Continuous counter-current organosolv processing of lignocellulosic feedstocks

Abstract

A modular process for organosolv fractionation of lignocellulosic feedstocks into component parts and further processing of said component parts into at least fuel-grade ethanol and four classes of lignin derivatives. The modular process comprises a first processing module configured for physico-chemically digesting lignocellulosic feedstocks with an organic solvent thereby producing a cellulosic solids fraction and a liquid fraction, a second processing module configured for producing at least a fuel-grade ethanol and a first class of novel lignin derivatives from the cellulosic solids fraction, a third processing module configured for separating a second class and a third class of lignin derivatives from the liquid fraction and further processing the liquid fraction to produce a distillate and a stillage, a fourth processing module configured for separating a fourth class of lignin derivatives from the stillage and further processing the stillage to produce a sugar syrup.

1 - 29 . (canceled) 
   
   
       30 . A modular system for organosolv fractionation of lignocellulosic feedstock into component parts and further processing of said component parts; the modular process comprising:
 a first processing module configured for receiving, physically processing, and physico-chemically digesting a lignocellulose feedstock therewith a separately supplied organic solvent thereby extracting component parts therefrom said feedstock, and separating said component parts into a cellulosic solids fraction and a first liquid fraction;   a second processing module configured for receiving therein said cellulosic solids fraction and for producing therefrom at least a fuel-grade ethanol, a first class of lignin derivatives, and a de-lignified stillage;   a third processing module configured for separating the first liquid fraction into a solids fraction comprising a second class of lignin derivatives, a third class of lignin derivatives and a filtrate, for separating furfurals from said filtrate, and for recovering a portion of the organic solvent from the filtrate by distillation thereby producing a first stillage; and   a fourth processing module configured for separating the first stillage into at least an acetic acid-containing liquid fraction, a fourth class of lignin derivatives, a monosaccharide sugar syrup, and a solid waste material.   
   
   
       31 . A modular system according to  claim 30 , additionally provided with a fifth processing module configured for anaerobic digestion and processing of the solid waste material separated by the fourth processing module, into at least a collectable biogas and an liquid effluent. 
   
   
       32 . A modular system according to  claim 30 , wherein the first processing module comprises a plurality of equipment selected and configured for controllable and manipulable communication and cooperation for:
 receiving therein a lignocellulosic feedstock;   processing the lignocellulosic feedstock by physically separating non-lignocellulosic materials therefrom;   physico-chemically digesting the processed lignocellulosic feedstock by commingling said feedstock with a separately supplied organic solvent while controllably manipulating at least the temperature and pressure therein and thereabout, thereby producing the cellulosic solids fraction and the first liquid fraction; and   separately and controllably discharging the cellulosic solids fraction and the first liquid fraction.   
   
   
       33 . A modular system according to  claim 30 , wherein the first processing module is configured to continuously receive, physically process, and physico-chemically digest a lignocellulosic feedstock thereby continuously producing the cellulosic solids fraction and the first liquid fraction. 
   
   
       34 . A modular process according to  claim 30 , wherein the first processing module is configured to receive, physically process, and physico-chemically digest a batch of lignocellulosic feedstock thereby producing the cellulosic solids fraction and the first liquid fraction. 
   
   
       35 . A modular system according to  claim 30 , wherein the first processing module is provided with a temperature-controllable and pressure-controllable digestion vessel configured to:
 receive therein the processed lignocellulosic feed stock at about a first end and to convey said feedstock therethrough to about a second end;   receive therein an organic solvent at about the second end, and to flow said organic solvent therethrough to about the first end;   discharge the cellulosic solids fraction through an outlet provided therefor approximate the second end; and   discharge the first liquid fraction through an outlet provided therefor approximate the first end.   
   
   
       36 . A modular system according to  claim 35 , wherein the temperature-controllable and pressure-controllable digestion vessel is configured to:
 receive therein the processed lignocellulosic feed stock at about a first end and to convey said feedstock therethrough to about a second end;   receive therein an organic solvent at about the first end, and to circulate said organic solvent therethrough and thereabout;   discharge the cellulosic solids fraction through an outlet provided therefor approximate the second end; and   discharge the first liquid fraction through an outlet provided therefor approximate the second end.   
   
   
       37 . A modular system according to  claim 35 , wherein the temperature-controllable and pressure-controllable digestion vessel is configured to:
 receive therein the processed lignocellulosic feed stock at about a first end and to convey said feedstock therethrough to about a second end;   receive therein an organic solvent interposed the first end and second end, and to circulate said organic solvent therethrough and thereabout;   discharge the cellulosic solids fraction through an outlet provided therefor approximate the second end; and   discharge the first liquid fraction through an outlet provided therefor approximate the first end.   
   
   
       38 . A modular system according to  claim 30 , wherein the first processing module is additionally provided with equipment configured to sequentially saturate and de-saturate the processed lignocellulosic feedstock prior to physico-chemically digesting said processed lignocellulosic feedstock. 
   
   
       39 . A modular system according to  claim 30 , wherein the second processing module comprises a plurality of equipment selected and configured for controllable and manipulable communication and cooperation for:
 receiving therein the cellulosic solids fraction discharged from the first processing module;   reducing the viscosity of the cellulosic solids fraction;   enzymatic digestion of the reduced-viscosity cellulosic fraction thereby producing a second liquid fraction;   fermentation of the second liquid fraction thereby producing a beer therefrom;   distillation of the beer thereby producing a fuel-grade ethanol and a second stillage therefrom; and   separating a first class of lignin derivatives from said second stillage.   
   
   
       40 . A modular system according to  claim 30 , wherein the de-lignified second stillage is recyclable for reducing the viscosity of the cellulosic solids fraction. 
   
   
       41 . A modular system according to  claim 30 , wherein the second processing module is provided with a vessel for containing therein concurrent enzymatic digestion of the reduced-viscosity cellulosic solids fraction and fermentation of the second liquid fraction produced therefrom. 
   
   
       42 . A modular system according to  claim 30 , wherein the anaerobic digestion module is provided with a plurality of equipment configured for:
 receiving and biologically hydrolyzing therein the solid waste material separated by the fourth processing module thereby producing a third liquid fraction;   receiving and biologically acidifying therein the third liquid fraction thereby producing a biologically acidified liquid fraction;   receiving and biologically acetifying therein the biologically acidified liquid fraction thereby producing at least acetic acid; and   receiving the at least acetic acid and biologically producing at least a biogas and a liquid effluent therefrom.   
   
   
       43 . A modular system according to  claim 42 , wherein the anaerobic digestion module is additionally configured for controllably receiving and commingling a portion of said monosaccharide sugar syrup separated in the fourth processing module with the a third liquid fraction. 
   
   
       44 . A modular system according to  claim 30 , additionally provided with a sixth processing module configured for receiving, fermenting and distilling therein said monosaccharide sugar syrup, and for separating therefrom a distillate and a stillage. 
   
   
       45 . A modular system according to  claim 44 , wherein said distillate comprises at least 1,3 propanediol. 
   
   
       46 . A modular system according to  claim 44 , wherein said distillate comprises at least polylactic acid. 
   
   
       47 . A first class of lignin derivatives, said first class of lignin derivatives produced by a process comprising:
 a first step comprising hydrolizing a cellulosic solids material thereby producing a liquid stream containing at least soluble monosaccharides;   a second step comprising fermentation of said liquid stream containing at least soluble monosaccharides thereby producing a fermentation beer;   a third step comprising distillation of said beer to produce an ethanol and a stillage therefrom; and   a fourth step of precipitating and separating lignin derivatives from said stillage.   
   
   
       48 . A second class of lignin derivatives, said second class of lignin derivatives produced by a process comprising:
 a first step comprising fractionating a lignocellulosic feedstock into a cellulosics solids fraction and a pressurized liquids fraction, and separating said fractions;   a second step comprising depressurizing and cooling the liquids fraction thereby precipitating a plurality of lignin derivatives from said liquids fraction; and   a third step comprising separating said precipitated plurality of lignin derivatives from said liquids fraction.