Api Intellectual Property Holdings, LLC

Granbio Intellectual Property Holdings, LLC

Ryan O'Connor

Theodora Retsina

Vesa Pylkkanen

Kimberly Nelson

Processes disclosed are capable of converting biomass into high-crystallinity nanocellulose with surprisingly low mechanical energy input. In some variations, the process includes fractionating biomass with an acid (such as sulfur dioxide), a solvent (such as ethanol), and water, to generate cellulose-rich solids and a liquid containing hemicellulose and lignin; and mechanically treating the cellulose-rich solids to form nanofibrils and/or nanocrystals. The crystallinity of the nanocellulose material may be 80% or higher, translating into good reinforcing properties for composites. The nanocellulose material may include nanofibrillated cellulose, nanocrystalline cellulose, or both. In some embodiments, the nanocellulose material is hydrophobic via deposition of some lignin onto the cellulose surface. Optionally, sugars derived from amorphous cellulose and hemicellulose may be separately fermented, such as to monomers for various polymers. These polymers may be combined with the nanocellulose to form completely renewable composites.

Processes and apparatus for producing nanocellulose, and compositions and products produced therefrom

The present invention provides a process for producing a nanocellulose material, comprising: fractionating a lignocellulosic biomass feedstock in the presence of a solvent for lignin and water, but no acid catalyst, to generate cellulose-rich solids; and then mechanically treating the cellulose-rich solids to form a nanocellulose material comprising cellulose nanofibrils and/or cellulose nanocrystals. Many organic or inorganic solvents are possible. In some embodiments, the solvent for lignin is an oxygenated organic compound, such as a C-Calcohol, e.g. ethanol, ethylene glycol, propanol, propanediol, glycerol, butanol, or butanediol. The solvent for lignin may be an aromatic alcohol, such as phenol, cresol, or benzyl alcohol. The solvent for lignin may be a ketone, an aldehyde, or an ether, such as methyl ethyl ketone or diethyl ether. The solvent for lignin may be a non-oxygenated alkane, olefin, or aromatic hydrocarbon. In some embodiments, the solvent for lignin is an ionic liquid.

Solvent-based processes for producing nanocellulose, and compositions and products produced therefrom

Processes disclosed are capable of converting biomass into high-crystallinity, hydrophobic cellulose. In some variations, the process includes fractionating biomass with an acid (such as sulfur dioxide), a solvent (such as ethanol), and water, to generate cellulose-rich solids and a liquid containing hemicellulose and lignin; and depositing lignin onto cellulose fibers to produce lignin-coated cellulose materials (such as dissolving pulp). The crystallinity of the cellulose material may be 80% or higher, translating into good reinforcing properties for composites. Optionally, sugars derived from amorphous cellulose and hemicellulose may be separately fermented, such as to monomers for various polymers. These polymers may be combined with the hydrophobic cellulose to form completely renewable composites.

Processes for producing lignin-coated hydrophobic cellulose, and compositions and products produced therefrom

Conventionally, sugarcane processing avoids leaving residual sucrose in the bagasse, since the bagasse will be burned and the value of the sucrose would be lost. However, when coupled with a Green Power+&#xae; process to extract hemicelluloses, sucrose may also be extracted and recovered from the bagasse. In some variations, a process includes mechanically treating a feedstock to generate a sucrose-rich stream and lignocellulosic material that intentionally retains a significant amount of the initial sucrose in the feedstock; extracting the lignocellulosic material with steam and/or hot water to produce cellulose-rich solids and an extract liquor containing hemicellulosic oligomers and sucrose; and then hydrolyzing the hemicellulosic oligomers into a hemicellulose sugar stream. Each of the sucrose-rich stream and the hemicellulose sugar stream (containing the starting residual sucrose) may be recovered or further processed (e.g., fermented to ethanol). Similar processes are possible with energy cane, sugar beets, and energy beets.

Processes and apparatus for refining sugarcane to produce sugars, biofuels, and/or biochemicals

Processes disclosed are capable of converting biomass into high-crystallinity nanocellulose with low mechanical energy input. In some variations, the process includes fractionating biomass with sulfur dioxide or a sulfite compound and water, to generate cellulose-rich solids and a liquid containing hemicellulose and lignin; and mechanically treating the cellulose-rich solids to form nanofibrils and/or nanocrystals. The total mechanical energy may be less than 500 kilowatt-hours per ton. The crystallinity of the nanocellulose material may be 80% or higher, translating into good reinforcing properties for composites. The nanocellulose material may include nanofibrillated cellulose, nanocrystalline cellulose, or both. In some embodiments, the nanocellulose material is hydrophobic via deposition of some lignin onto the cellulose surface. Optionally, sugars derived from amorphous cellulose and hemicellulose may be separately fermented, such as to monomers for various polymers. These polymers may be combined with the nanocellulose to form completely renewable composites.

Sulfite-based processes for producing nanocellulose, and compositions and products produced therefrom

Processes disclosed are capable of converting biomass into high-crystallinity nanocellulose with low mechanical energy input. In some variations, the process includes fractionating biomass with lignosulfonic acids, to generate cellulose-rich solids; and mechanically treating the cellulose-rich solids to form nanofibrils and/or nanocrystals. The strong lignosulfonic acids created during delignification give a pH less than 1 and hydrolyze preferentially the amorphous regions of cellulose. The total mechanical energy may be less than 500 kilowatt-hours per ton. The crystallinity of the nanocellulose material may be 80% or higher, translating into good reinforcing properties for composites. The nanocellulose material may include nanofibrillated cellulose, nanocrystalline cellulose, or both. In some embodiments, the nanocellulose material is hydrophobic via deposition of lignin onto the cellulose surface. Optionally, sugars derived from amorphous cellulose and hemicellulose may be separately fermented to co-products.

Nanocellulose production using lignosulfonic acid

Processes disclosed are capable of converting biomass into high-crystallinity nanocellulose with surprisingly low mechanical energy input. In some variations, the process includes fractionating biomass with an acid (such as sulfur dioxide), a solvent (such as ethanol), and water, to generate cellulose-rich solids and a liquid containing hemicellulose and lignin; and mechanically treating the cellulose-rich solids to form nanofibrils and/or nanocrystals. The total mechanical energy may be less than 500 kilowatt-hours per ton. The crystallinity of the nanocellulose material may be 80% or higher, translating into good reinforcing properties for composites. The nanocellulose material may include nanofibrillated cellulose, nanocrystalline cellulose, or both. In some embodiments, the nanocellulose material is hydrophobic via deposition of some lignin onto the cellulose surface. Optionally, sugars derived from amorphous cellulose and hemicellulose may be separately fermented, such as to monomers for various polymers. These polymers may be combined with the nanocellulose to form completely renewable composites.

Growing community of inventors

Minnetrista, MN, United States of America

Ryan O'Connor