Lignin conversion process

Abstract

This specification discloses a complete method to manufacture polyester articles from freshly harvested ligno-cellulosic biomass. The process steps include pretreating the biomass and the converting the lignin to one of several possible organic steams by deoxygenating and dehydrogenating the lignin in the presence of a Raney Nickel catalyst, separating the organics, and then processing the organics into polyester feedstocks and converting those feedstocks to polyester.

We claim: 
     
         1 . A process for a one-step conversion of a pre-treated lignin feedstream that has been pre-treated by steam explosion, hydrolysis and fermentation into a converted lignin stream, the process comprised of:
 a. combining in a lignin conversion vessel: the pre-treated lignin feedstream, water supplied from the group consisting of the pre-treated lignin feedstream, a source other than the pre-treated lignin feedstream and mixtures thereof, hydrogen having a hydrogen pressure which at 25° C. is in the range of 21.7 to 104.5 bar, and a first catalyst comprising an elemental metal catalyst, and   b. maintaining the combination in the lignin conversion vessel at a first temperature in the range of 245° C. to 300° C. for a time sufficient to create a converted lignin stream,   wherein the pre-treated lignin feedstream comprises lignin, cellulose and water wherein the ratio of moles of hydrogen to moles of lignin and cellulose is at least 0.5 and wherein the lignin of the pre-treated lignin feedstream is present as a solid.   
     
     
         2 . The process according to  claim 1 , wherein the first catalyst comprises an elemental metal selected from the group consisting of Platinum, Palladium, Cesium, Copper, Nickel, Ruthenium, Rhodium, Gold, and Iridium. 
     
     
         3 . The process according to  claim 1 , wherein the weight of the first catalyst to the dry weight of the pre-treated lignin feedstream is in the range of about 0.005 to about 2.0. 
     
     
         4 . The process according to  claim 1 , wherein the first catalyst is a bimetallic catalyst comprised of at least one metal selected from the group consisting of Platinum, Palladium, Cesium, Copper, Nickel, Ruthenium, Rhodium, Gold and Iridium. 
     
     
         5 . The process according to  claim 1 , wherein the lignin conversion further occurs in the presence of a second catalyst wherein the second catalyst is a zeolite. 
     
     
         6 . The process according to  claim 1 , wherein the first catalyst is selected from the group consisting of Nickel Catalysts, Raney Nickel catalysts, Ruthenium containing catalysts. Rhodium containing catalysts, Copper containing catalysts, Palladium containing catalysts, Cesium containing catalysts, Gold containing catalysts, Iridium containing catalysts and Platinum containing catalysts. 
     
     
         7 . A process for a one-step conversion of a pre-treated lignin feedstream that has been pre-treated by steam explosion, hydrolysis and fermentation into a converted lignin stream, the process comprised of:
 a. combining in a lignin conversion vessel: the pre-treated lignin feedstream, water supplied from the group consisting of the pre-treated lignin feedstream, a source other than the pre-treated lignin feedstream and mixtures thereof, hydrogen having a hydrogen pressure which at 25° C. is in the range of 104.5 to 173.3 bar, and a first catalyst comprising an elemental metal catalyst, and   b. maintaining the combination in the lignin conversion vessel at a first temperature in the range of 270° C. to 335° C. for a time sufficient to create a converted lignin stream,   wherein the pre-treated lignin feedstream comprises lignin, cellulose and water wherein the ratio of moles of hydrogen to moles of lignin and cellulose is at least 0.5 and wherein the lignin of the pre-treated lignin feedstream is present as a solid.   
     
     
         8 . The process according to  claim 7 , wherein the first catalyst comprises an elemental metal selected from the group consisting of Platinum, Palladium, Cesium, Copper, Nickel, Ruthenium, Rhodium, Gold, and Iridium. 
     
     
         9 . The process according to  claim 7 , wherein the weight of the first catalyst to the dry weight of the pre-treated lignin feedstream is in the range of about 0.005 to about 2.0. 
     
     
         10 . The process according to  claim 7 , wherein the first catalyst is a bimetallic catalyst comprised of at least one metal selected from the group consisting of Platinum, Palladium, Cesium, Copper, Nickel, Ruthenium, Rhodium, Gold and Iridium. 
     
     
         11 . The process according to  claim 7 , wherein the lignin conversion further occurs in the presence of a second catalyst wherein the second catalyst is a zeolite. 
     
     
         12 . The process according to  claim 7 , wherein the first catalyst is selected from the group consisting of Nickel Catalysts, Raney Nickel catalysts, Ruthenium containing catalysts. Rhodium containing catalysts, Copper containing catalysts, Palladium containing catalysts, Cesium containing catalysts, Gold containing catalysts, Iridium containing catalysts and Platinum containing catalysts. 
     
     
         13 . A process for a one-step conversion of a pre-treated lignin feedstream that has been pre-treated by steam explosion, hydrolysis and fermentation into a converted lignin stream, the process comprised of:
 a. combining in a lignin conversion vessel: the pre-treated lignin feedstream, water supplied from the group consisting of the pre-treated lignin feedstream, a source other than the pre-treated lignin feedstream and mixtures thereof, hydrogen having a hydrogen pressure which at 25° C. is in the range of 121.6 to 173.3 bar, and a first catalyst comprising an elemental metal catalyst, and   b. maintaining the combination in the lignin conversion vessel at a first temperature in the range of 290° C. to 340° C. for a time sufficient to create a converted lignin stream,   wherein the pre-treated lignin feedstream comprises lignin, cellulose and water wherein the ratio of moles of hydrogen to moles of lignin and cellulose is at least 0.5 and wherein the lignin of the pre-treated lignin feedstream is present as a solid.   
     
     
         14 . The process according to  claim 13 , wherein the first catalyst comprises an elemental metal selected from the group consisting of Platinum, Palladium, Cesium, Copper, Nickel, Ruthenium, Rhodium, Gold, and Iridium. 
     
     
         15 . The process according to  claim 13 , wherein the weight of the first catalyst to the dry weight of the pre-treated lignin feedstream is in the range of about 0.005 to about 2.0. 
     
     
         16 . The process according to  claim 13 , wherein the first catalyst is a bimetallic catalyst comprised of at least one metal selected from the group consisting of Platinum, Palladium, Cesium, Copper, Nickel, Ruthenium, Rhodium, Gold and Iridium. 
     
     
         17 . The process according to  claim 13 , wherein the lignin conversion further occurs in the presence of a second catalyst wherein the second catalyst is a zeolite. 
     
     
         18 . The process according to  claim 13 , wherein the first catalyst is selected from the group consisting of Nickel Catalysts, Raney Nickel catalysts, Ruthenium containing catalysts. Rhodium containing catalysts, Copper containing catalysts, Palladium containing catalysts, Cesium containing catalysts, Gold containing catalysts, Iridium containing catalysts and Platinum containing catalysts.