Note: Descriptions are shown in the official language in which they were submitted.
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A METHOD FOR PRODUCING BIOBASED CHEMICALS FROM PLANT BIOMASS
This application claims priority to U.S. Serial No. 13/292,222 entitled A
METHOD FOR
PRODUCING BIOBASED CHEMICALS FROM PLANT BIOMASS (filed November 9,
2011), U.S. Serial No. 13/292,437 entitled A METHOD FOR PRODUCING BIOBASED
CHEMICALS FROM WOODY BIOMASS (filed November 9, 2011), U.S. Serial No.
13/292,531 entitled A METHOD FOR PRODUCING BIOBASED CHEMICALS FROM
AGRICULTURAL BIOMASS (filed November 9, 2011), and U.S, Serial No, 13/292,632
entitled A METHOD FOR PRODUCING BIOBASED CHEMICALS FROM CULTIVATED
PLANT BIOMASS (filed November 9, 2011). All of the forgoing patent
applications are
incorporated herein by reference.
I. Background
[0001] Currently, the world faces depletion of fossil fuels while demands for
these fuels
are ever increasing. Petrochemicals provide an energy source and a component
of the majority
of raw materials used in many industries. In fact, approximately 95% of all
chemicals
manufactured today are derived from petroleum. However, this heavy reliance
upon fossil fuels
is creating harm to the environment. The burning of these fossil fuels has led
to the pollution of
air, water and land, as well as global warming and climate changes. Through
the use of fossil
fuels, the environment has been harmed, perhaps irreparably, in an effort to
meet the nearly
insatiable demand for energy and manufactured products. Fossil fuels are a
finite natural
resource, with the depletion of readily available oil reserves across the
globe; the supply chain
has shifted to more complex and environmentally risky production technologies.
A reduction in
the use and conservation of fossil fuels is clearly needed. Some alternatives
to fossil fuels, like
solar power, wind power, geothermal power, hydropower, and nuclear power, are
used to a
degree. However, a more efficient use of renewable resources is always being
sought.
[0002] As a stable and independent alternative to fossil fuels, biomass has
emerged as a
potentially inexhaustible resource for the production of energy,
transportation fuels, and
chemicals. The advantage in turning to domestic, renewable biomass for such
purposes would
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be magnified during periods of an oil crisis, a price surge, or political
unrest within oil producing
regions of the world. Herein biomass consists essentially of plant biomass,
including agricultural
biomass, woody biomass, and cultivated plant biomass. Biomass can be freshly
harvested,
stored, recovered, or recycled. Biomass can be employed as a sustainable
source of energy and
is a valuable alternative to fossil fuels in the production of chemicals. More
specifically, the
biorefining of biomass into derivative products typically produced from
petroleum could help to
lessen the dependence on foreign crude oil. Biomass can become a key resource
for chemical
production in much of the world. Moreover, biomass, unlike petroleum, is
renewable. Biomass
can provide sustainable substitutes for petrochemically derived feedstocks
used in existing
markets.
II. Summary
[0003] This Summary is provided to introduce a selection of concepts in a
simplified
form that are further described below in the Detailed Description. This
Summary is not intended
to identify key factors or essential features of the claimed subject matter,
nor is it intended to be
used to limit the scope of the claimed subject matter.
[0004] Accordingly, described herein is a method for biorefining. It may
include the
steps of providing biomass and treating the biomass to provide a plurality of
component streams.
The method may further include producing derivative products from the
plurality of component
streams.
[0005] In one implementation, the method for biorefining is provided herein,
comprising the steps of: providing biomass; processing the biomass to provide
a plurality of
component streams; and producing derivative products from the plurality of
component streams.
[0006] In another implementation, the biomass comprises plant biomass.
[0007] In still another implementation, plant biomass comprises woody biomass,
agricultural biomass, and cultivated plant biomass.
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[0008] In yet another implementation, woody biomass comprises at least one
softwood
biomass of softwood trees, softwood shrubs, and softwood bushes.
[0009] In still yet another implementation, woody biomass comprises at least
one
hardwood biomass of hardwood trees, hardwood shrubs, and hardwood bushes.
[0010] In one implementation, woody biomass comprises at least one hybrid
biomass of
hybrid trees, hybrid shrubs, and hybrid bushes.
[0011] In another implementation, woody biomass comprises at least one forest
biomass of forest trees, forest shrubs, and forest bushes.
[0012] In still another implementation, woody biomass comprises at least one
biomass
of recycled wood, recovered wood, recycled wood products, and recovered wood
products.
[0013] In yet another implementation, agricultural biomass comprises at least
one
agricultural biomass of agricultural plants, annual agricultural plants,
native annual agricultural
plants, hybrid annual agricultural plants, and genetically modified annual
agricultural plants.
[0014] In still yet another implementation, agricultural biomass comprises at
least one
perennial agricultural biomass of perennial agricultural plants, native
perennial agricultural
plants, hybrid perennial agricultural plants, and genetically modified
perennial agricultural
plants.
[0015] In one implementation, agricultural biomass comprises at least one
biennial
agricultural biomass of biennial agricultural plants, native biennial
agricultural plants, hybrid
biennial agricultural plants, and genetically modified biennial agricultural
plants.
[0016] In another implementation, agricultural biomass comprises of at least
one
agricultural residue of agricultural plants, annual agricultural plants,
perennial agricultural plants,
biennial agricultural plants, native annual agricultural plants, hybrid annual
agricultural plants,
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genetically modified annual agricultural plants, native perennial agricultural
plants, hybrid
perennial agricultural plants, genetically modified perennial agricultural
plants, native biennial
agricultural plants, hybrid biennial agricultural plants, and genetically
modified biennial
agricultural plants.
[0017] In still another implementation, cultivated plant biomass comprises at
least one
biomass of cultivated plants, cultivated trees, cultivated shrubs, and
cultivated bushes.
[0018] In yet another implementation, cultivated plant biomass comprises at
least one
cultivated plant of aquatic plants, medicinal plants, fiber plants, ornamental
plants, and grassy
plants.
[0019] In still yet another implementation, cultivated plant biomass comprises
at least
one annual cultivated plant of annual cultivated plants, native annual
cultivated plants, hybrid
annual cultivated plants, and genetically modified annual cultivated plants.
[0020] In one implementation, cultivated plant biomass comprises at least one
perennial
cultivated plant of perennial cultivated plants, native perennial cultivated
plants, hybrid perennial
cultivated plants, and genetically modified perennial cultivated plants.
[0021] In another implementation, cultivated plant biomass comprises at least
one
biennial cultivated plant of biennial cultivated plants, native biennial
cultivated plants, hybrid
biennial cultivated plants, and genetically modified biennial cultivated
plants.
[0022] In still another implementation, cultivated plant biomass comprises
cultivated
plant residues of at least one of cultivated plants, cultivated trees,
cultivated shrubs, cultivated
bushes, aquatic plants, medicinal plants, fiber plants, ornamental plants,
grassy plants, annual
cultivated plants, native annual cultivated plants, hybrid annual cultivated
plants, genetically
modified annual cultivated plants, perennial cultivated plants, native
perennial cultivated plants,
hybrid perennial cultivated plants, genetically modified perennial cultivated
plants, biennial
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cultivated plants, native biennial cultivated plants, hybrid biennial
cultivated plants, and
genetically modified biennial cultivated plants.
[0023] In yet another implementation, the plurality of component streams
comprises
lignin, cellulose, and hemicellulose.
[0024] In still yet another implementation, the step of processing the biomass
to
provide a plurality of component streams comprises mechanical processing and
component
separation processing.
[0025] In one implementation, the mechanical processing comprises at least one
mechanical process of chopping, chipping, cutting, shredding, debarking,
milling, and grinding.
[0026] In another implementation, the biomass is woody biomass and the
processing of
the woody biomass by the mechanical processing comprises at least one of
mechanical process
of debarking, chopping, chipping, milling, and grinding.
[0027] In still another implementation, the biomass is agricultural biomass or
cultivated
plant biomass and the processing of the plant biomass by the mechanical
processing comprises at
least one of chopping, cutting, shredding, milling, and grinding.
[0028] In yet another implementation, the step of component separation
processing
further comprises the step of providing cellulose.
[0029] In still yet another implementation, the component separation
processing
comprises at least one component of lignin and hemicellulose.
[0030] In one implementation, the step of processing the biomass to provide a
plurality
of component streams further comprises the step of completing a chemical
processing during the
processing of the biomass.
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[0031] In another implementation, the chemical processing comprises at least
one
treatment of solvent treatment, acidic treatment, basic treatment, and
enzymatic treatment.
[0032] In still another implementation, the method described further comprises
removing extractables from the chemical processing.
[0033] In yet another implementation, the step of removing extractables from
the
chemical processing further comprises the step of at least one process of
extracting metals from
ore, lubricating, cleaning, disinfecting, deodorizing, scenting, and producing
biofuels.
[0034] In still yet another implementation, the method further comprises the
steps of
recovering chemicals from the chemical processing and recycling the chemicals
from the
chemical processing.
[0035] In one implementation, the method further comprises the step of using a
residual
chemical removal in the step of processing the biomass.
[0036] In another implementation, the step of using residual chemical removal
produces hemicellulose and lignin.
[0037] In still another implementation, the step of using residual chemical
removal
further comprises the steps of adjusting a pH and producing hemicellulose and
lignin.
[0038] In yet another implementation, the method further comprises the steps
of
recovering at least one chemical from the residual chemical removal and
recycling the at least
one chemical from the residual chemical removal.
[0039] In still yet another implementation, the step of processing the biomass
to
provide a plurality of component streams further comprises the step of
utilizing an additional
treatment during the processing of the biomass.
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[0040] In one implementation, the additional treatment comprises at least one
treatment
of heat treatment, pressure treatment, kraft pulping, sulfite pulping,
pyrolysis, steam explosion,
ammonia fiber explosion, dilute acid hydrolysis, alkaline hydrolysis, alkaline
oxidative
treatment, and enzymatic treatment.
[0041] In another implementation, the method further comprises the step of
selectively
utilizing at least two of the additional treatments during the processing of
the biomass.
[0042] In still another implementation, the method further comprises the step
of
removing extractables from the additional treatment.
[0043] In yet another implementation, the method further comprises the steps
of
recovering at least one chemical from the additional treatment and recycling
at least one
chemical from the additional treatment.
[0044] In still yet another implementation, the method further comprises the
step of
selectively utilizing one of the component streams for producing the
derivative products.
[0045] In one implementation, the method further comprises the step of
selectively
utilizing at least two of the component streams for producing the derivative
products.
[0046] In another implementation, the plurality of component streams is a
mixture of
the component streams.
[0047] In still another implementation, at least one component stream of the
plurality of
component streams is an independent and separate component stream from the
plurality of
component streams.
[0048] In yet another implementation, the method includes the step of
selectively
producing one derivative product from the independent and separate component
stream.
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[0049] In still yet another implementation, the method further comprises the
step of
selectively producing at least two derivative products from the independent
and separate
component stream.
[0050] In one implementation, the method further comprises the step of
producing at
least one derivative product from a residue component stream.
[0051] In another implementation, derivative products comprise at least one
product of
commodity chemicals, fine chemicals, and specialty chemicals.
[0052] In still another implementation, producing derivative products
comprises at least
one process of chemical processing, biological processing, catalytic
processing, and pyrolytic
processing.
[0053] In yet another implementation, one of the component streams is lignin,
wherein
derivative products from lignin comprise at least one product of aromatic
chemicals and fuels.
[0054] In still yet another implementation, derivative products from lignin
comprise at
least one product of aromatic carboxylic acids, aromatic esters, aromatic
aldehydes, aryl
alcohols, aryl ketones, styrenes, aryl ethanes, aryl propenes, aryl propanes,
cresols, phenols,
benzenes, and pyrolytic oils.
[0055] In one implementation, derivative products from lignin comprise at
least one
product of methyl and ethyl 4-hydroxybenzoate, methyl and ethyl vanillate,
methyl and ethyl
syringate, 4-hydroxybenzoic acid, (4-hydroxyphenyl)acetic acid, vanillic acid,
homovanillic
acid, syringic acid, homosyringic acid, 4-hydroxybenzaldehyde, vanillin,
syringaldehyde, 4-
hydroxybenzyl alcohol, 2-(4-hydroxyphenyl)ethanol, vanillyl alcohol,
homovanillyl alcohol,
syringyl alcohol, homosyringyl alcohol, 4-hydroxyacetophenone, acetoguaiacone,
acetosyringone, 4-hydroxystyrene, 3-methoxy-4-hydroxystyrene, 3,5-dimethoxy-4-
hydroxystyrene. (4-hydroxypheny1)-1-propene, (4-hydroxypheny1)-2-propene,
eugenol, iso-
eugenol, syringeugenol, iso-syringeugenol, ethyl phenol, ethyl guaiacol, ethyl
syringol, propyl
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phenol, propyl guaiacol, propyl syringol, cresol, creosol, syringyl creosol,
phenol, guaiacol,
syringol, benzene, toluene, xylene, ethyl benzene, propyl benzene, biphenyl,
and pyrolytic oils.
[0056] In another implementation, one of the components streams is cellulose,
and the
derivative products from cellulose comprise at least one product of aliphatic
chemicals,
heterocyclic chemicals, and fuels.
[0057] In still another implementation, derivative products from cellulose
comprise at
least one product of cellulosic esters, aliphatic carboxylic acids, aliphatic
esters, polyols, furans,
dihydrofurans, tetrahydrofurans, lactones, and ethanol.
[0058] In yet another implementation, derivative products from cellulose
comprise at
least one product of cellulose acetate, cellulose propionate, cellulose
benzoate, methyl and ethyl
adipate, methyl and ethyl levulinate, methyl and ethyl succinate, methyl and
ethyl 2,5-
furandicarboxylate, adipic acid, levulinic acid, succinic acid, 2,5-
furandicarboxylic acid, 3,4-
dehydro-y-valerolactone, y-valerolactone, 2-methyltetrahydrofuran, sorbitol,
hexane-1,6-diol,
pentane-1,4-diol, butane-1.4-diol, 2.5-di(hydroxymethyl)furan, 2,5-
di(hydroxymethyl)tetrahydrofuran, glyercol, propylene glycol, and ethanol.
[0059] In still yet another implementation, method of claim 1, wherein one of
the
component streams is hemicellulose, and the derivative products from
hemicellulose comprise at
least one product of aliphatic chemicals, heterocyclic chemicals, and fuels.
[0060] In one implementation, derivative products from hemicellulose comprise
at least
one product of polyols, furans, dihydrofurans, tetrahydrofurans, lactones, and
butenes.
[0061] In another implementation, derivative products from hemicellulose
comprise at
least one product of furfural, ybutyrolactone, tetrahydrofuran, ribitol,
arabitol, xylitol, glyercol,
propylene glycol, and isoprene.
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[0062] In still another implementation, the plurality of derivative products
comprises at
least one of product of achiral, racemic, and optically pure products.
[0063] In yet another implementation, the method further comprises the step of
using at
least one of the derivative products in the production of other chemicals,
materials, and products.
[0064] In still yet another implementation, the biomass has a weight, and a
waste
product of the biomass is less than 25% of the biomass weight.
[0065] In one implementation, biomass has a weight, and a waste product of the
biomass is less than 15% of the biomass weight.
[0066] In another implementation, the method further comprises the step of
producing
energy utilizing the waste product.
[0067] In still another implementation, a method for biorefining comprises the
steps of
providing biomass, processing the biomass to provide a plurality of component
streams resulting
in at least one waste product, and utilizing at least one waste product to
produce energy.
[0068] In yet another implementation, the energy is heat or power.
[0069] In still yet another implementation, the method for biorefining
comprises the
steps of providing woody biomass, agricultural biomass, and cultivated plant
biomass; providing
the woody biomass comprising at least one biomass of softwood trees, softwood
shrubs,
softwood bushes, hardwood trees, hardwood shrubs, hardwood bushes, hybrid
trees, hybrid
shrubs, hybrid bushes, cultivated trees, cultivated shrubs, cultivated bushes,
forest trees, forest
shrubs, forest bushes; providing the woody biomass comprising of at least one
biomass of
recycled wood, recovered wood, recycled wood products, and recovered wood
products;
providing the agricultural biomass comprising at least one biomass of
agricultural plants, annual
agricultural plants, perennial agricultural plants, biennial agricultural
plants, native annual
agricultural plants, hybrid annual agricultural plants, genetically modified
annual agricultural
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plants, native perennial agricultural plants, hybrid perennial agricultural
plants, genetically
modified perennial agricultural plants, native biennial agricultural plants,
hybrid biennial
agricultural plants, and genetically modified biennial agricultural plants;
providing the
agricultural biomass comprising at least one agricultural residues of
agricultural plants, annual
agricultural plants, perennial agricultural plants, biennial agricultural
plants, native annual
agricultural plants, hybrid annual agricultural plants, genetically modified
annual agricultural
plants, native perennial agricultural plants, hybrid perennial agricultural
plants, genetically
modified perennial agricultural plants, native biennial agricultural plants,
hybrid biennial
agricultural plants, and genetically modified biennial agricultural plants;
providing the cultivated
plant biomass comprising at least one biomass of cultivated plants, cultivated
trees, cultivated
shrubs, cultivated bushes, aquatic plants, medicinal plants, fiber plants,
ornamental plants, and
grassy plants, annual cultivated plants, native annual cultivated plants,
hybrid annual cultivated
plants, genetically modified annual cultivated plants, perennial cultivated
plants, native perennial
cultivated plants, hybrid perennial cultivated plants, genetically modified
perennial cultivated
plants, biennial cultivated plants, native biennial cultivated plants, hybrid
biennial cultivated
plants, and genetically modified biennial cultivated plants; providing the
cultivated plant biomass
comprising at least one cultivated plant residues of cultivated plants,
cultivated trees, cultivated
shrubs, cultivated bushes, aquatic plants, medicinal plants, fiber plants,
ornamental plants, grassy
plants, annual cultivated plants, native annual cultivated plants, hybrid
annual cultivated plants,
genetically modified annual cultivated plants, perennial cultivated plants,
native perennial
cultivated plants, hybrid perennial cultivated plants, genetically modified
perennial cultivated
plants, biennial cultivated plants, native biennial cultivated plants, hybrid
biennial cultivated
plants, and genetically modified biennial cultivated plants; processing the
biomass using
mechanical processing, component separation processing, optional chemical
processing, residual
chemical removal, and an additional treatment; providing a plurality of
component streams
comprising lignin, cellulose, and hemicellulose from the biomass; recovering
chemicals used in
the optional chemical processing and the residual chemical removal for
recycling; removing
extractables from the optional chemical processing and the additional
treatment; reducing a
waste product of the biomass, wherein the biomass has a weight, and the waste
product of the
biomass is less than 25% of the biomass weight; producing energy utilizing the
waste product;
producing at least one product of commodity chemicals, fine chemicals, and
specialty chemicals;
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and producing at least one product of aromatic carboxylic acids, aromatic
esters, aromatic
aldehydes, aryl alcohols, aryl ketones, styrenes, aryl ethanes, aryl propenes,
aryl propanes,
cresols, phenols, benzenes, pyrolytic oils, cellulosic esters, aliphatic
carboxylic acids, aliphatic
esters, polyols, ethanol, furans, dihydrofurans, tetrahydrofurans, lactones,
and butenes from at
least one of the component streams.
[0070] Further, the method described herein provides a method for biorefining
that is
easy to implement and use.
[0071] To the accomplishment of the foregoing and related ends, the
following
description and annexed drawings set forth certain illustrative aspects and
implementations.
These are indicative of but a few of the various ways in which one or more
aspects may be
employed. Other aspects, advantages and novel features of the disclosure will
become apparent
from the following detailed description when considered in conjunction with
the annexed
drawings.
III. Brief Description of the Drawings
[0072] What is disclosed herein may take physical form in certain parts and
arrangement of parts, and will be described in detail in this specification
and illustrated in the
accompanying drawings which form a part hereof and wherein:
[0073] FIGURE 1 is a flow diagram schematically illustrating what is disclosed
herein.
[0074] FIGURE 2 is a flow diagram schematically illustrating what is disclosed
herein.
[0075] FIGURE 3 is a flow diagram schematically illustrating what is disclosed
herein.
[0076] FIGURE 4 is a flow diagram schematically illustrating what is disclosed
herein.
[0077] FIGURE 5 is a flow diagram schematically illustrating what is disclosed
herein.
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[0078] FIGURE 6 is a flow diagram schematically illustrating what is disclosed
herein.
[0079] FIGURE 7 is a flow diagram schematically illustrating what is disclosed
herein.
IV. Detailed Description
[0080] Referring now to the drawings wherein the showings are for purposes of
illustrating embodiments of the invention only and not for purposes of
limiting the same.
Relative language used herein is best understood with reference to the
drawings, in which like
numerals are used to identify like or similar items.
[0081] Biomass is made up primarily of cellulose, hemicellulose, and lignin.
These
components, if economically separated from one another, can provide vital
sources of chemicals
normally derived from petrochemicals. The use of biomass can also be
beneficial with plants
that are sparsely used and by-products, residues and plant wastes that
currently have little or no
use. Biomass can provide valuable chemicals and reduce dependence on coal,
gas, and fossil
fuels, in addition to boosting local and worldwide economies. Biomass can
include agricultural
biomass, woody biomass, and cultivated plant biomass. Agricultural biomass can
be considered
to be plants, roots, leaves, stems, stocks, seeds, fruits, nuts, or other
products of agriculture.
Agricultural residues may include stover, straw, hay, bagasse, hulls, straw,
nut shells, crop
residues, and clippings and prunings from orchards and vineyards. Woody
biomass may include
wood, wood by-products, wood residues, and wood wastes. Cultivated plant
biomass can be
comprised of plants whose origin or selection is primarily due to intentional
human activity.
[0082] Biomass is also plentiful throughout the United States and the world.
For
example, some estimates of the amount of sustainably harvestable forest
biomass in the United
States alone are about 370 million dry tons per annum, a small fraction of the
total timberlands
inventory of more than 20 billion dry tons. Also, some estimates of the
agricultural biomass in
the United States are about 1 billion tons annually with about 200 million
tons of that amount in
agricultural residues. Another aspect of biomass is that it is often a by-
product, residue or waste
product of other processes, such as farming, forestry, landscaping, timber and
the pulp and paper
industry, and the biomass and biomass residues are underutilized and left to
rot or are burned.
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Instead of creating a waste product, biomass can provide valuable chemicals
and reduce
dependence on coal, gas, and fossil fuels, in addition to boosting local and
worldwide economies.
Additionally, there are several other benefits to using biomass. Some of these
benefits may
include reducing the threat and impact of wildfires on communities, improving
recreation and
scenic opportunities by thinning overcrowded forests, improving human health
through better air
quality and reduced wildfire and prescribed fires emissions, providing rural
community vitality
though the provision of sustainable environments and economies over the long
term, providing
increased societal awareness by using forest restoration activities as a
learning tool to promote
wise forest management, and lowering treatment costs by finding new markets
for removed
residue. Some of the ecological and environmental benefits may include
decreasing insect and
disease outbreaks toward endemic levels, decreasing unnaturally severe fires
within forests and
grasslands, facilitating the removal of invasive woody species, increasing
ability to protect and
restore critical wildlife habitat, providing clean air through decreased
wildfires size and severity,
increasing the longevity of landfills which reduces the amount of land that
needs to be converted
into new landfills, improving vigor of remaining trees, reducing fire related
erosion and maintain
healthy watersheds, improving forest health, reducing dependence on fossil
fuels, reducing
greenhouse gas emissions, and reducing atmospheric concentrations of
greenhouse gases through
substitution of fossil fuels energy when woody biomass is regrown. Economic
benefits may
include providing new jobs and income through new biomass industries,
decreasing energy costs
by substituting woody biomass for other fuels, providing private land owners
opportunities for
carbon market income by growing short rotation woody crops for energy,
lessening the potential
of wildfire near communities, reducing cost of treatment for land managers,
providing
employment and economic stability to rural, forest-dependent communities,
attracting
investments in new industry and markets and stabilizing existing markets
including tourism,
complementing traditional utilization of higher values wood products, avoiding
fire suppression
and resource damage costs of wildfires, and increasing capacity to pursue new
management
incentives and opportunities such as emission reduction credits in energy
production.
[0083] The use of biomass in the production of chemicals historically has
focused
mostly on bioethanol and biodiesel. Cellulosic bioethanol production requires
a breakdown of
the biomass into component streams with often only the cellulose component
utilized. The
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OrganoSolvu\'I and Alcell processes can be used to efficiently separate
cellulose from biomass
under mild conditions, namely through the use of an aqueous organic solvent,
usually ethanol.
These processes provide the simultaneous removal of the hemicellulose sugar
and lignin in
separated streams. Even though an organic solvent is used during this process,
it can be recycled
and used again in the process. Alternatively, separate component streams can
be obtained from
biomass through at least one known process of kraft pulping, sulfite pulping,
steam explosion,
ammonia fiber explosion, dilute acid hydrolysis, alkaline hydrolysis, alkaline
oxidative
treatment, enzymatic hydrolysis, pyrolytic processes, and enzymatic treatment.
Of these, the
kraft pulping of woody biomass is by far the dominant chemical pulping method
practiced across
the world today.
[0084] Although the cellulosic fraction of biomass has garnered attention as a
feedstock
for bioethanol and solid biofuel, the intrinsic value of the other components
of biomass in
chemical production continues to be largely overlooked. Other than fossil
fuels, lignin is an
abundant source of aromatic chemicals. Lignin can be used in developing
technologies that
transform biomass into value-added, aromatic chemicals. In addition, the
cellulose and
hemicellulose portions of biomass can also be converted into useful biobased
chemicals.
[0085] FIGURE 1 shows a flow diagram schematically depicting the general
overview
for the illustrative flow for a method for treating and processing biomass 10
for production of
biobased chemicals 40. First, biomass 10 may be obtained for processing.
Biomass 10 refers to
any plant derived organic matter, whether native, non-native, or hybrid.
Biomass 10 may be
used for the production of biobased chemicals 40. Biomass 10 can include woody
biomass,
agricultural biomass, cultivated plant biomass, and any plant biomass. Biomass
10 can be
received in any number of forms, including loose, bailed, wrapped, pellets,
cubes, and briquettes.
[0086] Specific types of biomass 10, namely woody biomass, agricultural
biomass, and
cultivated plant biomass, may include different forms. First, woody biomass 10
may include
limbs, tops, needles, leaves, and other woody parts, grown in a forest,
woodland, or rangeland
environment, that are the by-products of forest management. Woody biomass 10
can also
include but is not limited to logs, wood chips, wood bark, wood powder,
sawdust, pulp products,
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wood pellet products, sawmill products, salvaged wood products, logging waste,
forest products,
and wood products. Sources of woody biomass 10 can encompass both native and
cultivated
trees including hybrids. The woody biomass 10 may include softwood trees,
softwood shrubs,
and softwood bushes. This woody biomass 10 may include hardwood trees,
hardwood shrubs,
and hardwood bushes. Additionally, the woody biomass 10 may include hybrid
trees, hybrid
shrubs, and hybrid bushes. Woody biomass 10 can also include native trees,
forest trees, native
shrubs, forest shrubs, native bushes, and forest bushes. Woody biomass 10 may
also include
residential or commercial landscaping trees, shrubs, and bushes. The woody
biomass 10 may
include recycled and/or recovered wood and wood products. Second, agricultural
biomass 10
can include but is not limited to agricultural food and feed crops, whether or
not hybrid or
genetically modified, agricultural products, and agricultural residues like
stover, hay, straw,
prunings, and clippings. Agricultural biomass 10 can be considered to contain
plants, leaves,
stems, stalks, roots, seeds, fruits, nuts, or other products of agriculture.
Some types of
agricultural biomass 10 may include agricultural biomass that is annual,
biennial, or perennial.
Agricultural biomass 10 can also contain an agricultural residue product of
agricultural biomass.
These agricultural residues from the agricultural biomass 10 may include
stover, straw, hay,
bagasse, hulls, straw, nut shells, crop residues, and clippings and prunings
from orchards and
vineyards. Third, cultivated biomass 10 can include but is not limited to
cultivated crop plants
like switchgrass, miscanthus and sweet sorghum that may be grown for the
production of fuels
and chemicals. Cultivated plant biomass 10 can be comprised of plants whose
origin or selection
is primarily due to intentional human activity. Some examples of cultivated
plant biomass 10
can include but are not limited to cultivated plants like switchgrass,
miscanthus, hemp, King
grass, sugarcane, sweet sorghum, duckweed, and a variety of cultivated tree
species ranging from
eucalyptus to palm oil. Some of this cultivated plant biomass 10 may be grown
for the
production of fuels and chemicals. Because of their typical higher biomass
density per acre,
cultivated plant biomass 10 may provide a biomass source where they are
utilized, particularly in
geographies and/or soils where certain higher value agricultural and woody
biomass do not grow
as well. In other words, cultivated plant biomass 10 may provide a use for
marginal lands where
environmental stress is inherent and the land cannot be used for typical
agricultural or timber
purposes. In the process described herein, this cultivated plant biomass 10
may be used for the
production of biobased chemicals 40. The cultivated plant biomass 10 may be
considered to
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include cultivated plants, cultivated trees, cultivated shrubs, and cultivated
bushes. Sources of
cultivated plant biomass 10 can encompass native plants, hybrid plants, and
genetically modified
plants. In addition, cultivated plant biomass 10 may include annual cultivated
plants. native
annual cultivated plants, hybrid annual cultivated plants, genetically
modified annual cultivated
plants, perennial cultivated plants, native perennial cultivated plants,
hybrid perennial cultivated
plants, genetically modified perennial cultivated plants, biennial cultivated
plants, native biennial
cultivated plants, hybrid biennial cultivated plants, and genetically modified
biennial cultivated
plants. Cultivated plant biomass 10 may also include residential landscaping
plants and
commercial landscaping plants. Cultivated plant biomass 10 may include some
agricultural
plants, medicinal plants, fiber plants, ornamental plants, aquatic plants, and
grassy plants. The
cultivated plant biomass 10 described herein can also be a by-product, residue
or waste product
of cultivated plants, cultivated trees, cultivated shrubs, cultivated bushes,
aquatic plants,
medicinal plants, fiber plants, ornamental plants, grassy plants, annual
cultivated plants, native
annual cultivated plants, hybrid annual cultivated plants, genetically
modified annual cultivated
plants, perennial cultivated plants, native perennial cultivated plants,
hybrid perennial cultivated
plants, genetically modified perennial cultivated plants, biennial cultivated
plants, native biennial
cultivated plants, hybrid biennial cultivated plants, and genetically modified
biennial cultivated
plants.
[0087] In essence, biomass 10 may include any plant based source that can be
added to
the process to create at least one component stream, typically lignin 34,
cellulose 26, and
hemicellulose 36, for the production of biobased chemicals 40. Depending on
the type of
biomass 10 material, the amounts of the biomass 10, and the compositions of
the biomass 10,
these component streams can differ.
[0088] Next, the biomass 10 may undergo a mechanical processing 12 in order to
reduce the size of the biomass 10 and prepare it for further processing. For
the mechanical
processing 12, the biomass 10 can undergo chopping, chipping, cutting,
shredding, debarking,
milling, and grinding. In order to break down the biomass, there can be one or
more mechanical
processing 12 steps needed. The type of mechanical processing 12 may be
dependent upon the
type of biomass 10 and its requirements for breaking it down for further
treatment.
17
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[0089] After the mechanical processing 12, the biomass 10 may be subjected to
an
optional chemical processing 14. This optional chemical processing 14 may
serve to further
break down the biomass 10 as well as remove fats, oils, resins, pitches,
waxes, and other
extractables. After both mechanical processing 12 and optional chemical
processing 14, a
biomass fractionation 16 can be formed.
[0090] Still referring to FIGURE 1, the biomass fractionation 16 may undergo a
first
filtration 18 if the optional chemical processing 14 is completed. The first
filtration 18 serves to
remove the optional chemical processing 14 from the biomass fractionation 16.
The fats, oils,
resins, pitches, waxes, and other extractables removed in the optional
chemical processing 14 can
be further separated during the first filtration 18 and marketed as useful
products of commerce.
From the first filtration 18, the chemical used from the optional chemical
processing 14 can be
recycled under a chemical recycling 38 step. This chemical recycling 38
process will be detailed
further in FIGURE 7.
[0091] Using the biomass fractionation 16 step can provide a greener process
by
utilizing at least three of the component streams of biomass 10. These three
component streams
of biomass 10 may include cellulose 26, hemicellulose 36, and lignin 34.
Typically for woody
biomass 10, the cellulose 26 may be about 39% to about 57%, the hemicellulose
36 may be
about 8% to about 28%, and the lignin 34 may be about 15% to about 28%.
Depending on the
different species of woody biomass 10, these ratios can vary. For hardwood
woody biomass 10.
the hemicellulose 36 amounts can be higher. For softwood woody biomass 10, the
lignin 34
amounts and the cellulose 26 amounts can be higher. In looking at the ranges
for agricultural
biomass 10, the cellulose 26 may be about 30% to about 42%, the hemicellulose
36 may be
about 12% to about 39%, and the lignin 34 may be about 11% to about 29%.
Different species
of agricultural biomass 10, like woody biomass 10, can also vary for these
ratios. Likewise, for
cultivated plant biomass 10, the amounts of cellulose 26, hemicellulose 36,
and lignin 34 will
vary for different species of cultivated plant biomass 10. Depending on the
type of biomass 10
used or targeted, the amounts of each of the component streams can determine
the end products
in the production of biobased chemicals 40.
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[0092] After the first filtration 18 with the optional chemical processing 14,
the filtered
biomass fractionation 20 may be formed. Either the filtered biomass
fractionation 20 from the
optional chemical processing 14 or the biomass fractionation 16 from the
mechanical processing
12 alone can be broken down even further by component separation processing
22. In the
component separation processing 22, a high pressure and temperature can
successfully break
down the biomass even further. Alternatively, the filtered biomass
fractionation 20, or the
biomass fractionation 16 from the mechanical processing 12 alone, can be
broken down with
other processes in the component separation processing 22 that may include at
least one of kraft
pulping, sulfite pulping, pyrolysis, steam explosion, ammonia fiber explosion,
dilute acid
hydrolysis, alkaline hydrolysis, alkaline oxidative treatment, and enzymatic
treatment. A second
filtration 24 can then be done to separate the cellulose 26 from the lignin
and hemicellulose
mixture 28. This lignin and hemicellulose mixture 28 can then go through both
a residual
chemical removal 30 and a third filtration 32 in order to separate the lignin
and hemicellulose
mixture 28 into lignin 34 and hemicellulose 36. Further, an optional pH
adjustment 50 may take
place prior to the third filtration 32 to effect a more complete separation of
lignin 34 and
hemicellulose 36. With the separated component streams for cellulose 26,
lignin 34, and
hemicellulose 36, the production of biobased chemicals 40 can be achieved.
[0093] FIGURE 2 is a flow diagram schematically depicting the process in which
biomass 10 may be mechanically and optionally chemically processed to provide
both a
fractionated and filtered biomass product in accordance with an embodiment of
the present
invention.
[0094] In FIGURE 2, the biomass 10 may undergo mechanical processing 12 in
order
to reduce the size of the biomass 10 and prepare it for further processing.
For the mechanical
processing 12, the biomass 10 can be delivered for processing. Depending on
the type of
biomass 10, the mechanical processing 12 can vary. The mechanical processing
12 can include
chopping, chipping, cutting, shredding, debarking, milling, and grinding. For
example, logs and
branches of woody biomass may undergo one or more of debarking, chopping,
chipping, milling
and grinding. Sawdust can also undergo additional mechanical processing, but
would have been
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subjected to previous mechanical processing. However, agricultural biomass
such as corn stover
or cultivated plant biomass like miscanthus, switchgrass and sweet sorghum are
fibrous
materials, and may only require one or more of chopping, cutting, shredding,
milling and
grinding. No matter what type of biomass 10 may be used, milling or chopping
may be needed
in order to reduce size of the material for ease and efficiency of processing.
The biomass 10 can
be milled to various sizes, but the size of the milled biomass is tied to the
efficiency of how it is
broken down within the subsequent processes. For instance, larger particle
sizes of milled
biomass may take longer to be broken down in both the optional chemical
processing 14 and
later processes within the component separation processing 22 due to less
surface area in which
to react during the breakdown processes. Wood and agricultural biomass 10 can
typically be
milled to a particle diameter of less than I/8". The maximum particle diameter
for milling of
woody biomass 10 can typically be about 1/4". Other sources of biomass 10 such
as agricultural
stover can be processed using particle sizes longer than I/8" because the thin
fiber widths of such
biomass 10 like stover provide greater surface area for reaction than a
rounder particle of the
same length. Preferably, a uniform particle size or thin fiber length can be
reached for ease and
consistency of processing during the subsequent processes.
[0095] After the mechanical processing 12, the biomass 10 may be subjected to
an
optional chemical processing 14. Biomass 10 may undergo the optional chemical
processing 14
if additional breakdown of the biomass 10 is needed. Some biomass 10, like
agricultural stover.
may not require optional chemical processing 14 since it may be sufficiently
broken down with
mechanical processing 12 alone. Some types of biomass 10, like trees, may
benefit from the
optional chemical processing 14 in the production of biobased chemicals 40.
This optional
chemical processing 14 may typically be done through a solvent treatment.
During the optional
chemical process 14, the biomass 10 can be further broken down after the
mechanical processing
12. Typically, the optional chemical processing 14 can be performed in a
solvent like ethanol.
Besides ethanol, other organic solvents, acids, bases, or enzymes can be used
for the optional
chemical processing 14. However, the use of these acids, bases, or enzymes may
lead to varying
degrees of hydrolysis.
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[0096] The optional chemical processing 14 can also undergo an optional
extractables
removal 52. The optional extractables removal 52 helps to remove any
extractables from the
biomass 10. Some of these extractables can include fats, oils, resins,
pitches, and waxes present
in different forms of biomass. Depending on the biomass source, the type and
amount of these
extractables can vary. The extractables do not have to be taken out, but their
removal may allow
for a purer end product with the production of biobased chemicals 40 in FIGURE
1. Further, the
optional extractables removal 52 may provide products of importance to
commerce and for more
of a comprehensive utilization of the biomass resource and generation of less
waste. The
extractables removed during the optional extractables removal 52 can be
further separated,
processed, and marketed as useful products of commerce for at least one of
biofuels, lubricants,
cleaning agents, disinfectants, deodorant additives, scents, and extraction of
metal from ores.
[0097] After both mechanical processing 12 and optional chemical processing
14, the
biomass fractionation 16 may be formed. The biomass fractionation 16 can then
filtered to form
the filtered biomass fractionation 20 if it was subjected to optional chemical
processing 14. In
this filtration after the mechanical and chemical processing, which is
referred to as the first
filtration 18, the optional chemical processing 14 can be partially removed
from the biomass
fractionation 16. For the first filtration 18, there are a series of steps
where the biomass
fractionation 16 may be filtered, then washed with additional chemical which
is used in the
optional chemical processing 14, typically ethanol or another alcohol, and
then filtered again to
remove some of the chemical from the optional chemical processing 14. After
the wash and first
filtration 18, typically about 50% of the chemical may be removed. The
filtered biomass
fractionation 20 may or may not contain some of the chemical from the optional
chemical
processing 14 step. From this step, either the filtered biomass fractionation
20 or the biomass
fractionation 16 will be subjected to the component separation processing 22
as detailed in
FIGURE 3.
[0098] With reference now to FIGURE 3, the flow diagram schematically depicts
the
process in which the biomass fractionation 16 or the filtered biomass
fractionation 20 may be
processed further to obtain a treated biomass fractionation 42 in accordance
with an embodiment
of the present invention. The biomass fractionation 16 or the filtered biomass
fractionation 20
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can be subjected to a component separation processing 22. The component
separation
processing 22 may include a high pressure and temperature treatment to form
the treated biomass
fractionation 42. The pressure can be generated and controlled by heating in a
sealed vessel.
The pressure typically ranges from about 100 psi to about 800 psi. The
temperature can range
from about 150 C to about 300 C (about 300 F to about 572 F), with about
200 C to about
250 C (about 392 F to about 482 F) typically used. The high pressure and
temperature
treatment can be conducted in a solvent, generally under alkaline conditions.
Often, an ethanol
and water mixture may be used as the solvent. Other alcohols or water mixtures
may also be
used in component separation processing 22. The high pressure and temperature
treatment may
serve to breakdown and solubilize the hemicellulose and lignin components of
biomass. Because
both the hemicellulose and lignin are solubilized, the lignin and
hemicellulose mixture 28 can be
later separated from the insoluble cellulose 26. Also, extractables may be
removed and
recovered/recycled from this treatment as well as any chemicals like alcohols.
[0099] After the high pressure and temperature treatment, a treated biomass
fractionation 42 may then be attained. Alternatively, the biomass
fractionation 16 or filtered
biomass fractionation 20 can also be broken down with other processes in the
component
separation processing 22 that may include at least one of kraft processing,
sulfite pulping,
pyrolysis, steam explosion, ammonia fiber explosion, dilute acid hydrolysis,
alkaline hydrolysis,
alkaline oxidative treatment, and enzymatic treatment. No matter what process
is used within the
component separation processing 22, the biomass can be broken down to the
treated biomass
fractionation 42 after the component separation processing 22 is completed.
During the
component separation processing 22, the hemicellulose component may hydrolyze
the easiest
whereas cellulose may be the most difficult to hydrolyze. The hydrolyzation
difference in the
method described herein can help to separate the component streams of the
biomass. From the
hydrolysis, a physical division of the component streams may occur.
[0100] From there, the second filtration 24 can be done on the treated biomass
fractionation 42 in order to separate the cellulose 26 from the lignin and
hemicellulose mixture
28. The second filtration 24 serves to remove the insoluble cellulose 26 from
the soluble lignin
and hemicellulose mixture 28. Optionally, the insoluble cellulose 26 can be
washed with water
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or a chemical like aqueous ethanol and separated from the wash in the second
filtration 24. The
filtration leaves an aqueous mixture of hemicellulose sugars and solubilized
lignin. The residual
chemical(s) can be removed from this filtrate through concentration or
distillation by applying a
low to modest temperature and a minimal vacuum which may be sufficient to
evaporate the
chemical in the residual chemical removal 30 of FIGURE 1. When the chemical is
ethanol, this
temperature may be about 25 C to about 40 C (about 77 F to about 104 F)
and the pressure
typically may vary from about 30 millimeters of mercury to about 70
millimeters of mercury.
The chemical may then be recycled for reuse. Ideally, 100% of the chemical
would be recovered
so that it can be recycled back into the process, which reduces costs
associated with purchasing
additional chemicals. Typically, at least 90% may be recovered for recycling.
The second
filtration 24 also can assist in separating the solubilized lignin and
hemicellulose mixture 28
from the insoluble and solid cellulose 26. After this step, the separated
cellulose 26 can undergo
the production of biobased chemicals 40.
[0101] FIGURE 4 is a flow diagram schematically depicting the process in which
the
treated biomass fractionation 42 can provide cellulose 26, which may be
further processed to
produce derivative products in accordance with an embodiment of the present
invention. In
separating the cellulose 26 after the second filtration 24, the cellulose 26
can then be processed
to allow for the production of biobased chemicals 40. The second filtration 24
also may provide
a way to obtain the soluble lignin and hemicellulose mixture 28. For instance,
the cellulose 26
can be hydrolyzed, reacted, and purified to provide for the production of
biobased chemicals 40,
namely cellulosic esters, aliphatic carboxylic acids, aliphatic esters,
polyols, furans,
dihydrofuran, tetrahydrofurans, lactones, and ethanol. Some of these biobased
chemicals from
cellulose 26 can include but are not limited to cellulose acetate, cellulose
propionate, cellulose
benzoate, methyl and ethyl adipate, methyl and ethyl levulinate, methyl and
ethyl succinate,
methyl and ethyl 2,5-furandicarboxylate, adipic acid, levulinic acid, succinic
acid, 2,5-
furandicarboxylic acid, 3,4-dehydro-y-valerolactone, 7-valerolactone, 2-
methyltetrahydrofuran,
sorbitol, hexane-1,6-diol, pentane-1,4-diol, butane-1,4-diol, 2,5-
di(hydroxymethyl)furan, 2,5-
di(hydroxymethyl)tetrahydrofuran, glyercol, propylene glycol, and ethanol.
23
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[0102] FIGURE 5 is a flow diagram schematically depicting the treated biomass
fractionation 42 which can be further processed to obtain lignin 34 and
hemicellulose 36 in
accordance with an embodiment of the present invention. After the treated
biomass fractionation
42 is subjected to a second filtration 24, the lignin and hemicellulose
mixture 28 may be attained.
From this step, the residual chemical removal 30 can then be completed. In
addition to
chemicals added during the component separation processing 22 shown in FIGURE
3, the
residual chemical removal 30 can remove any chemicals carried over from the
optional chemical
processing 14 shown in FIGURE 2, which may also be recycled back into the
process. In the
residual chemical removal 30, a chemical, typically an alcohol like ethanol
can be recovered
through concentration or distillation by applying a low to modest temperature
and a minimal
vacuum which may be sufficient to evaporate the alcohol in the residual
chemical removal 30.
When the alcohol is ethanol, this temperature may be about 25 C to about 40
C (about 77 F to
about 104 F) and the pressure typically may vary from about 30 millimeters of
mercury to about
70 millimeters of mercury. The chemical may then be recovered and recycled for
reuse. After a
third filtration 32, the mixture can then be separated into lignin 34 and
hemicellulose 36. In
some instances, the processing may require the optional pH adjustment 50 using
an acid to adjust
the pH of the solution to a point which the lignin and hemicellulose can be
efficiently separated
from each other prior to the third filtration 32. Typically, sulfuric acid can
be used in the
optional pH adjustment 50, but other acids may be employed. Optionally, the
precipitated lignin
can be washed with water and separated from the wash in the third filtration
32. In the third
filtration 32, the hemicellulose 36 can be primarily soluble and may be in an
aqueous solution of
the filtrate. The optional removal of the water from the hemicellulose 36
provides a concentrated
form of hemicellulose sugars. The separation of the component streams to
lignin 34 and
hemicellulose 36 can permit the production of biobased chemicals 40. Lignin 34
can be a source
of aromatic chemicals like aromatic carboxylic acids, aromatic esters,
aromatic aldehydes, aryl
alcohols, aryl ketones, styrenes, aryl ethanes, aryl propenes, aryl propanes,
cresols, phenols,
benzenes, and pyrolytic oils. Some of the specific biobased chemicals from
lignin 34 can
include but are not limited to methyl and ethyl 4-hydroxybenzoate, methyl and
ethyl vanillate,
methyl and ethyl syringate, 4-hydroxybenzoic acid, (4-hydroxyphenyl)acetic
acid, vanillic acid,
homovanillic acid, syringic acid, homosyringic acid, 4-hydroxybenzaldehyde,
vanillin,
syringaldehyde, 4-hydroxybenzyl alcohol, 2-(4-hydroxyphenyl)ethanol, vanillyl
alcohol,
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homovanillyl alcohol, syringyl alcohol, homosyringyl alcohol, 4-
hydroxyacetophenone,
acetoguaiacone, acetosyringone, 4-hydroxystyrene, 3-methoxy-4-hydroxystyrene,
3,5-
dimethoxy-4-hydroxystyrene, (4-hydroxypheny1)-1-propene, (4-hydroxypheny1)-2-
propene,
eugenol, iso-eugenol, syringeugenol, iso-syringeugenol, ethyl phenol, ethyl
guaiacol, ethyl
syringol, propyl phenol, propyl guaiacol, propyl syringol, cresol, creosol,
syringyl creosol,
phenol, guaiacol, syringol, benzene, toluene, xylene, ethyl benzene, propyl
benzene, biphenyl,
and pyrolytic oils. Hemicellulose 36 can provide furans, dihydrofurans,
tetrahydrofurans,
polyols, lactones, and butenes. Some of the specific biobased chemicals from
hemicellulose 36
may include but are not limited to furfural, y-butyrolactone, tetrahydrofuran,
ribitol, xylitol,
arabitol, glyercol, propylene glycol, and isoprene.
[0103] FIGURE 6 is a diagram schematically depicting the plurality of the
component
streams and their conversion to derivative biobased products in accordance
with an embodiment
of the present invention. It shows the production of some derivative products
from the plurality
of component streams, namely cellulose 26, lignin 34, and hemicellulose 36.
The processes
described herein may provide only one independent and separate component
stream or a plurality
of component streams. These derivative biobased product(s) may be obtained
from only one
independent and separate component stream or more that one of the component
streams. Each
component stream may provide only one derivative product or more than one
derivative product,
which may also be used in the production of another chemical or other
chemicals. A derivative
product or a plurality of derivative products may be commodity, fine, and/or
specialty chemicals,
and be produced through at least one of chemical processing, biological
processing, catalytic
processing, and/or pyrolytic processing. These products can be at least one of
aromatic
chemicals, aliphatic chemicals, heterocyclic chemicals, and fuels. These
products can be at least
one of aromatic carboxylic acids, aromatic esters, aromatic aldehydes, aryl
alcohols, aryl
ketones, styrenes, aryl ethanes, aryl propenes, aryl propanes, cresols,
phenols, benzenes,
pyrolytic oils, cellulosic esters, aliphatic carboxylic acids, aliphatic
esters, polyols, ethanol,
furans, dihydrofuran, tetrahydrofurans, lactones, ethanol, and butenes. For
example, aliphatic
carboxylic acids may include but are not limited to adipic acid, levulinic
acid and succinic acid.
For instance, polyols may include but are not limited to sorbitol, xylitol,
arabinitol, hexane-1,6-
diol, pentane-1,4-diol, butane-1,4-diol, 2,5-hydroxymethylfuran, 2,5-
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hydroxymethyltetrahydrofuran, glyercol, propylene glycol. For example,
aromatic aldehydes
may include but are not limited to 4-hydroxybenzaldehyde, vanillin, and
syringealdehyde. For
instance, benzenes may include benzene, toluene, xylene, and biphenyl. Since
the process can
generate a plurality of component streams which may then be used for the
production of
biobased chemicals, waste can be minimized. The residual biomass waste from
this process can
be less than 25%. It can also be less than 15%. The waste from the process may
also be used to
produce energy, including heat and/or power. This method for reducing waste
can provide
greener process where the majority of the biomass provided at the beginning of
the process can
be converted into usable products in the production of biobased chemicals.
[0104] FIGURE 7 is a flow diagram schematically depicting an illustrative flow
of the
biomass treatment and processing along with the recovery of chemicals 44 used
within the
process in accordance with an embodiment of the present invention. In this
diagram, the
chemicals used for treating the biomass 10 in the optional chemical processing
14, the first
filtration 18, the component separation processing 22, and the second
filtration 24 can be
recoverable and recyclable for reuse. First, the biomass 10 may undergo a
mechanical
processing 12. After the optional chemical processing 14, the biomass
fractionation 16 can be
formed. Then, the first filtration 18 may be performed. Typically, the
chemical for the optional
chemical processing 14 is an alcohol like ethanol. After the first filtration
18, there may be a
recovery of chemicals 44 in which the chemical can be removed from the
filtered biomass
fractionation 20. Besides the recovery of chemicals 44 from the first
filtration 18, the analogous
recovery of chemicals 44 may be applicable from the residual chemical removal
30. From the
recovery of chemicals 44, the chemical may be subjected to a distillation
and/or filtration 46, and
can then be placed into a chemical holding tank 48 for reuse in one or more of
the optional
chemical processing 14, the washes of the first filtration 18, the component
separation processing
22, or the washes of the second filtration 24 steps. Ideally, 100% of the
chemicals used in the
process would be recovered. Preferably, at least a 90% recovery can provide a
greener process
where fewer chemicals are used and costs associated with purchasing more
chemicals from the
recovery loss are minimized. Additionally, during this process, the recovery
of chemicals from
the component stream can be processed to derivative products.
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[0105] The flow diagrams depicted herein are provided merely as an example to
clearly
and concisely describe embodiments of the method within the scope of the
present invention.
Some steps may be skipped or modified, new steps may be added, existing steps
may be deleted,
or the order of steps may be altered from that shown in the flow diagrams
without departing from
the scope of the present invention. It will be apparent to those skilled in
the art that the above
methods may incorporate changes and modifications without departing from the
general scope of
the appended claims or the equivalents thereof. It is intended to include all
such modifications
and alterations in so far as they come within the scope of the appended claims
or the equivalents
thereof.
27
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