Catalytic biomass deconstruction

Abstract

The present invention provides processes for catalytically converting biomass to oxygenated compounds suitable for use in bioreforming processes.

1 . A method of converting a biomass slurry to lower molecular weight oxygenated hydrocarbons, the method comprising:
 catalytically reacting a biomass slurry comprising water and a biomass component, with hydrogen and a heterogeneous deconstruction catalyst at a deconstruction temperature and a deconstruction pressure to produce an oxygenated hydrocarbon having a lower molecular weight than the biomass component.   
     
     
         2 . The method of  claim 1  wherein the biomass component comprises at least one member selected from the group including a cellulose, lignocellulose, agricultural residue, wood material, an energy crop, municipal solid waste, recycled fiber, corn stover, straw, bagasse, switch grass, miscanthus, sorghum, and poplar. 
     
     
         3 . The method of  claim 1  wherein the heterogeneous deconstruction catalyst comprises an acidic resin or a basic resin. 
     
     
         4 . The method of  claim 1  wherein the heterogeneous deconstruction catalyst comprises a support and a member adhered to the support, wherein the member is selected from the group consisting of Cu, Fe, Ru, Ir, Co, Rh, Pt, Pd, Ni, W, Mo, alloys thereof, and combinations thereof. 
     
     
         5 . The method of  claim 4  wherein the heterogeneous deconstruction catalyst further comprises one or more members selected from the group consisting of Cu, Mn, Cr, Mo, B, W, V, Nb, Ta, Ti, Zr, Y, La, Sc, Zn, Cd, Ag, Au, Sn, Ge, P, Al, Ga, In, Tl, Ce, alloys thereof, and combinations thereof. 
     
     
         6 . The method of  claim 1  wherein the oxygenated hydrocarbon is selected from the group consisting of a starch, a carbohydrate, a polysaccharide, a disaccharide, a monosaccharide, a sugar, a sugar alcohol, an alditol, an organic acid, a phenol, a cresol, ethanediol, ethanedione, acetic acid, propanol, propanediol, propionic acid, glycerol, glyceraldehyde, dihydroxyacetone, lactic acid, pyruvic acid, malonic acid, a butanediol, butanoic acid, an aldotetrose, tartaric acid, an aldopentose, an aldohexose, a ketotetrose, a ketopentose, a ketohexose, a hemicellulose, a cellulosic derivative, a lignocellulosic derivative, and a polyol. 
     
     
         7 . A method of converting a biomass slurry to lower weight oxygenated hydrocarbons, the method comprising:
 extracting the biomass slurry using hot water to produce a first liquid portion and a first solid slurry portion;   separating the first liquid portion from the first solid slurry portion;   catalytically reacting the first solid slurry portion with hydrogen in the presence of a heterogeneous deconstruction catalyst at a deconstruction temperature and a deconstruction pressure to produce a second solid slurry portion and a second liquid portion;   separating the second liquid portion from the second solid slurry portion; and   obtaining lower weight oxygenated hydrocarbons comprising a C 2+ O 1+  hydrocarbon in a liquid phase from the first and second liquid portion.   
     
     
         8 . The method of  claim 7  wherein the cellulosic slurry comprises at least one member selected from the group including a cellulose, lignocellulose, agricultural residue, wood material, energy crop, municipal solid waste, recycled fiber, corn stover, straw, bagasse, switch grass, miscanthus, sorghum, and poplar. 
     
     
         9 . The method of  claim 7  wherein the first liquid portion comprises at least one member selected from the group consisting of a saccharide and an extractive. 
     
     
         10 . The method of  claim 7  wherein the first solid slurry portion comprises at least one member selected from the group consisting of cellulose, hemicellulose, lignin, and ash. 
     
     
         11 . The method of  claim 7  wherein the heterogeneous deconstruction catalyst comprises an acidic resin or a basic resin. 
     
     
         12 . The method of  claim 7  wherein the heterogeneous deconstruction catalyst comprises a support and a member adhered to the support, wherein the member is selected from the group consisting of Cu, Fe, Ru, Ir, Co, Rh, Pt, Pd, Ni, W, Mo, alloys thereof, and combinations thereof. 
     
     
         13 . The method of  claim 12  wherein the heterogeneous deconstruction catalyst further comprises one or more members selected from the group consisting of Cu, Mn, Cr, Mo, B, W, V, Nb, Ta, Ti, Zr, Y, La, Sc, Zn, Cd, Ag, Au, Sn, Ge, P, Al, Ga, In, Tl, Ce, alloys thereof, and combinations thereof. 
     
     
         14 . The method of  claim 7  wherein the deconstruction temperature is in the range of about 150° C. to 350° C. 
     
     
         15 . The method of  claim 7  wherein the deconstruction pressure is in the range of about 150 psi to 2000 psi. 
     
     
         16 . The method of  claim 7  wherein the C 2+ O 1+  hydrocarbon is selected from the group consisting of a starch, a carbohydrate, a polysaccharide, a disaccharide, a monosaccharide, a sugar, a sugar alcohol, a alditol, an organic acid, a phenol, a cresol, ethanediol, ethanedione, acetic acid, propanol, propanediol, propionic acid, glycerol, glyceraldehyde, dihydroxyacetone, lactic acid, pyruvic acid, malonic acid, a butanediol, butanoic acid, an aldotetrose, tartaric acid, an aldopentose, an aldohexose, a ketotetrose, a ketopentose, a ketohexose, a hemicellulose, a cellulosic derivative, a lignocellulosic derivative, a polyol, a diol, and a mono-oxygenated hydrocarbon. 
     
     
         17 . A method of converting cellulosic slurry to water-soluble oxygenated hydrocarbons comprising:
 extracting the cellulosic slurry using an organosolv process to produce a first liquid portion and a first solid slurry portion;   separating the first liquid portion from the first solid slurry portion;   separating a solvent from the first liquid portion;   catalytically reacting the first solid slurry portion with hydrogen in the presence of a heterogeneous deconstruction catalyst at a deconstruction temperature and a deconstruction pressure to produce a second solid portion and a second liquid portion;   separating the second liquid portion from the second solid portion; and   obtaining water-soluble oxygenated hydrocarbons comprising a C 2+ O 1+  hydrocarbon in an aqueous liquid phase from the first and second liquid portions.   
     
     
         18 . The method of  claim 17  further comprising recycling the solvent back into the organosolv process. 
     
     
         19 . The method of  claim 17  wherein the cellulosic slurry comprises at least one member selected from the group including a cellulose, lignocellulose, agricultural residue, wood material, energy crop, municipal solid waste, recycled fiber, corn stover, straw, bagasse, switch grass, miscanthus, sorghum, and poplar. 
     
     
         20 . The method of  claim 17  wherein the first liquid portion comprises at least one member selected from the group consisting of a saccharide, an extractive, and lignin. 
     
     
         21 . The method of  claim 17  wherein the first solid portion comprises at least one member selected from the group consisting of cellulose, hemicellulose, lignin, and ash. 
     
     
         22 . The method of  claim 17  wherein the heterogeneous deconstruction catalyst comprises an acidic resin. 
     
     
         23 . The method of  claim 17  wherein the heterogeneous deconstruction catalyst comprises a support and a member adhered to the support, wherein the member is selected from the group consisting of Cu, Fe, Ru, Ir, Co, Rh, Pt, Pd, Ni, W, Mo, alloys thereof, and combinations thereof. 
     
     
         24 . The method of  claim 23  wherein the heterogeneous deconstruction catalyst further comprises one or more members selected from the group consisting of Cu, Mn, Cr, Mo, B, W, V, Nb, Ta, Ti, Zr, Y, La, Sc, Zn, Cd, Ag, Au, Sn, Ge, P, Al, Ga, In, Tl, Ce, alloys thereof, and combinations thereof. 
     
     
         25 . The method of  claim 17  wherein the deconstruction temperature is in the range of about 80° C. to 350° C. 
     
     
         26 . The method of  claim 17  wherein the deconstruction pressure is in the range of about 100 psi to 2000 psi. 
     
     
         27 . The method of  claim 17  wherein the C 2+ O 1+  hydrocarbon is selected from the group consisting of a starch, a carbohydrate, a polysaccharide, a disaccharide, a monosaccharide, a sugar, a sugar alcohol, a alditol, an organic acid, a phenol, a cresol, ethanediol, ethanedione, acetic acid, propanol, propanediol, propionic acid, glycerol, glyceraldehyde, dihydroxyacetone, lactic acid, pyruvic acid, malonic acid, a butanediol, butanoic acid, an aldotetrose, tartaric acid, an aldopentose, an aldohexose, a ketotetrose, a ketopentose, a ketohexose, a hemicellulose, a cellulosic derivative, a lignocellulosic derivative, and a polyol, a diol, and a mono-oxygenated hydrocarbon.