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    10 views16 pages

    Ethanol From Biomass

    Uploaded by

    Cristina Ballesteros Barrio

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    of 16
    United States Patent 11» Van Draanen et al. (54] (75) (73] tl 21) (2 [63] G51] [52] [58] (56) PRODUCTION OF ETHANOL AND OTHER FERMENTATION PRODUCTS FROM BIOMASS Inventors: Arlen Yan Draanen, Bellevue, Wash. Steven Mello, Bedford, N. Assigoee: Ingram-Howell, LL.C., Haverhill, Mass, Notice: This patent is subject to a terminal dis- claimer. Appl. No. 08/949,176 Filed: Oct. 10, 1997 Related U.S. Application Data CContinastion-in-part of application No, 08/477,782, Jun, 7, 1905, Pat. No. 3,677,154 Int. CL! CLP 7/48; C12P 7/04; C12P 7106; C12P 7/10 US. Cl. 435/144; 435/157; 435/160; 435/101; 435/163; 435/165; 435/171; 435/267 Field of Seare 435/144, 160, 435/161, 163, 165, 157, 171, 267 References Cited U.S. PATENT DOCUMENTS 2,257,567 9/1941 Matanovieh-Manov etal 35570685 1/1971. Scheoering 3814248 6/1974 Lawhead 3878005 4/1975 Nash BS8B.351 6/1975 Wilson 3,983,055 3/1976 Korenkow ota. 4127487 11/1978. Grit et al 4187.75 2/1980 Flender 4,349,628 9/1982 English tal $400,470 8/1983 Zeikus et 4)553,977 11/1985 Fry 4'561,800 12/1985. Gulley et al. 44662,569 5/1987 Acker 4.667.291 5/1987 Weitzman ota 4.701.814 10/1987 Van Dijkea al. 85/163 4894.06 1/1990 Castell Us O0S932456A Patent Number: 5,932,456 *Aug. 3, 1999 fa) [45] Date of Patent: 4.98535 5,000,000 5028539 534044 5.162516 51182,199 5.250100 5407817 5.424202 5.487.089 567715 yi991 31991 71991 si1902 11902 11993 11993 ‘91995 61995 11006 10/1997 Milichip 485/161 Ingram etal Ingram et Keller et al Ingram et al Hatley Armbristor Lightsey et a Ingram et al Fovler etal Van Draanen eta. 35/105 485/161 435/165 45/163 FOREIGN PATENT DOCUMENTS 0127 S81 6-70782 1403 480 Wo 92/16615 raj984 3/1904 nas? 10/1992 European Pat Of Japan United Kingdom ‘WIPO OTHER PUBLICATIONS “Bioenergy”, Bioenergy laternational, Inc. p. 1 “Ethanol from Biomass: The Five-Carbon Solution”, The National Renewable Engergy Laboratory (Feb. 1995). Cellulose Conversion Key to Fuel to the Future” National Renewable Engergy Laboratory (Aug. 1994). “Joining Forces for Biofuels", The National Renewable Engeray Laboratory (Jan, 1995), The Primary Examiner—Herbert J. Lilling Attorney, Agent, or Firn-—Choate, Hall & S (57 ABSTRACT ‘A method and apparatus for the produetion of ethanol and olher fermentation products including citric acid, butanol and isopropanol from non-virgin biomass having deleterious ‘materials therein is provided. The deleterious. materials prevent or retard the production of ethanol and other fer- ‘mentation products when the aon-viggin biomass is com- bined with a fermentation material, The method includes primary processing, secondary processing and/or blending the non-virgin biomass with virgin biomass such that the effect of the deleterious materials is reduced, thereby allow- ing production of ethanol and other fermentation products, when the biomass is combined with the fermentation mate- tial, scl s, $ Drawi 5,932,456 Sheet 1 of 5 Aug. 3, 1999 US. Patent 1°14 Bursse00d 1 ssewioig UB, t 40014 dit SSEWOIg UIBIIA, t 62 82 qbz 22 seleog wuoneld ssewoig ub, BuNWooU| Le quelg |UeNS oO} sseworg Tesodsiq BAHEWOY Buisseo1g Mepuces, ssewoig UIB.IA-UON SIOEW seiqejohooy Buissao01g Alewud ssewolg UI6s1\-UON Joo} diy SSEWOIG UIGA-UON sareog woneig sseworg UIBsI,-UON BuIWCoU 5,932,456 Sheet 2 of 5 Aug. 3, 1999 US. Patent 2 Old Burssaz0lg ‘Asepuoses Weld jouewrg, SSeWOIg Ui6.1A-UON, OL ‘ssewoig /Passadod 8S ssewor| | uuuon} | dewug T Tt 001 oz Tesodsiq eAnewory SOMEW seigerkooy Buisse201g 1s0d. saigerokooy wo1e1edeg wueung Appa so1e1edag neue snouay 5,932,456 Sheet 3 of 5 Aug. 3, 1999 US. Patent £9l4 $5800id 180g saiqephosy ssewoig Passeoolg 7 q06, que id 1oueWS, Of ssewoig ‘SSeWOIg Passazolg J2YISSEID ay ieverew Pezisiepun, tesodsiq, ennewony teverew pazisianQ SSeWOIg ‘UIBu1A-UON passeooig Krewud T 89 5,932,456 Sheet 4 of 5 Aug. 3, 1999 US. Patent yoweW OL, fouetn3 82l uonespfyeq jouew3 92! 6ursseo0s ase ad q22i deel ( 2)b O14 SIEUaIEW uoneweuties 1B SISKIOIpAH vonejueune 4 asojued SIEUEIEW uoneueuie °B SISKIOIPAH esom|e, uiBIA SIELSIEW uonejueue, ‘esoqueg asojuad SIEUaIEN, uonejueues F 601 °B SISKIOIpAH qweuneenald q2ol SSeWOIR u6.1A sseWwoig ui6.1A-UON 5,932,456 Sheet 5 of 5 Aug. 3, 1999 US. Patent (Vp Olds ssewo1g uiBs1A, oe! queujeenald: uonespfyag joueurg 9g) a2zl vezi JOHEW OL foueur3 uonelnsiq "9 GusseGieg uoneiueuue4 puy voneoyUeYsoeS snoeUEYNWIS, T T 82 eel SIEUBIEW SIEUOTEW vonewweuuss| | sisiospay Opzi 5,932,456 1 PRODUCTION OF ETHANOL AND OTHER FERMENTATION PRODUCTS FROM BIOMASS PRIORITY CLAIM ‘The present application is a Continuation-in-part of allowed application U.S. Ser. No. 08/477,782, filed Jun. 7, 1995 now U.S. Pat. No. 5,677,154. The entire contents of this prior application are incorporated herein by reference. ‘TECHNICAL FIELD. ‘The present invention relates generally to 4 method and apparatus for the production of fermentation produets from biomass, and more particularly to the production of citric acid and other fermentation products such as butanol, isopropanol, ethanol and related chemicals from waste mate rials, BACKGROUND OF THE INVENTION Ethanol has widespread application as an industrial ‘chemical, gasoline additive or Straight liquid fuel. As a fuel oo fuel additive, ethanol dramatically reduces air emissions while improving engine performance. As a renewable fuel, ‘ethanol reduces national dependance on finite and largely foreign fossil fuel sources while decreasing the net accu- ‘mulation of carbon dioxide in the atmosphere. Citric acid has widespread application as a food additive to adjust the pH of foods, as a synergistic antioxidant, and san industrial chemical in the manufacture of alkyd resins, as a plasticizer and as a sequestering agent to remove trace ‘metals. Isopropanol is also used as an industrial chemical as a solvent, in the composition of antifreeze, as well as in the manufacture of quick-drying inks and oils. Butanol is also used as an industrial chemical asa solvent, including use in industrial cleaning compounds and the like Biomass includes materials containing cellulose, hemicellulose, Tigain, protein and carbohydrates such as Starch and sugar. Common forms of biomass include tees, ‘shrubs and grasses, corn and cora husks as well as municipal solid waste, waste paper and yard waste, Biomass high in Starch, sugar or protein such as com, grains, fruits and ‘vegetables are usually consumed as foad. Conversely, bio- ‘mass high in cellulose, hemicellulose and lignin are not readily digestible and are primarily utilized for wood and paper products, fuel, or are disposed of. Ethanol and other chemical fermentation products typi cally have been produced from sugars derived from feed- stocks high in starches and sugars, such as com, While the discussion of fermentation products described herein describes the method and apparatus of the current invention using the example of how the current invention is used fo produce ethanol, it will be appreciated by those skilled in the art that the current invention also has application to other fermentation products, including citric acid, butanol and isopropanol and that references to ethanol encompass these ‘ther fermentation products. Recently, the conversion to ethanol of polymeric hexose and pentose sugars in cellulose and hemicelTulose has been achieved. See U.S. Pat. No. 4,349,628 to English et al; see also USS. Pat. No. 4,400,470 to Zeikus et at; US. Pat. No. 5,000,000 to Ingram ct al; US. Pat, No. 5,028,539 o Ingram ct a and US. Pat. No. 5,162,516 to Ingram et al, all of ‘which are incorporated herein by reference. Despite these advancements, certain “non-virgin” forms of biomass have not been successfully utilized im the pro- 0 os ss 4s ss 6s 2 duction of ethanol. For example, municipal solid waste (MSW) as a complex mixture of organic and inorganic materials (approximately 45% paper, 15-20% food and yard waste, 3-5% wood, 12-18% metal and glass, S~7% plastics and textiles and $-20% other materials) has certain con- stituents such as ferrous, non-ferrous and heavy metals, inks, dyes, plastics and clays as well as solvent, pesticide and herbicide residues which can have a deleterious effect on its conversion to ethanol. Similarly, other sources of noa-virgin biomass also typically contain deleterious materials which inhibit or prevent their conversion to ethanol Disposing of MSW and other non-virgin biomass in an economic and environmentally sound manner is a matter of public concern. Various waste disposal, sorting and recovery systems are known in the art. See’ eg., U.S. Pat, No, 2,257,567 to Matanovich-Manov et al; US. Pat. No. 3,557, {85 16 Schroering; U.S. Pat. No. 3,804,248 to Talamantz: US. Pat. No. 3,878,995 to Nash; U.S. Pat. No. 3,888,351 t0 Wilson; U.S. Pat, No, 4,187,775 to lender; US. Pat. No, 4,553,977 to Fry; US. Pat. No. 4,561,860 to Gulley et al; US. Pat. No. 4,662,569 to Acker; U.S. Pat. No. 4,667,291 to Weitzman etal; U.S. Pat. No. 4,894,066 to Castelli US. Pat. No. 5,134,944 to Keller etal and U.S. Pat. No. 5,250,100 to ‘Ammbristor, all of which are incosporated herein by refer- fence. The most common disposal techniques currently uti= lized by industrial societies are recycling, waste-to-energy ‘conversion and! landfilling. Each of these methods has cer- tain disadvantages associated therewith. These disadvantages, including economic and environmental shortcomings, make these techniques less than wholly desir- able as a means of disposal Recycling can be accomplished through “source separa- tion” wherein wastes are segregated into bins, containers, ot “blue bags" by the generator, Alternatively, mixed wastes ‘may be manually and mechanically separated into its con- stituents without pre-sorting. Recyeling programs, although popular, are expensive and ineflicient; managing only about 15-25% of municipal solid waste streams. The significant portion of waste materials which cannot be recycled con- tinue to require alternative disposal with attendant infra- structure and cost ‘Waste-lo-cnergy conversion is typically accomplished by either preparing from wastes a fuel product for incineration for by “mass-burming” it, These techaologies have largely fallen out of favor due to their high cast and negative ceavironmental impact. Moreover, serious ait emission and residue toxicity issues remain unresolved giving rise to health and safety concerns. Landfilling as well, has serious environmental issues associated therewith. For example, landfill gas emissions ‘can be dangerous and toxic leachate ean pollute groundwa- ter, Further, landfills often create noxious odors. This technology, although low in cost, results in wasting valuable land, energy and material resources. In many areas where land, energy and material resources are highly valued, there is a tend toward banaing the landlilling of wastes Various forms of biomass have potential as renewable feedstocks for ethanol production due to their enormous availability and low cost. However, prior attempls to dispose ‘of noa-virgin biomass through fermentation to ethanol have been largely unsuccessful. I would therefore be desirable to provide a method and apparatus for the production of ethanol from biomass containing deleterious materials therein, thereby providing an alternative waste disposal technique and overcoming the shortcomings associated with the prior art 5,932,456 3 SUMMARY OF THE INVENTION Iris an object ofthe present invention to provide a method and apparatus for the production of ethanol and other fermentation prods from biomass containing deleterious imatrils therein, Itis another object of the invention to provide a method and apparatus for the production of ethanol and other fermentation prosts from biomass containing deleterious materials by effectively removing these estes. It is another object of the invention to provide a method and apparatus to blend biomass containing deleterious mate~ rials with biomass substantially free of these constituents, thereby prodicing blended biomass in which deleterious materials ate effectively diluted such that conversion to ethanol and other fermentation proviucts ean be realized Itis another objec of the invention fo provide a system for the separation and classification of biomass material for purposes of reeyeling atleast a portion ofthe material while preparing the remainder for conversion to ethanol and other fermentation products or alternative disposal These and other objects ofthe invention are provided by 4 method and apparatus in which biomass ot non-vigin biomass is converted to ethanol and other fermentation proxets, The non-virgin biomass iitlly contains delete= Fious materials which prevent or inhibit iis conversion to ‘thanol and other fermentation products, The deleterious materials are effectively diminished during separation and processing, thereby allowing forthe production of ethanol dnd other fermentation products. Alternatively the effect of the deleterious materials inthe aon-vigin biomass may be cilectively diminished wit the addition of sulciet virgin biomass such that conversion of the blended biomass to cthanol and other fermentation products can be accom plished, In yet another embodiment of the invention, the non-virgin biomass may be subjected fo 4 secondary pro- ‘cessing treatment to further reduce the presence of delete- tious materials remaining therein. The non-virgin biomass, ‘which has been subjested to primary and. secondary processing, then may be combined with virgin biomass (0 further reduce the effects of any remaining deleterious materials, of it may be directly converted to elbanol and other fermentation products. “The foregoing has outlined some of the more pertinent objects of the present invention, These objects should be construed to be merely illsiative of some of the more prominent features and applications thereof, Other beneficial resulsean be attained by applying the disclosed invention in 2 ditferent mannet or modifying it as will be deseribed ‘Accordingly, other objects and «fuller understanding ofthe invention may be had by rfeering tothe following Detailed Description ofthe Invention. BRIEF DESCRIPTION OF THE DRAWINGS For a fuller understanding of the present invention, ref- ‘erence is had to the Following description taken in conjune- tion with the accompanying drawings, in which: FIG. 1 illustrates a process flow diagram for the prepa- ration of biomass for conversion to ethanol and other fermentation products in accordance with one embodiment of the invention; FIG. 2 illustrates a process flow diagram for the primary processing of non-virgin biomass in preparation for conver- sion to ethanol and other fermentation products; FIG, 3 illustrates a process flow diagram for the secondary processing of non-virgin biomass for conversion to ethanol 0 as os ss 4s ss 6s 4 and other fermentation products in accordance with the present invention; FIG, 4(@) illustrates a process flow diagram for the conversion of biomass andlor blended biomass 10 ethanol and other fermentation products according to the present invention; and FIG, 4(6) illustrates a process flow diagram for an alter native method of conversion of biomass and/or blended biomass to ethanol and other fermentation products in accordance with the present invention. Similar reference characters refer to similar parts through- cout the several views of the drawings. DETAILED DESCRIPTION OF THE INVENTION While not to be construed as limiting, the terms used herein have the following definitions unless indicated oth- exwise “Agricultural biomass” includes branches, bushes, canes, corn and corn husks, energy crops, forests, fruits, lowers, rains, grasses, herbaccous crops, Ieaves, bark, needles, logs, roots, saplings, short rotation woody crops, shrubs, switch grasses, tees, vegetables, vines and hard and soft ‘woodls (not including woods with deleterious materials). In addition, agricultural biomass includes organic waste mate- rials generated from agricultural processes including farm- ing and forestry activities, specifically including forestry ‘wood waste. Agricultural biomass may be any of the afor- estated singularly or in any combination or mixtuee thereof. “Biomass” includes virgin biomass andor noa-virgin biomass such as agricultural biomass, commercial organics, construction andl demolition debris, municipal solid waste, waste paper and yard waste “Blended biomass” is any mixture or blend! of virgin and non-virgin biomass, preferably having about 5-95% by ‘weight non-virgin biomass. “Bulky waste” includes mattresses, sofas, large chairs or other furniture, household appliances or white goods, large industrial scrap, rolls of plastic, motor vehicles including ‘major motor vehicle parts such as automobile transmissions, rear ends, springs and fenders, agricultural and farm machin- ery and equipment, marine vessels and major parts thereof, and any other large type of machinery, equipment or large type industrial waste “Byproducts” are any and all materials other than ethanol or water or ethanoliwater mixtures produced or remaining after the conversion of biomass or blended biomass to ethanol, “Commercial organics” includes beverage industry waste; brewery waste; sweet, acid and salt cheese whey: dairy waste; food processing waste, including potato, chocolate, apple, grape, citrus and other fruit and vegetable pumace; lumber and industrial wood waste; pulp and paper facility waste, including paper sludge; restaurant waste or the like. “Construction and demolition debris” includes asphalt, brick, concrete, conduit, dint, flashings, gravel, insulation, masonry, metal, nails, piping, plaster, rock, roofing materials, screws, sheetrock, sheet metal, steel, tar paper, tiles, wire, wood and the like generate from the construetion ‘ demolition of commercial or residential structures. “Conversion” includes any biological, chemical andor bbio-chemical activity which produces ethanol or ethanol and byproducts from biomass andor blended biomass. Such conversion includes hydrolysis, fermentatioa and simulta- ‘ncous saccharification and fermentation (SSF) of such bio- 5,932,456 5 mass and/or blended biomass. Preferably, conversion includes the use of fermentation materials and hydrolysis materials as defined herein, “Deleterious materials” includes any organie or inorganic material which has the ability to degrade or limit fermen- lation materials or hydrolysis materials in any manner, including the prevention or retardation of the hydrolysis ‘conversion of any biomass or its fermentation to ethanol. Examples of deleterious materials include ferrous metals, non-ferrous and heavy metals, grit, dit, dyes, plastics, clays, solvents, pesticides, herbicides, preservatives, paints, stains, glues, adhesives, and certain phenolic compounds and resins, for example those present in soft wood. “Ethanol” includes ethyl alcohol or mixtures of ethyl alcohol and water. “Fermentation products” includes ethanol, citric acid, butanol and isopropanol as well as derivatives thereof. “Fermentation materials” includes any material or organ- ism capable of producing ethanol. While not to be construed as limiting, the term encompasses bacteria, such as Zymomo- ‘nas mobili and Escherichia coli; yeasts such as Saccharo- ‘myces cerevisiae ot Pichia spits; and fungi that are natural ‘thanol-producers. Fermentation materials also encompass ‘engineered! organisms that are induced to produee ethanol through the introduction of foreign genetic material (such as pyruvate decarboxylase and/or alcohol dehydrogenase genes from a natural ethanol producer). The term further encom- passes mutants and derivatives, such as those produced by known genetic andjor recombinant techniques, of ethanol- producing organisms, which mutants and derivatives have been produced and/or selected on the basis of enbanced andior altered ethanol production. Preferred fermenting ‘organisms for use in the present invention are ethanol- producing Zymomonas mobilis or Escherichia coli strains ot derivatives thereof, Preferred Escherichia coli steains or ‘derivatives thereof are those transformed with recombinant ‘constructs containing a Zymomonas mobilis pyruvate deby-

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