, the vapor component trapped in stream 8 is routed through heat exchanger 9 to heat it to the target operating temperature. The heat source can include steam, electricity, hot flue gases or any other applicable heat source known to those skilled in the art.
[00100] In a preferred embodiment, the temperature is controlled such that the pressure in the system is maintained at the target and there is adequate energy present to evaporate the desired amount of liquid. The pressure can also be controlled through the flow rate of the superheated steam stream and the heat entering the heat exchanger 9. Preferably, the recovery system 100 operates continuously where prepared biomass material 1 is continuously fed at a desired rate. , and vapor component 10 and solid component 6 are continuously removed at a continuous rate. In a preferred embodiment, the “fresh” 8 steam component from one run is retained continuously at a target rate to be used as the superheated steam stream for the next run. Any of these rates are adjustable to achieve desired operating conditions. As mentioned, system fan 14 circulates the superheated steam stream through system 100 and can be adjusted to obtain target flow rate or target speed.
[00101] Referring to FIG. 1, the remaining portion of the vapor component stream 5, represented as the numeral 10, is routed to a distillation step 11. Depending on the distillation configuration, the vapor component portion 10 may be condensed prior to further purification or preferably fed directly to the steam distillation column. In a preferred embodiment, the distillation product from distillation step 11 has an ethanol content of about 95.6% by weight of ethanol (the ethanol/water azeotrope), which can be further purified to above about about of 99% by weight using common ethanol dehydration technology, which is shown as step 12. The final ethanol product 13 will typically then be used as a biofuel to blend with gasoline.
[00102] FIG. 2 illustrates another example recovery system and process employing a superheated steam dryer, referred to as system 200 ie representative of Ring Dryer provided by various manufacturers. Prepared biomass material 201 is fed to system 200 via inlet 202, which preferably comprises a screw extruder. In one embodiment, at least a portion of the liquid from the prepared biomass material 201 is removed before entering system 200. The dewatering mechanism may be a plug screw feeder through which the prepared biomass material 201 passes. At least a portion of the liquid removed from the biomass material 201 can be routed directly to the distillation step 211 via stream 215 without passing through the recovery system 200. Optionally, an weir can be coupled with the output of the removal mechanism. water can be used to facilitate the introduction of dehydrated biomass material to compartment 203.
[00103] Referring to FIG. 2, recovery system 200 comprises compartment 203, which preferably comprises a rotating drum that provides target operating conditions for VOC recovery, including residence time of prepared biomass material 201, heat transfer to superheated steam, and the operating temperature and pressure. Upon entering compartment 203, during steady state operation, prepared biomass material 201 contacts superheated steam which flows through system 200 at the operating temperature and flow rate and becomes fluidized. As described above, in a preferred embodiment, the superheated steam, or at least a portion thereof, is the steam component obtained from the prepared biomass material previously fed to system 200 for the recovery of VOC. The fluidized biomass flows through compartment 203 at a target flow rate and remains in contact with the superheated vapor for the target residence time to achieve the target liquid vaporization from the biomass. The fluidized biomass then reaches the separation unit 204, which is preferably a cyclone separator, where the vapor component and solid component are separated from each other. As shown, the vapor component is routed away from the solid component through overhead stream 205, and solid component 207 is discharged from separation unit 204. As shown, solid component 207 exits system 100 through extruder 206 and may have subsequent uses as mentioned above. A portion of the steam component, referred to as stream 208, is retained and recycled as a portion of the superheated steam used to vaporize newly introduced prepared biomass material. As shown, trapped steam component 208 is routed through heat exchanger 209 to heat it to the desired or target temperature. The heat source or thermal energy source can include steam, electricity, hot flue gases or any other desired heat source. As shown, hot flue gas is used. The temperature is controlled such that the pressure in the system is maintained at the target and there is adequate energy present to evaporate the desired amount of liquid. Pressure can also be controlled through the flow rate of the superheated steam stream and the heat entering the heat exchanger 209.
[00104] Referring to FIG. 2, the remaining portion of vapor component stream 205, represented as numeral 210, is routed to a distillation step. Depending on the distillation configuration, the vapor component portion 210 may be condensed prior to further purification or preferably fed directly to the steam distillation column. The product from the distillation step can further be concentrated using known processes.
[00105] Preferably, the recovery system 200 operates continuously where prepared biomass material 201 is continuously fed at a desired rate, and vapor component 210 and solid component 206 are continuously removed at a continuous rate. In a preferred embodiment, the “fresh” steam component 208 from one run is retained continuously at a target rate to be used as the superheated steam stream for the next run. All of these rates are adjustable to achieve desired operating conditions. System fan 214 creates a superheated steam stream circulation loop and can be adjusted to achieve the target flow rate.
[00106] Through the use of a solvent-free recovery system in accordance with aspects of the present invention, the heat transfer points in the system, i.e., adding heat to the system and transferring heat to the prepared biomass material, occur in the vapor phase in a preferred modality, which provides an advantage that vapor phase heat transfer (convection) is more efficient than solid phase heat transfer (conduction) in the prepared biomass material, which is a bad conductor as it has insulating properties. As mentioned above, in certain embodiments, once the steady state is reached in vapor other than that vaporized from the liquid of the prepared biomass material it contacts the solid component and gas component of the prepared biomass material in the system, which prevents or reduces the dilution that can come from adding process steam or other steam to replenish the superheated steam stream. The collected gas component can be fed directly into a distillation column for separation of the desired volatile organic compounds, which can provide significant energy savings. The advantage of this system is that the vapors that contact the wet solids are only those vapors that have previously been removed from the solids so that there is no dilution or risk of explosion, etc.
[00107] The following examples are presented to further illustrate the invention, but they are not to be construed as limiting the scope of the invention. Illustrative modalities Example A
[00108] In this example, several samples of fresh cut sorghum are mixed with a variety of added components as listed in Table A.1 and are stored in the silage tubes for 258 days. The amount of ethanol produced in each experiment is shown in the bottom row of the table. The addition rates of selected additives are shown in Table A.2.


[00109] The experiments in Example A demonstrate the principle of ethanol production in silage piles and the duration of that storage. Additionally, the demonstrated effects of a certain additive. All the cases in the example produced a significant amount of ethanol which indicates the embodiments of the invention can be quite robust. In Table A.l, all but the last row describe which additives pass the test. The bottom row describes the result in terms of ethanol production by the fact that the experiment. In general, the acid experiments showed superior stability to those without acid. Regardless of this the acid-free experiments still yield ethanol production, indicating an acid additive is optional. Example B
[00110] In Example B, three additional experiments are shown in Table Bl The addition rates of the selected additives are shown in Table B.2.


[00111] The experiments in Example B also demonstrate the effects of certain additives as well as the scaling effects. Experiments 1 and 2 of Example B were conducted in the same warehouse which demonstrates that this fermentation technology is suitable and efficient on a commercial scale. Example C
[00112] In these experiments, the GEA SSD™ is used as the solvent-free recovery unit. In Table Cl below, the top section describes certain properties of the prepared biomass material that has been fed into the system. The next section describes the condition of the solid component exiting the solvent-free recovery system. The third section shows the operating conditions of the solvent-free recovery system and the last section gives the recovery rates of the main liquid components: ethanol, acetic acid and water. What is shown here in all cases is the ability to recover >90% ethanol ie solids (100% in some cases), and the ability to vary the amount of ethanol and water recovery based on system conditions solvent-free recovery process. Samples 10, 11, and 12 below also contain significant amounts of acetic acid, and show that this process can also be used for efficient recovery of acetic acid.
Example D
[00113] Some of the conditions tested provide sufficient pre-treatment of the biomass coming from the volatile recovery unit to allow the conversion of some remaining cellulose to biomass. Conditions from samples 6 and 7 in Example C above produce statistically significant amounts of ethanol when a small amount of enzymes and yeast were added to the remaining solid component sample and stored in an anaerobic environment. Other conditions tested were from samples 3, 4, 8, 10, and 12. These samples did not produce ethanol when placed under the same test conditions as samples 6 and 7. The conclusion from this is that under the test conditions described in sample numbers 6 and 7, certain embodiments of the present invention can be used for the subsequent production of cellulosic ethanol by ensiling the solid component from the volatile organic recovery unit. Example E
[00114] In these experiments, a 711,232 kg (700 tons) pile was prepared according to aspects of the invention and stored in a warehouse. On day 504 of storage in the warehouse, three samples were taken from the top, center, and bottom of the pile, all showing similar levels of compounds. Samples were stored at 4 degrees C. Prep. Sample:
[00115] The samples were squeezed through a 60 mL syringe without filtration, and the liquid was collected. Test conditions: 1) Samples were tested with an Agilent 7890 GC with a 5975 C mass spectrometer under the following conditions: • Agilent CTC autosampler with airspace option • 2.5 ml heated syringe, 1 ml size injection for S/SL inlet @ 130 °C, 20:1 split ratio • Separation on a 60M DB 624 column, 0.25 id with 1.4 μm film
[00116] Samples were prepared by 0.25 ml in a 20 ml airspace vial. 1 ml of steam was injected after equilibration at 60°C for 10 min. 2) The samples were tested with an Agilent 6890 GC with a 5973 mass spectrometer under the following conditions: • Perkin Elmer Turbomatrix 40 Airspace Autosampler • 60 M DB5 MS 0.25 mm id, 1.0 μm film; 100:1 split ratio
[00117] Samples were prepared by placing 0.25 ml in a 20 ml airspace vial. Steam was injected for 20 seconds after equilibration at 90°C for 15 min.
[00118] The following compounds have been identified in airspace under both conditions, indicating that these compounds were produced and potentially can be recovered using the solvent-free recovery system and captured during a subsequent distillation process in certain modalities.

[00119] Additional modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Appropriately, this description is to be interpreted as illustrative only and is for the purpose of teaching those skilled in the art the general manner of carrying out the invention. It is to be understood that the forms of the invention shown and described herein are to be taken as the presently preferred embodiments. Elements and materials may be substituted for those illustrated and described herein, parts and processes may be reversed, and certain features of the invention may be used independently, all as may be apparent to one skilled in the art after having the benefit of this description of the invention . Changes may be made to the elements described herein without departing from the spirit and scope of the invention as described in the following claims.

权利要求:
Claims (10)
[0001]
1. Method for producing volatile organic compounds from biomass material, characterized in that it comprises: generating at least 10,160 kg (10 tons) of prepared biomass material (1, 201) comprising at least one additive added to a biomass solid comprising a sugar, wherein the at least one additive comprises a microbe and, optionally, an acid and/or an enzyme; storing the prepared biomass material for at least 24 hours in a storage facility to allow for the production of at least one volatile organic compound from at least a portion of the sugar; and capturing the at least one volatile organic compound by feeding the stored biomass material to a solvent-free recovery system (100, 200) to separate the stored biomass material into at least one vapor component (10, 210) comprising at least one volatile organic compound and a solid component (6, 7, 207), wherein the capture step further comprises: introducing the prepared biomass material stored in a closed compartment (3, 203) of the recovery system, in which the material prepared biomass contains one or more volatile organic compounds; contacting the stored prepared biomass material with the superheated vapor stream in the compartment to vaporize at least a part of at least an initial liquid content in the stored prepared biomass material, the initial liquid content comprising from 2% by weight to 50% by weight of ethanol based on the initial liquid content and the superheated vapor stream comprising at least one volatile organic compound, wherein the superheated vapor is a vapor that is heated above its saturation temperature at the operating pressure; recovering less than 100% of the volatile organic compounds in the prepared biomass material to provide the vapor component comprising at least one volatile organic compound and the solid component; and separating a vapor component and a solid component from the prepared biomass material; retaining at least a portion of the steam component for use as part of the superheated steam stream; and, collecting the vapor component, wherein the collected vapor component contains between 4% by weight and 15% by weight of ethanol.
[0002]
2. Method according to claim 1, characterized in that at least 700 tons of prepared biomass material are generated in a period of time in an interval of 1 to 7 months.
[0003]
3. Method according to claim 2, characterized in that at least 25,000 tons of prepared biomass material are generated.
[0004]
4. Method according to claim 1, characterized in that 53-61 liters (14-16 gallons) of ethanol are recovered by one ton of prepared biomass material.
[0005]
5. Method according to claim 1, characterized in that the biomass substance comprises at least one plant that produces fermentable sugar.
[0006]
6. Method according to claim 5, characterized in that the at least one plant that produces fermentable sugar comprises at least one of sorghum, sugar cane, sugar beet, energy cane, and any combination thereof.
[0007]
7. Method according to claim 6, characterized in that the prepared biomass material comprises at least two different types of plants, in which each type of plant has different harvest times.
[0008]
8. Method according to claim 5, characterized in that at least one sugar-producing plant is harvested when the plant has reached at least 80% of its sugar production potential.
[0009]
9. Method according to claim 1, characterized in that the storage step comprises the storage of the prepared biomass material for a period of time in a range from 72 hours to 700 days.
[0010]
10. Method according to claim 1, characterized in that it further comprises operating the recovery system at a gauge pressure in the range of 20.6 kPa (3 psi) to 413.6 kPa (60 psi).

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法律状态:
2020-07-14| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2020-07-21| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2021-05-18| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2021-08-03| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 16/05/2013, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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US201261648109P| true| 2012-05-17|2012-05-17|

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US61/648,109|2012-05-17|

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US61/648109|2012-05-17|

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US201361786860P| true| 2013-03-15|2013-03-15|

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US201361786844P| true| 2013-03-15|2013-03-15|

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US61/786,860|2013-03-15|

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US61/786,844|2013-03-15|

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US61/786844|2013-03-15|

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US61/786860|2013-03-15|

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PCT/US2013/041313|WO2013173563A1|2012-05-17|2013-05-16|Process for producing volatile organic compounds from biomass material|

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