NZ726115B2 - Processing Biomass - Google Patents

Abstract

method comprising: a. wet milling a reduced recalcitrance (e.g. treated with an electron beam) lignocellulosic material (e.g. wood or municipal solid waste) and applying a jet mixer during wet milling; b. adding an enzyme to the reduced recalcitrance lignocellulosic material after wet milling to saccharify it; and c. adding a microorganism to the reduced recalcitrance lignocellulosic material after wet milling has been completed, to give a fermentation product such as ethanol. Wet-milling may be performed using a rotor/stator head, such as one including nesting rings of teeth. accharify it; and c. adding a microorganism to the reduced recalcitrance lignocellulosic material after wet milling has been completed, to give a fermentation product such as ethanol. Wet-milling may be performed using a rotor/stator head, such as one including nesting rings of teeth.

Description

Specification for Patent Application Title: Processing Biomass Applicant: Xyleco, Inc.

Country: New d Type: Divisional Number: 729489 Date: 14 February 2012 WO 70707 SING BIOMASS RELATED APPLICATIONS This application claims priority to US. ional ation Serial No. 61/495,217, filed June 9, 201 1. The complete disclosure of this provisional application is hereby incorporated by reference herein.

BACKGROUND Cellulosic and lignocellulosic materials are produced, processed, and used in large ‘10 quantities in a number of applications. Often such materials are used once, and then discarded as waste, or are simply considered to be waste materials, e.g., sewage, bagasse, sawdust, and stover.

SUMMARY Processes are disclosed herein for saccharifying or liquifying a biomass material, e.g., cellulosic, lignocellulosic and/or starchy feedstocks, by converting biomass material to low molecular weight sugars, e.g., saccharifying the feedstock using an enzyme, e.g., one or more cellulase and/or amylase. The ion also relates to converting a feedstock to a product, e.g., by bioprocessing, such as fermentation. The processes include wet milling a feedstock. The inventors have found that wet milling the feedstock tends to reduce the time required for saccharification, and increase the concentration of sugar that can be obtained in a given saccharification time. Wet milling alone or working synergistically with any ent described herein can reduce itrance of a biomass The processes disclosed herein can utilize low bulk density materials, for example osic or lignocellulosic ocks that have been physically pretreated to have a bulk density ofless than about 0.75 g/cm3, e.g., less than about 0.7, 0.65, 0.60, 0.50, 0.35, 0.25, 0.20, 0.15, 0.10, 0.05. or less, e.g., less than 0.025 g/cm3.

Such materials can be difficult to disperse in liquids, e.g., with water or a solvent system for saccharification, fermentation, or other processing. Due to their low bulk y, the materials tend to float on the surface of the liquid rather than being wetted out and dispersed into the liquid. In some cases, the materials can be hydrophobic, highly crystalline, or otherwise difficult to wet. At the same time, it is ble to process the feedstock in a relatively high solids level dispersion, in order to obtain a high final concentration of sugar in the saccharified material, or a high concentration of the desired product after processing (e.g., of ethanol or other alcohol(s) after fermentation). In some cases, ing the methods described herein the solids level of the dispersion during processing can be, for example, at least 10, 15, 20, 22.5, 25, 27.5, 30, 35, 40, 45, or even at least 50 percent by weight dissolved solids. For example, the solids level can be from about 10 to 50%, e.g., about 10-40%, 10-30%, or 10-20%.

In one aspect, the invention features reducing the particle size of a ellulosic material to less than 3000 µm, e.g. less than 2000 µm, less than 1000 µm or even less than 500 µm, e.g., less than 250 µm or less than 100 µm. The particle size range can be between 100 - 3000 µm, e.g., 200–2000 µm, 200–1000 µm, 500- 1000 µm.

In one aspect, the invention features ng recalcitrance of a lignocellulosic material and wet milling the lignocellulosic material. In some cases, itrance is reduced prior to wet milling. The material can be densified prior to reducing the recalcitrance or after reducing the recalcitrance and prior to wet milling the material.

In another aspect, the invention features a method comprising wet milling a lignocellulosic material, e.g., a lignocellulosic material having a reduced recalcitrance.

In another aspect, the invention features a method of processing lignocellulosic material, the method comprising: a. wet milling a reduced recalcitrance lignocellulosic material and applying a jet mixer during wet milling; b. adding an enzyme to the d recalcitrance ellulosic material after wet milling; and c. adding a microorganism to the reduced recalcitrance lignocellulosic material after wet milling has been completed.

Either of these aspects of the invention can e, in some implementations, any of the ing features.

The recalcitrance of the biomass material, e.g., a lignocellulosic material, can be reduced, for example, by irradiating the lignocellulosic material, e.g., by exposing the material to an on beam. In some cases, irradiating comprises delivering a dose of at least 5 Mrad to the lignocellulosic material, e.g., at least 10, 20, 30, 50, 100, 150 or even 200 Mrad. For example, doses can be in the range of 5-200 Mrad, e.g., 5- 100 Mrad, 5-50 Mrad, 5-10 Mrad, 10-100 Mrad, or 10-50 Mrad.

The lignocellulosic material may be, for e, a material is ed from the group consisting of wood, particle board, sawdust, agricultural waste, sewage, silage, grasses, rice hulls, bagasse, cotton, jute, hemp, flax, bamboo, sisal, abaca, straw, wheat [Text continued on page 3] straw, corn cobs, corn stover, switchgrass, alfalfa, hay, coconut hair, seaweed, algae, and mixtures thereof.

The biomass may also be combinations of starchy, lignocellulosic and/or cellulosic materials. For example, a biomass can be an entire plant or part(s) ofa plant e.g., a wheat plant, cotton plant, a corn plant, rice plant or a tree.

In some implementations, wet milling is performed using a rotor/stator head. The rotor and stator may include nesting rings of teeth. In some cases, the stator comprises two or more concentric rings of teeth, and the rotor comprises a ring of teeth configured to fit between adjacent rings of teeth of the . The clearance between the rotor and stator is lly small, to generate high shear, and may be, for example from about 0.01 to 0.25 inches (0.25 to 6.4 mm). The spacing between the teeth in each ring of teeth is also generally small, e.g., from about 0.1 to 0.3 inch (2.5 to 7.6 mm).

Wet milling may be performed using a ity of rotor/stator heads, e.g., when the process is med in a large tank or vessel.

Wet milling is generally performed at a relatively high shear rate. The shear rate may be, for example, at least 20,000 sec'], (e.g., at least 25,000 sec], at least 30,000 sec"’ at least 40,000 sec'1 or at least 50,000 sec'l). The shear rate can be, for example from about 30,000 sec’1 to about 50,000 sec'l (e.g., from about 25,000 sec'1 to about 50,000 sec'l, from about 30,000 sec"| to about 50,000 sec'], from about 35,000 sec" to about 50,000 sec", from about 40,000 sec'1 to about 50,000 sec'l, from about 20,000 sec'1 to about 45,000 see", from about 20,000 sec'1 to about 40,000 see", from about 20,000 sec‘ to about 30,000 sec", from about 30,000 sec" to about 40,000 sec").

In some implementations, wet milling is performed in-line. A jet mixer may be applied during wet milling. The jet mixer may also be used during subsequent sing, e. g., during fermentation. The method may further include adding an enzyme to the biomass material, e.g., a lignocellulosic al, before, during or after wet milling, and/or adding a microorganism to the biomass material or a sugar derived from the biomass material. In some cases, the microorganism is added after wet milling has been completed, e.g., to avoid damage to the microorganism from wet milling. In some implementations, the microorganism converts the biomass ock or sugar to a product selected from the group consisting of alcohols, organic acids, sugars, hydrocarbons, and mixtures thereof.

The s described herein generally provide vely rapid and effective processing of a vely high solids level of feedstock. By increasing the initial solids level of feedstock in the mixture, the process can proceed more rapidly, more efficiently and more cost—effectively, and a high resulting concentration can generally be achieved in the final product. In some cases, solids may be removed during saccharification, e.g., by a centrifuge, and more feedstock may be added. The removed solids may be used as a t, e.g., as a tible fuel for cogeneration of electricity and/or as an animal 1O feed.

The saccharification processes described herein allow s material, e.g., a cellulosic or lignocellulosic feedstock, to be converted to a convenient and concentrated form which can be easily transported and utilized in another manufacturing facility, e.g., a facility configured to ferment sugar solutions to alcohols, to manufacture a product, e. g., a fuel such as ethanol, butanol or a hydrocarbon. Such concentrates can use less water, which can result in ntial manufacturing and transportation cost savings.

Some processes disclosed herein include saccharification of the feedstock, and transportation of the feedstock from a remote location, e. g., where the feedstock is produced or stored, to the manufacturing facility. In some 'cases, saccharification can take place partially or ly during transport.

In some cases, the systems described herein, or components thereof, may be portable, so that the system can be transported (e.g., by rail, truck, or marine vessel) from one location to another. Such mobile sing is bed in US. Serial No. 12/374,549 filed January 21, 2009 and International Application No. , the full disclosures of which are incorporated herein by nce. ary products that can be produced by employing the methods described herein include hydrocarbons, ns, alcohols (e.g., a monohydric alcohols or a dihydric alcohols), such as ethanol, isobutanol, n—propanol or n-butanol, carboxylic acids, such as acetic acid, lactic acid, citric acid, propionic acid, succinic acid, 3—hydroxyproprionic acid or butyric acid, salts ofa carboxylic acid, a e of carboxylic acids and salts of carboxylic acids and esters of carboxylic acids (e.g., methyl, ethyl and n—propyl esters), s, aldehydes, alpha unsaturated acids, beta unsaturated acids, such as c acid, olefins, such as ethylene, butenes, and mixtures of any of these. Specific examples include ethanol, propanol, ene glycol, butanol, 1.,4-butanediol, 1,3-propanediol, methyl or ethyl esters of any of these alcohols, methyl acrylate, methylmethacrylate, Products also include sugars, e.g., glucose, xylose and xylitol. These and other products are described in US. Serial No. 12/417,900 filed April 3, 2009; the full disclosure of which is incorporated by reference herein.

In one aspect, the ion features a wet milling system comprising a wet mill disposed in a fluid having a s material dispersed therein. The system can, for example, be used fOr processing lingocellulosic material that has optionally been irradiated (e.g., with an electron beam). The system can include ajet mixer disposed in the fluid. The wet milling systems can include a rotor/stator head, for example with the rotor and stator including nesting rings of teeth. Furthermore, the stator can have two or more concentric rings of teeth. Other aspects of the invention include a tank with one or more jet head, and one or more wet mill disposed in the tank.

Bulk y is determined using ASTM D1895B. Briefly, the method involves filling a measuring cylinder of known volume with a sample and obtaining a weight of the sample. The bulk density is calculated by ng the weight of the sample in grams by the known volume of the cylinder in cubic centimeters.

All publications, patent applications, patents, and other references mentioned herein or ed hereto are incorporated by reference in their entirety for all that they contain.

DESCRIPTION OF THE DRAWINGS FIG. I is a diagram illustrating the enzymatic hydrolysis of cellulose to glucose. is a flow diagram illustrating conversion of a feedstock to sugars and other products. is a diagrammatic ration of a saccharification system according to one ment. is a diagrammatic illustration of a saccharification system ing to another embodiment. is a schematic diagram of an ethanol manufacturing facility that has been retrofitted to utilize the solutions and suspensions disclosed herein. is a top plan view of the assembled rotor and stator ofa wet milling head according to one embodiment. is an enlarged section view of showing the nce between the rotor and stator. is a perspective view of the rotor and stator together. is an exploded perspective of the rotor and stator. is a bottom plan view of the rotor taken along view-line 7-7 of is a top plan View of the stator taken along view line 8-8 of is an enlarged view of the area of the rotor indicated in is an enlarged view of the area of the stator indicated in 1O 1 is a top plan view of the assembled rotor and stator ofa wet milling head according to a second ment. A is an enlarged section view of showing the clearance between the rotor and stator. is a perspective view of the rotor and stator together. is an exploded perspective of the rotor and . is a bottom plan view of the rotor taken along view line 14—14 of . is a top plan view of the stator taken along view line 15-15 of . is an enlarged view of the area ofthe rotor indicated in . is an enlarged view of the area of the stator indicated in .

FIGS. 18 and 18A are diagrams illustratingjet flow exiting a jet mixer nozzle. is a diagrammatic perspective view of a jet-flow agitator according to one embodiment. A is an enlarged perspective View of the impeller and jet tube of the jet—flow agitator of . B is an enlarged perspective View of an alternate impeller. is a cross-sectional view ofa system for wet milling.

DETAILED DESCRIPTION Using the methods bed herein, s (e.g., plant biomass, animal biomass, paper, and municipal waste biomass) can be processed to produce useful intermediates and products such as organic acids, salts of organic acids, ides, esters of organic acids and fuels, e.g., fuels for internal tion engines or feedstocks 2012/041382 for fuel cells. Systems and processes are described herein that can use as feedstock cellulosic and/or lignocellulosic materials that are readily available, but often can be difficult to process, e.g., municipal waste streams and waste paper streams, such as streams that e newspaper,- kraft paper, ated paper or es of these.‘ lly, if required, materials can be physically treated for processing and/or after processing, often by size reduction. Many ofthe processes described herein can ively lower the recalcitrance level of the feedstock, making it easier to process, such as by bioprocessing (e.g., with any microorganism described herein, such as a homoacetogen or a heteroacetogen, and/or any enzyme described herein), thermal processing (e.g., gasification or sis) or chemical methods (e.g., acid hydrolysis or oxidation). Biomass feedstock can be treated or processed using one or more of any of the s described herein, such as mechanical treatment, al treatment, radiation, tion, oxidation, pyrolysis or steam explosion. The various treatment systems and methods can be used in combinations of two, three, or even four or more of these technologies or others described herein and elsewhere. In some instances wet milling alone can reduce recalcitrance or act synergistically or with other treatment processes described herein.

The processes disclosed herein can utilize low bulk density materials, for example cellulosic or lignocellulosic feedstocks that have been ally pretreated to have a bulk density of less than about 0.75 g/cm3, e.g., less than about 0.7, 0.65, 0.60, 0.50, 0.35, 0.25, 0.20, 0.15, 0.10, 0.05. or less, e.g., less than 0.025 g/cm3. Bulk density is determined using ASTM D1895B. Briefly, the method involves filling a measuring cylinder of known volume with a sample and obtaining a weight of the sample. The bulk density is calculated by dividing the weight of the sample in grams by the known volume of the er in cubic centimeters. If desired, low bulk density materials can be densified, for example, by methods described in US. Patent 7,971,809 the full disclosure of which is hereby incorporated by reference.

Saccharification In order to convert the feedstock to a form that can be readily processed, the glucan- or containing cellulose in the feedstock is hydrolyzed to low molecular weight carbohydrates, such as sugars, by a saccharifying agent, e.g., an enzyme or acid, a WO 70707 process referred to as saccharification. The low molecular weight carbohydrates can then be used, for example, in an existing manufacturing plant, such as a single cell protein plant, an enzyme manufacturing plant, or a fuel plant, e.g., an ethanol manufacturing facility.

The ock is combined with the saccharifying agent in a liquid medium, e.g., a solvent such as an aqueous solution, and the mixture is wet milled. Methods for wet milling the material in the liquid medium are discussed in detail below. In some implementations, during and/or after wet milling the saccharifying agent, material and liquid medium are mixed using ajet mixer. In some cases jet mixing continues throughout rification.

In some implementations, the material and/or the saccharifying agent are added incrementally rather than all at once. For example, a portion of the al can be added to the liquid medium, dispersed therein, and mixed with the saccharifying agent until the material is at least partially saccharified, at which point a second n of the material is sed in the medium and added to the mixture. This process can ue until a desired sugar concentration is ed.

The feedstock can be hydrolyzed using an enzyme, such as a cellulase or an amylase or mixtures of these enzymes. For example, the biomass material can be combined with the enzyme in a solvent, e.g., in an s solution.

Enzymes and biomass-destroying organisms that break down biomass, such as the cellulose and/or the lignin portions of the biomass, contain or manufacture various cellulolytic enzymes (cellulases), ligninases or various small molecule biomass- destroying metabolites. These enzymes may be a complex of enzymes that act synergistically to degrade crystalline cellulose or the lignin portions of s.

Examples of cellulolytic enzymes include: endoglucanases, cellobiohydrolases, and cellobiases (B-glucosidases). Referring to a cellulosic substrate is initially hydrolyzed by endoglucanases at random locations producing oligomeric intermediates.

These intermediates are then substrates for exo-splitting ases such as cellobiohydrolase to produce cellobiose from the ends of the cellulose polymer. iose is a soluble 1,4-linked dimer of glucose. y cellobiase cleaves cellobiose to yield glucose. Suitable cellulases will be discussed herein in a later section.

The time required for complete saccharification will depend on the process conditions and the feedstock and enzyme used. If saccharification is performed in a manufacturing plant under controlled conditions, the cellulose may be substantially ly ted to glucose in about 12—96 hours, e.g., less than 48 hour, less than 36 hours, less than 24 hours, less than 18 hours, less than 12 hours or even less than 8 hours.

If saccharification is performed partially or completely in transit, saccharification may take longer.

In some cases, saccharification is performed at a pH of about 4 to 7, e.g., about 4.5 to 6, or about 5 to 6.

It is generally red that the final concentration of glucose in the sugar solution be relatively high, e.g., greater than 10 wt.%, or r than 15, 20, 30, 40, 50, 60, 70, 80, 90 or even greater than 95% by . This reduces the volume to be shipped, and also inhibits microbial growth in the solution. After saccharification, the volume of water can be reduced, e.g., by evaporation or distillation.

A relatively high concentration solution can be obtained by limiting the amount of medium, e.g., water, added to the feedstock with the enzyme. The concentration can be controlled, e. g., by controlling how much saccharification takes place. For example, concentration can be increased by adding more ock to the solution. In some cases, solids are removed during saccharification, e.g., by centrifuge, ng more feedstock to be added. Solubility of the feedstock in the medium can be increased, for example, by increasing the temperature of the on, and/or by adding a surfactant as will be discussed below. For example, the solution can be maintained at a temperature of 40- 50°C, 50-60°C, 60—80°C, or even higher.

Fermentation Microorganisms can produce a number of useful intermediates and products by fermenting a low molecular weight sugar produced by rifying the d feedstock. For example, fermentation or other bioprocesses can produce alcohols (e.g., n-butanol, isobutanol, ethanol or erythritol), organic acids (e.g., , butyric, citric or lactic acid), hydrocarbons, hydrogen, proteins or mixtures of any of these materials.

Yeast and Zymomonas bacteria, for example, can be used for fermentation or conversion. Other microorganisms are discussed in the Materials section, below. The optimum pH for fermentations is about pH 4 to 7. The optimum pH for yeast is from about pH 4 to 5, while the optimum pH for Zymomonas is from about pH 5 to 6. Typical fermentation times are about 24 to 168 (e.g., 24-96 hrs) hours with temperatures in the range of 20 °C to 40 °C (e.g., 26 °C to 40 °C), however philic microorganisms prefer higher temperatures.

In some embodiments e. g., when anaerobic organisms are used, at least a portion of the fermentation is conducted in the absence of oxygen e.g., under a blanket of an inert gas such as N2, Ar, He, C02 or mixtures thereof. Additionally, the mixture may have a nt purge of an inert gas flowing through the tank during part of or all of the fermentation. In some cases, anaerobic conditions can be achieved or maintained by carbon dioxide production during the fermentation and no additional inert gas is needed.

In some ments, all or a portion of the fermentation process can be interrupted before the low molecular weight sugar is completely converted to a product (e.g. ethanol). The intermediate fermentation products include high concentrations of sugar and carbohydrates. The sugars and carbohydrates can be isolated as discussed below. These intermediate fermentation products can be used in ation of food for human or animal ption. onally or atively, the intermediate fermentation products can be ground to a fine particle size in a stainless-steel laboratory mill to produce a flour-like nce.

The fermentations include the methods and products that are disclosed in US.

Provisional Application Serial No. 61/579,559, filed December 22, 2011 and US.

Provisional Application Serial No. 61/579,576, filed December 22, 2011 the disclosure of which is incorporated herein by reference.

Mobile fermenters can be utilized, as bed in US. ional Patent Application Serial No. 60/832,735, now Published International Application No. WO 2008/011598. Similarly, the saccharification equipment can be mobile. Further, saccharification and/or fermentation may be performed in part or entirely during transit.

Fuel Cells Where the methods described herein produce a sugar solution or suspension, this solution or sion can uently be used in a fuel cell. For example, fuel cells utilizing sugars derived from cellulosic or ellulosic materials are disclosed in US.

Provisional ation Serial No. 61/579,568, filed December 22, 2011, the complete disclosure of which is incorporated herein by reference.

Thermochemical Conversion Thermochemical sion can be performed on the treated feedstock to e one or more desired intermediates and/or products. A thermochemical conversion? '10 s includes ng molecular structures of carbon-containing material at elevated temperatures. Specific examples include gasification, pyrolysis, reformation, partial oxidation and mixtures of these (in any order).

Gasification converts carbon-containing materials into a synthesis gas (syngas), which can include methanol, carbon monoxide, carbon dioxide and hydrogen. Many microorganisms, such as acetogens or homoacetogens are capable of utilizing a syngas from the thermochemical conversion of biomass, to produce a product that includes an alcohol, a carboxylic acid, a salt of a carboxylic acid, a carboxylic acid ester or a mixture of any of these. Gasification of biomass (e.g., cellulosic or lignocellulosic materials), can be accomplished by a y of techniques. For example, gasification can be accomplished utilizing staged steam reformation with a fluidized-bed reactor in which the carbonaceous material is first zed in the absence of oxygen and then the pyrolysis vapors are reformed to synthesis gas with steam providing added hydrogen and oxygen.

In such a technique, process heat comes from g char. Another technique utilizes a screw auger reactor in which moisture and oxygen are introduced at the pyrolysis stage and the process heat is generated from burning some of the gas produced in the latter stage. Another technique utilizes ned flow reformation in which both al steam and air are introduced in a single-stage gasification reactor. In partial oxidation gasification, pure oxygen is utilized with no steam.

SYSTEMS FOR NG A FEEDSTOCK Referring to a process for conversion of a feedstock to sugars and other products, e.g., ethanol, can include, for example, ally physically pre—treating the ock, e.g., to reduce its size (step 110), before and/or after this treatment, optionally treating the ock to reduce its recalcitrance (step 112), and saccharifying the feedstock to form a sugar on (step 114). Saccharification can be performed by mixing a dispersion of the feedstock in a liquid medium, e.g., water with an enzyme (step 11 1), as will be discussed in detail below. During or after saccharification, the mixture (if saccharification is to be partially or completely performed en route) or solution can be transported, e.g., by pipeline, railcar, truck or barge, to a manufacturing plant (step 1 16).

At the plant, the solution can be bio—processed to e a desired product, e.g., ethanol (step 1 18), which is then processed r, e.g., by distillation (step 120). The individual steps of this s will be described in detail below. If desired, the steps of measuring lignin content (step 122) and setting or adjusting process parameters (step 124) can be performed at s stages of the process, for example just prior to the s step(s) used to change the structure of the feedstock, as shown. If these steps are included, the s parameters are adjusted to compensate for variability in the lignin content of the feedstock, as described in US. Application Series No. 12/704,519 filed in February 1 1, 2010, the complete disclosure of which is incorporated herein by reference.

The mixing step 1 11 and saccharifying step 1 14 can be performed using, for example, either of the systems shown in and 2B. These systems include a tank 136, which initially contains a liquid medium and later contains a mixture 138 of liquid medium, feedstock and saccharifying agent. The liquid medium is delivered to the tank through a valved piping system (not shown). The systems also include a hopper 130, in communication with a dispersing unit 134. In the embodiment shown in FIG. ZB, the hopper 130 receives feedstock that has been treated to reduce its size and optionally to reduce its recalcitrance (steps 110 and 1 12 above) by a feedstock pretreatment module 132. In both embodiments, the hopper may e other dry ingredients, such as yeast and nutrients, e.g., from a supply 30. Optionally, a vibrating device 36 may be associated with the hopper, to facilitate delivery of material from the hopper. The system may also ally include a dispersing unit 134, e.g., ifthe feedstock is difficult to initially wet with the liquid. The liquid medium is drawn into the dispersing unit 134 from the tank, and returned to the tank by the dispersing unit via an outlet pipe 137. The opening of outlet pipe 137 may be above the liquid level, as shown, or may in some instances be submerged in the liquid in the tank. In some cases, depending on the type of milling unit and dispersing unit used, the system may include a pump 139, e.g., a positive displacement pump, red to ate the liquid medium, and/or a viscometer 141 to monitor the viscosity of the dispersion and activate the pump when the measured viscosity reaches a predetermined value.

In the embodiment shown in , the feedstock is delivered to the surface of the liquid medium in the tank, e.g., via a delivery device 32 having a delivery conduit 34 (e.g., hose or pipe). The delivery device 32 may also be associated with a vibrating device 36, to facilitate flow of material into the device. The ry device 32 may be, for example, a blower configured to blow fibrous and/or particulate material from a source to a location remote from the source h a hose, e.g., an insulation blower such as the FORCE 3 blower available from Intec, Frederick, Colorado. Alternatively, the material can be delivered to the surface of the liquid using other techniques, such as y feed or a screw conveyor.

In some implementations, the tank is ed with a e, air ble cover, or other device red to allow air to vent from the tank during delivery of the feedstock, while preventing feedstock from blowing out of the tank and/or contaminants from entering the tank.

When the particles are generally spherical, e.g., as is the case with hammermilled corn cobs, or otherwise of a morphology that allows them to be easily fed, the feedstock can be gravimetrically fed. For example, the feedstock can be delivered from a hopper above the tank.

As the feedstock material is delivered through delivery conduit 34 onto the surface of the liquid in the tank, liquid is discharged through outlet pipe 137 of the dispersing unit 134 onto the material. The discharged liquid wets the feedstock material, causing it to sink into the liquid, where it can be dispersed by the dispersing unit 134 (if one is provided), optionally in combination with the mixing action of a jet mixer 144, discussed below.

Once the feedstock has been delivered to the tank, it is wet milled, using wet milling unit 160, which generally includes a high shear rotor/stator head. Examples of suitable g units are described in detail below. The wet milling unit can be mounted in any desired location in the tank. It can be side—mounted, as shown, or top and bottom mounted. In some implementations, the wet milling unit can be external to the tank and the tank contents can be pumped through the wet milling unit and returned to the tank. In some cases, the wet milling unit is mounted nt to the jet mixing unit 144, described below. In some cases, multiple wet milling heads are provided. For example, in a large tank multiple wet milling heads may be d at spaced ons within the tank.

Wet milling can be performed in-line or as a batch process.

Wet milling is generally performed at a high shear rate, for example from about ,000 sec'1 to 60,000 sec‘l, or from about 30,000 sec'1 to 50,000 560'].

The wet milling unit may be run for any desired length of time. The wet milling unit can be run in a pulsed manner (e.g., the power to the motor driving the wet milling is pulsed), for example the shearing rate can be varied periodically or non-periodically, or, as another example the wet milling unit can be turned on an off repeatedly. Generally, wet milling is discontinued when either the efficiency of saccharification ceases to be improved by wet g (this can be determined by experimentation for a given set of process parameters), or the shear generated by the wet milling unit causes the temperature of the tank contents to exceed a predetermined maximum value. The predetermined maximum value may be set, for example, based on the temperature at which the rifying agent would be denatured in a short period of time.

Shearing can cause the mean le size of the biomass material to be reduced.

For example the size can be reduced from about more than 1 mm (e.g. more than 5 mm or more than 10 mm) to less than 1 mm (e.g., less than 0.5mm, less than 0.1 mm or even less than 0.01mm).

In some implementations, the wet milling unit can be used to heat, or partially heat, the tank contents. to a desired sing temperature. For example, in one implementation the tank ts are heated by another means to approximately 40°C, and then the‘wet milling unit is operated for a time ent to raise the temperature to approximately 50°C, a temperature which is ageous for saccharification. In some cases, wet milling is performed for less than 8 hours, e.g., for I to 4 hours or 1 to 2 hours.

Wet milling may be med for an even shorter time, e.g., 30 minutes or less. Once this desired temperature is reached the wet milling device is turned off so as to prevent a further se in temperature. In some cases, the tank contents may be cooled during or after wet milling to prevent overheating. In order to prevent denaturing of the enzymes used in saccharification, it is generally preferred that the tank contents be maintained at or below 50°C, or at least that temperature excursions above 50°C be of sufficiently short duration so as not to re the enzymes.

Before, during, or after wet milling, a saccharifying agent is delivered to the tank from a hopper 140, which includes a metering device 142. During saccharification, the contents of the tank are mixed, e.g., by one or more jet mixers. In some cases, the jet mixers are operated during wet milling. A jet mixer 144 is represented diagrammatically in FIGS. 2A and 2B; examples of le jet mixers will be described in detail below, and are also described in US. Serial Nos. 12/782,694 filed May 18, 2010; I3/293,985 filed November 10, 2011; and 13/293,977 filed November 10, 2011 the full disclosures of . which are hereby incorporated by reference herein. The jet mixer produces a jet using a motor 146 that drives a pump and/or a rotor (not . The torque d by the motor 146 correlates with the solids level of the mixture in the tank, which in turn reflects the degree to which the mixture has saccharified. The torque is measured by a torque monitor 148, which sends a signal to a motor 150 that drives the conveyor I30 and also to the metering device 142 of the hopper 140. Thus, the supply of the treated feedstock and the enzyme can be interrupted and resumed as a function of the saccharification of the contents of the tank. The data measured by the torque monitor can also be used to adjust thejet mixer, e.g., to a lower RPM for a mixer that es a rotor, or to a lowerjet velocity for a pump-driven mixer. d of, or in addition to, the torque monitor, the system may include an Amp monitor (not shown) that measures the full load amperage of the motor. In some cases, the jet mixer may include a variable frequency drive (VFD) to allow the speed of the motor to be adjusted.

The system may also include a heat monitor (not shown) that monitors the temperature of the liquid medium and adjusts the feed rate of the feedstock and/or the mixing ions in se to increases in temperature. Such a temperature feedback loop can be used to prevent the liquid medium from reaching a temperature that will denature the enzyme. The heat monitor can also be used to determine when to shut off the wet milling unit to avoid overheating of the tank ts.

When one or more pumps are used in the systems described herein, it is generally preferred that positive displacement (PD) pumps be used, e.g., progressive cavity or screw-type PD pumps.- .

In some cases, the manufacturing plant can be, for example, an existing grain- based or sugar—based ethanol plant or one that has been retrofitted by removing or decommissioning the equipment upstream from the bio-processing system (which in a typical l plant generally includes grain receiving equipment, a hammerrnill, a slurry mixer, cooking equipment and liquefaction ent). Thus, the feedstock received by the plant is input directly into the fermentation equipment. A retrofitted plant is shown schematically in The use of an existing grain-based or sugar-based ethanol plant in this manner is bed in US. Serial No. 12/704,521, filed February 11, 2010, the full disclosure of which is incorporated herein by reference.

In some embodiments, rather than transporting the saccharified feedstock (sugar solution) to a separate cturing plant, or even a separate tank, the sugar solution is inoculated and fermented in the same tank or other vessel used for saccharification.

Fermentation can be completed in the same vessel, or can be started in this manner and then completed during transport as discussed above. Saccharifying and fermenting in a single tank are described in US. Application Serial No. 12/949,044, Nov 18, 2011, the full disclosure of which is incorporated herein by nce.

Generally, the oxygen level in the tation vessel should be controlled, e.g., by ring the oxygen level and g the tank, aerating (e.g., by mixing or sparging in oxygen or mixtures of gases containing oxygen) or de-aerating (e.g., by mixing in or sparging in inert gases such as nitrogen, carbon dioxide, helium and/or argon) the mixture as ary. In some cases, for example where anaerobic conditions are desirable as discussed previously, the rate of mixing is critical. For example, at times during the process, no mixing may be desirable so that gases produced during fermentation (e.g., C02, H2 and or methane) can more effectively displace oxygen from the fermentation vessel. It is also ble to monitor the level of ethanol in the vessel, so that when the ethanol level begins to drop the fermentation process can be d, e.g., by heating or the addition of sodium bisulfite. Other methods of stopping fermentation include adding a peroxide (e. g., peroxy acetic acid or hydrogen peroxide), adding succinic acid or a salt thereof, cooling the contents of the vessel, or reducing the oxygen sparge rate. Combinations of any two or more of these methods may be used. If fermentation is to be conducted or completed during transport, the ortation vessel (e.g., the tank ofa rail car or tanker truck) can be fitted with a control unit that es an oxygen r and ethanol monitor, and a ry system for delivering sodium bisulfite (or other fermentation terminating additive) to the tank and/or a system for adjusting the parameters in the tank to stop fermentation.

If desired, jet mixing can be utilized during fermentation, and if fermentation is conducted in the same vessel as saccharification the same jet mixing equipment can be utilized. However, in some embodimentsjet mixing is not ary. For example, if fermentation is conducted during transport the movement of the rail car or tanker truck may provide adequate agitation.

DISPERSING, WET MILLING, AND MIXING Systems are disclosed herein that include one or more tanks, one or more ors, e.g., one or more jet head agitators, and one or more wet mills. In some instances, all mills and agitator heads are within tanks.

Dispersing The optional dispersing unit 134 may include any type of dispersing equipment that wets the feedstock with the liquid medium. Many dispersing units include a chamber and a rotor in the chamber positioned such that the feedstock and liquid medium are drawn towards the rotor axially, and forced outward radially to the periphery of the rotor and thus through the outlet of the unit, in the manner of a centrifugal pump. ing upon the construction of the sing unit, a back-up pump may be required (pump 139, discussed above) to draw the fluid through the sing unit at high viscosities. Some dispersing units are constructed to generate very high static fluid re within the unit; when such units are used a p pump is generally not required.

Example of le dispersing systems are disclosed in US. Serial No. 12/949,004, filed November 18, 2010, the full disclosure of which is incorporated herein by reference.

Wet Milling Two examples of wet milling heads for use in wet milling unit 160 are shown in FIGS. 4-10 and FIGS. 1 l—17. Each head includes a rotor and a stator, and is mounted on a shaft (not shown) as is well known in the rotor/stator mixer art. In both cases, when the rotor and stator are assembled, the gaps between the teeth of the rotor are out of alignment with the gaps between the teeth of the stator. This creates a shearing gap through which liquid flows under high shear during rotation of the rotor.

Wet milling devices are commercially available, for example, from Quadro Engineering, (Waterloo Ontario), IKA Works Inc., (Wilmington, Delaware), Admix Inc.

(Manchester, NH) and Silverson, (Dartmouth Massachusetts).

In the entation shown in FIGS. 4-10, the stator includes two concentric rings of teeth (see . Under a given set of conditions, this stator configuration will generally e higher shear than the single ring stator configuration shown in FIGS. .20 1 l—17.’ On the other hand, the rotor of the head shown in FIGS. 11-17 includes an impeller-like portion, as will be shown below, which provides a pumping action which may be desirable in certain cases.

Referring to FIGS. 4-10, head 162 includes a rotor 164 and a stator 166. The rotor and stator each include a central hub 158 and 159, respectively, which define apertures dimensioned to receive a shaft (not shown). The shaft is connected to a motor for on of the rotor within the stator, with the aperture in the rotor being keyed with the shaft and the shaft rotating freely within the aperture in the stator as is well known in the art.

Arms 161 and 163, respectively, extend from the hubs to t rotor and stator toothed rings. As shown in FIGS. 6 and 8, the stator 166 includes two rings of teeth — an outer ring of teeth 170 and an inner ring ofteeth 171. The rotor 164 includes a single ring of teeth 169, which fit n the rings of the stator in a nested relationship. The upper surface 165 of rotor 164 includes three projections 167 which create turbulence around the head.

As shown in , a clearance 01 is provided between the outer surface 168 of the teeth 169 of the rotor (the OD of the rotor) and the adjacent inner surface 172 of the outer ring of teeth 170 of the stator. Clearance (1 is preferably small, to generate high shear, and may be, for example, from about 0.01 to 0.250 inch (0.25 to 0.64 mm), e.g., from about 0.03 to 0.10 inch (0.76 to 2.5 mm). The distance between the inner and outer rings of the stator is equal to this clearance plus the radial thickness of the teeth of the rotor, discussed below.

The outer diameters of the rotor and stator (ODl and OD2, FIGS. 7 and 8) will depend on the volume of the tank in which the milling head is used, and how many milling heads are positioned in the tank. The outer diameter of the stator, OD2, can be, for example, from about 3 to 50”, e.g., from about 5 to 25 inches, with larger heads being used in larger tanks. As an example, a 4” stator may be used in a 300 gallon tank.

As shown in each tooth 170 on the outer ring of the stator includes a chamfer 174 between its top surface 176 and outer side wall 178.

The ferential spacing between adjacent teeth is lly the same for the rotor (SI, and both rings of the stator (S2 and S3, ). Like the clearance or, this g will also affect the amount of shear generated by the head during rotation of the stator, with a larger spacing resulting in reduced shear. In some implementations, the spacing SI, 82 and S3 is about 0.1 to 0.5 inch (2.5 to 12.5 mm).

The tooth size may vary to some extent based on the d head diameter, with larger heads having in some cases somewhat larger teeth for durability. r, generally the tooth size and tooth spacing will remain relatively nt as head diameter increases, with the number of teeth increasing with increasing head diameter.

Referring to FIGS. 9 and 10, in some implementations the tooth dimensions can be, for example, as follows: Tl: 0.10” T2: 0.3 5” T3: 0.10” T4: 0.30” T5: 0.10” T6: 0.30” where T1 is the radial thickness of the rotor teeth, T2 is the circumferential thickness of the rotor teeth, T3 is the radial ess of the outer stator teeth, T4 is the circumferential thickness of the outer stator teeth, and T5 and T6 are, respectively, the radial and ferential thicknesses of the inner stator teeth.

As noted above, an alternative embodiment is shown in FIGS. 1 1-17, in which the stator has only a single row of teeth. This embodiment also differs from that shown in FIGS. 4—10 in other respects.

First, the arms 1 161 of the rotor are curved in two planes, as shown in FIGS. 1 1- 13, causing the rotor to act as an impeller in addition to its shearing action in the rotor/stator arrangement. This impeller functionality is enhanced by the ce of three larger teeth 1180 (see FIGS. 13 and 14) in the rotor ring, which act as extensions of the rotor arms.

Second, the adjacent side walls 1182 of the teeth 1 169 of the rotor are not arranged at an angle R with respect to the radii of the ring, as best seen in FIGS. 14 and 16. This angle may be, for example, from about 0 to 30 degrees. The angle of the teeth helps to pump material through the gap.

The ions of the rotor and stator in this embodiment are generally the same as those described above for the embodiment shown in FIGS. 11-17.

The rotor or stator can be made with a variety of als. For example, ceramics (e.g., oxides, carbides or nitrides), ess steel, or super alloys (e.g., Hastelloy, Inconel, Waspaloy, Ren alloys, Haynes alloys, TMS alloys and CMSX single crystal alloys).

The rotor/stator head is in some cases interchangeable with the jet mixing heads described below, in particular those shown in FIGS. l9-19B. For example, in the case of converting a jet mixer to a stator, shroud 208 () and mixing element 206 (A) are removed and the rotor/stator head is mounted on shaft 204. shows a cross-sectional view ofa system for wet milling that includes a tank (252), two motors (250) two shafts (254), a wet milling head (256) and ajet mixer head (258). As shown, one of the shafts is connected to one of the motors on one end and a wet milling head, as described above. Also as shown, the other shaft is connected to the other motor on one end and a jet milling head on the other end.

Jet Mixing Particularly advantageous mixers for use during saccharification and fermentation are known as “jet mixers.” In general, suitable mixers have in common that they produce high velocity circulating flow, for example flow in a toroidal or elliptical pattern.

Generally, preferred mixers exhibit a high bulk flow rate. red mixers provide this mixing action with vely low energy consumption. It is also generally preferred that 1O the mixer produce relatively low shear and avoid heating of the liquid medium, as shear and/or heat can deleteriously affect the saccharifying agent (or microorganism, e.g., in the case of fermentation). As will be discussed in detail below, some preferred mixers draw the mixture through an inlet into a mixing element, which may include a rotor or impeller, and then expel the mixture from the mixing element through an outlet nozzle.

This circulating action, and the high velocity of the jet exiting the nozzle, assist in sing material that is floating on the e of the liquid or material that has settled to the bottom of the tank, depending on the ation of the mixing element. Mixing elements can be positioned in different ations to disperse both floating and settling material, and the orientation of the mixing elements can in some cases be adjustable.

In some red mixing systems the velocity vo of the jet as meets the ambient fluid is from about 2 to 300 m/s, e.g., about 5 to 150 m/s or about 10 to 100 rn/s. The power ption of the mixing system may be about 20 to 1000 KW, e.g., 30 to 570 KW, 50 to 500 KW, or 150 to 250KW for a 100,000 L tank.

Jet mixing involves the discharge of a submerged jet, or a number of submerged jets, of high velocity liquid into a fluid medium, in this case the mixture of biomass feedstock, liquid medium and saccharifying agent. The jet of liquid penetrates the fluid medium, with its energy being dissipated by turbulence and some initial heat. This turbulence is associated with velocity nts (fluid shear). The surrounding fluid is accelerated and entrained into the jet flow, with this secondary entrained flow increasing as the ce from the jet nozzle increases. The momentum of the secondary flow remains generally nt as the jet expands, as long as the flow does not hit a wall, 2012/041382 floor or other obstacle. The longer the flow ues before it hits any obstacle, the more liquid is entrained into the secondary flow, increasing the bulk flow in the tank or . When it encounters an obstacle, the secondary flow will lose momentum, more or less depending on the geometry ofthe tank, e.g., the angle at which the flow es on the obstacle. It is generally desirable to orient thejets and/or design the tank so that hydraulic losses to the tank walls are minimized. For example, it may be desirable for the tank to have an arcuate bottom (e.g., a domed headplate), and for the jet mixers to be oriented vely close to the sidewalls. The tank bottom (lower head plate) may have any desired domed configuration, or may have an elliptical or conical ry.

Jet mixing differs from most types ofliquid/liquid and liquid/solid mixing in that the g force is hydraulic rather than mechanical. d of shearing fluid and propelling it around the mixing vessel, as a mechanical agitator does, ajet mixer forces fluid through one or more nozzles within the tank, creating high—velocity jets that entrain other fluid. The result is shear (fluid against fluid) and circulation, which mix~ the tank contents efficiently.

Referring to , the high velocity gradient between the core flow from a submerged jet and the surrounding fluid causes eddies. A illustrates the general characteristics of a submerged jet. As the submerged jet expands into the surrounding ambient environment the velocity profile flattens as the ce (x) from the nozzle increases. Also, the velocity gradient dv/dr changes with r (the distance from the centerline of the jet) at a given distance x, such that eddies are created which define the ‘ mixing zone (the conical expansion from the nozzle).

In an mental study ofa submerged jet in air (the results ofwhich are ‘ applicable to any fluid, including , Albertson et al. (“Diffusion of Submerged Jets,” Paper 2409, Amer. Soc. of Civil Engineers Transactions, Vol. 1152639-697, 1950, at p. 657) developed dimensionless relationships for V(X]r=0/Vo (centerline velocity), v(r)x/v(x}r=o (velocity profile at a given x), Qx/Qo (flow entrainment), and Ex/Eo (energy change with x): (1) Centerline velocity, v(x) r=o/vo: WO 70707 v(r = 0) i = 6.2 0 Do [2) velocity profile at any x, v(rjx/v(x]r=o: mgr“) -' i] = 0.79 — 33’—v D (3) Flow and energy at any x: = ‘3 Q0 D, (10.21) g: = 4.11:0 (10.22) where: v(r = 0] = line velocity erged jet (m/s), v0 = velocity ofjet as it emerges from the nozzle (m/s), x = distance from nozzle (m), r = distance from centerline ofjet (m), DD = diameter ofnozzle (m), Q = flow of fluid across any given plane at distance x from the nozzle (me/s), Q0 ; flow of fluid emerging from the nozzle (m3/s), E = energy flux of fluid across any given plane at distance x from the nozzle (m3/s), E0 = energy flux of fluid emerging from the nozzle (m3/s).

(“Water Treatment Unit Processes: Physical and Chemical,” David W. Hendricks, CRC Press 2006, p. 411.) WO 70707 Jet mixing is particularly cost-effective in large-volume (over 1,000 gal) and low— viscosity (under 1,000 cPs) ations. It is also lly advantageous that in most cases the pump or motor of the jet mixer not be submerged, e.g., when a pump is used it is generally located outside the vessel.

One advantage ofjet mixing is that the temperature of the ambient fluid (other than directly adjacent the exit of the nozzle, where there may be some localized heating) is increased only slightly if at all. For example, the temperature may be increased by less than 5°C, less than 1°C, or not to any measureable extent.

Jet-Flow Agitators One type ofjet-flow agitator is shown in FIGS. 19-19A. This type of mixer is available commercially, e.g., from IKA under the tradename ROTOTRONTM. Referring to , the mixer 200 includes a motor 202, which rotates a drive shaft 204. A mixing element 206 is mounted at the end ofthe drive shaft 204. As shown in A, the mixing element 206 includes a shroud 208 and, within the , an impeller 210.

As indicated by the arrows, when the impeller is rotated in its “forward” direction, the impeller 210 draws liquid in through the open upper end 212 of the shroud and forces the liquid out through the open lower end 214. Liquid exiting end 214 is in the form ofa high velocity stream orjet. 1f the direction of rotation of the impeller 210 is reversed, liquid can be drawn in h the lower end 214 and ejected through the upper end 212.

This can be used, for example, to suck in solids that are floating near or on the surface of the liquid in a tank or vessel. (It is noted that “upper” and ” refer to the orientation of the mixer in ; the mixer may be oriented in a tank so that the upper end is below the lower end.) The shroud 208 includes flared areas 216 and 218 adjacent its ends. These flared areas are believed to contribute to the lly toroidal flow that is observed with this type of mixer. The ry ofthe shroud and impeller also concentrate the flow into a high velocity stream using relatively low power consumption.

Preferably, the clearance n the shroud 208 and the impeller 210 is sufficient so as to avoid excessive milling of the material as it passes through the shroud.

For example, the clearance may be at least 10 times the average‘particle size of the solids in the mixture, preferably at least 100 times.

In some implementations, the shaft 204 is configured to allow gas delivery through the shaft. For example, the shaft 204 may include a bore (not shown) through which gas is delivered, and one or more orifices through which gas exits into the mixture.

The orifices may be within the shroud 208, to enhance mixing, and/or at other locations along the length of the shaft 204.

The impeller 210 may have any desired geometry that will draw liquid through the shroud at a high velocity. The impeller is preferably a marine impeller, as shown in A, but may have a different design, for example, a n impeller as shown in B, or a modified Rushton er, e.g., tilted so as to provide some axial flow.

In order to generate the high velocity flow through the shroud, the motor 202 is preferably a high speed, high torque motor, e.g., capable of operating at 500 to 20,000 RPM, e.g., 3,000 to 10,000 RPM. However, the larger the mixer (e.g., the larger the shroud and/or the larger the motor) the lower the rotational speed can be. Thus, if a large mixer is used, such as a 5 hp, 10 hp, 20 hp, or 30 hp or greater, the motor may be ed to operate at lower rotational speeds, e.g., less than 2000 RPM, less than 1500 RPM, or even 500 RPM or less. For example, a mixer sized to mix a 10,000—20,000 liter tank may operate at speeds of 900 to 1,200 RPM. The torque of the motor is preferably self-adjusting, to maintain a relatively constant er speed as the mixing conditions changeover time, e.g., due to rification of the solids.

Advantageously, the mixer can be ed at any d or location in the tank, to direct the jet flow in a desired direction. Moreover, as discussed above, depending on the direction of rotation of the impeller the mixer can be used to draw fluid from either end of the shroud.

In some implementations, two or more jet mixers are positioned in the vessel, with one or more being configured to jet fluid upward (“up pump”) and one or more being-configured to jet fluid downward (“down pump”). In some cases, an up pumping mixer will be positioned adjacent a down pumping mixer, to enhance the turbulent flow created by the mixers. If desired, one or more mixers may be switched between upward flow and rd flow during processing. It may be advantageous to switch all or most of the mixers to up g mode during initial dispersion of the feedstock in the liquid , particularly if the feedstock is dumped or blown onto the surface of the liquid, as up pumping creates significant turbulence at the e. Up pumping can also be used during fermentation to help remove CO; from the liquid by causing the gas to bubble to the e where it can be vented.

Other suitable jet mixers are described in US. Applications Serial Nos. ,694 filed May 18,2011; 13/293,985 filed November 10, 2011; 13/293,977 filed November 10, 2011 and US. 12/782,694, filed May 18, 2010, the full disclosures of which are incorporated herein by reference.

MATERIALS Biomass Materials The biomass can be, e.g., a cellulosic or ellulosic material. Such materials include paper and paper products (e.g., polycoated paper and Kraft paper), wood, wood- related materials, e.g., particle board, grasses, rice hulls, bagasse, jute, hemp, flax, bamboo, sisal, abaca, straw, switchgrass, alfalfa, hay, corn cobs, corn stover, wheat straw, coconut hair; and materials high in a—cellulose content, e.g., cotton. Feedstocks can be obtained from virgin scrap textile materials, e. g., remnants, post er waste, e. g., rags. When paper products are used they can be virgin materials, e.g., scrap virgin materials, or they can be onsumer waste. Aside from virgin raw materials, post- consumer, industrial (e.g., offal), and processing waste (e.g., effluent from paper processing) can also be used as fiber sources. Biomass ocks can also be obtained or derived from human (e. g., sewage), animal or plant wastes. Additional cellulosic and ellulosic materials have been described in US. Patent Nos. 6,448,307; 6,258,876;6,207,729; 5,973,035 and 5,952,105.

In some embodiments,'the biomass material includes a carbohydrate that is or includes a material having one or more B— l ,4-linkages and having a number average molecular weight between about 3,000 and 50,000. Such a carbohydrate is or includes cellulose (I), which is derived from (B-glucose 1) through condensation of B(l,4)- glycosidic bonds. This linkage contrasts itself with that for a(1,4)-glycosidic bonds present in starch and other carbohydrates.

HO OH In some embodiments, the biomass material includes starchy materials, e. g., corn starch, wheat starch, potato starch or rice , a derivative of starch, or a material that includes starch, such as an edible food product or a crop. For example, the starchy material can be arracacha, buckwheat, banana, barley, corn kernels, a, kudzu, oca, sago, sorghum, regular household potatoes, sweet potato, taro, yams, or one or more beans, such as favas, lentils or peas. Blends of any two or more starchy materials are also starchy materials. Mixtures of starchy, cellulosic and or lignocellulosic materials can also be used. For example, a biomass can be an entire plan, a part of a plant or ent parts of a plant e.g., a wheat plant, cotton plant, a corn plant, rice plant or a tree. The y materials can be d by any of the methods described herein.

In other embodiments, the biomass als, such as osic, starchy and lignocellulosic feedstock materials, can be obtained from plants that have been modified with t to a wild type variety. Such modifications may be, for example, through the iterative steps of selection and breeding to obtain desired traits in a plant. Furthermore, the plants can have had genetic material removed, modified, silenced and/or added with respect to the wild type variety. For example, genetically modified plants can be produced by recombinant DNA methods, where genetic modifications include ucing or ing specific genes from al varieties, or, for example, by using transgenic breeding wherein a specific gene or genes are introduced to a plant from a different species of plant and/or bacteria. Another way to create c variation is through mutation breeding wherein new alleles are artificially created from endogeneous genes. The artificial genes can be created by a variety of ways including treating the plant or seeds with, for example, chemical mutagens (e.g., using alkylating agents, epoxides, alkaloids, peroxides, formaldehyde), irradiation (e.g., X—rays, gamma rays, neutrons, beta particles, alpha particles, protons, ons, UV radiation) and temperature shocking or other external ing and subsequent selection techniques. Other methods of providing modified genes is through error prone PCR and DNA shuffling followed by insertion of the desired modified DNA into the desired plant or seed. Methods of introducing the desired genetic ion in the seed or plant e, for example, the use of a bacterial carrier, biolistics, calcium phosphate itation, electroporation, gene splicing, gene silencing, lipofection, microinjection and viral carriers. Additional genetically modified materials have been described in US. Application Serial No 13/396,369 filed February 14, 2012 the full disclosure of which is incorporated herein by reference.

In some cases the biomass is a microbial material. Microbial sources include, but are not limited to, any naturally occurring or cally modified microorganism or organism that ns or is capable of providing a source of carbohydrates (e. g., ose), for example, protists, e.g., animal protists (e.g., protozoa such as flagel-lates, amoeboids, ciliates, and sporozoa) and plant protists (e.g., algae such ates, chlorarachniophytes, cryptomonads, euglenids, glaucophytes, haptophytes, red algae, stramenopiles, and viridaeplantae). Other es include seaweed, plankton (e. g., macroplankton, mesoplankton, microplankton, nanoplankton, picoplankton', and femptoplankton), phytoplankton, bacteria (e.g., gram positive bacteria, gram negative bacteria, and extremophiles), yeast and/or mixtures of these. In some instances, microbial biomass can be obtained from natural sources, e.g., the ocean, lakes, bodies of water, e.g., salt water or fresh water, or on land. Alternatively or in on, microbial biomass can be ed from e systems, e.g., large scale dry and wet culture systems.

Saccharifying Agents Suitable enzymes include cellobiases, cellulases and amylases capable of degrading 1O biomass.

Suitable iases e a cellobiase from Aspergillus niger sold under the tradename NOVOZYME 188W.

Cellulases are e of degrading biomass, and may be of fungal or bacterial origin. Suitable enzymes include cellulases from the genera Bacillus, Pseudomonas, Humicola, Fusarium, Thielavia, Acremonium, Chrysosporium and Trichoderma, and include species of Humicola, Caprinus, via, Fusarium, Myceliophthora, Acremonium, Cephalosporium, Scytalidium, Penicillium or Aspergillus (see, e. g., EP 458162), especially those produced by a strain selected from the species Humicola ns (reclassified as idium thermophilum, see, e.g, US Patent No. 4,435,307), Coprinus cinereus, Fusarium oxysporum, Myceliophthora thermophi/a, Meripilus giganteus, Thielavia terrestris, Acremom'um sp., Acremonium persicinum, Acremonium acremonium, Acremonium brachypenium, Acremonium dichromosporum, Acremonium obclavatum, Acremonium pinkertoniae, Acremonium roseogriseum, Acremonium incoloratum, and niumfuraium; preferably from the species Humicola insolens DSM 1800, Fusarium oxysporum DSM 2672, Myceliophthora phi/a CBS 1 17.65, Cephalosporium sp. RYM-202, Acremonium Sp. CBS 478.94, Acremonium Sp. CBS , Acremonium inum CBS 169.65, Acremonium acremom'um AHU 9519, Cephalosporium sp. CBS 535.71, Acremonium brachypeniuin CBS 866.73, Acremonium dichromosporum CBS 683.73, Acremom'um obclavatum CBS 31 1.74, Acremonium pinkertoniae CBS 157.70, Acremonium roseogriseum CBS 134.56, Acremonium incoloratum CBS , and Acremoniumfuratum CBS 299.70H. Cellulolytic enzymes may also be obtained from Chrysosporium, ably a strain of Chrysosporium lucknowense. Additionally, Trichoderma (particularly Trichoderma viride, Trichoderma reesei, and Trichoderma koningii), alkalophilic Bacillus (see, for example, US. Patent No. 3,844,890 and EP 458162), and Streptomyces (see, e.g., EP 458162) may be used.

Enzyme complexes may be utilized, such as those available from Genencore under the tradename ERASE®, for e, Accellerase® 1500 enzyme complex. Accellerase® 1500 enzyme complex contains multiple enzyme activities, mainly exoglucanase, endoglucanase (2200-2800 CMC U/g), hemi-cellulase, and beta- glucosidase 75 pNPG U/g), and has a pH of 4.6 to 5.0. The endoglucanase activity of the enzyme complex is expressed in carboxymethylcellulose activity units (CMC U),_ while the beta—glucosidase activity is reported in pNP-glucoside activity units (pNPG U).

In one embodiment, a blend of Accellerase® 1500 enzyme complex and NOVOZYMETM 188 cellobiase is used.

In some entations, the saccharifying agent comprises an acid, e.g., a mineral acid. When an acid is used, co-products may be generated that are toxic to microorganisms, in which case the process can further include removing such co- ts. Removal may be performed using an activated carbon, e.g., activated charcoal, or other le techniques.

Fermentation Agents The microorganism(s) used in fermentation can be natural microorganisms and/or engineered microorganisms. For example, the microorganism can be a bacterium, e. g., a cellulolytic bacterium, a fungus, e.g., a yeast, a plant or a protist, e.g., an algae, a oa or a fungus-like protist, e. g., a slime mold. When the organisms are compatible, mixtures of organisms can be ed.

Suitable fermenting microorganisms have the ability to convert carbohydrates, such as e, xylose, arabinose, e, galactose, oligosaccharides or polysaccharides into fermentation ts. Fermenting microorganisms include strains of the genus Sacchromyces Spp. e.g., Sacchromyces cerevisiae (baker’s yeast), Saccharomyces distaticus, romyces uvarum; the genus Kluyveromyces, e. g., species Kluyveromyces marxianus, Kluyveromycesfragilis; the genus Candida, e.g., Candida pseudotrapicalis, and Candida brassicae, Pichia is (a relative of Candida shehatae, the genus pora, e.g., species Clavispora lusitaniae and Clavispora opuntiae, the genus Pachysolen, e.g., species Pachysolen tannophilus, the genus Bretannomyces, e.g., species Bretannomyces clausenii ppidis, G. P., 1996, Cellulose bioconversion technology, in Handbook on Bioethanol: tion and Utilization, Wyman, C.E., ed., Taylor & s, Washington, DC, 179-212). Other suitable microorganisms include, for example, Zymomonas mobilis, Clostridium thermocellum (Philippidis, 1996, supra), Clostridium saccharobugllacetanicum, Clostridium saccharobutylicum, Clostridium Puniceum, Clostridium beijernckii, Clostridium acetobutylicum, Moniliella pollinis, Yarrowia Iipolytica, Aureobasidium sp., Trichosporonoides sp., Trigonopsis variabilis, Trichosporon sp., ellaacetoabutans, Typhula variabilis, Candida magnoliae, Ustilaginomycetes, Pseudozyma tsukubaensis, yeast species of genera Zygosaccharomyces, Debaryomyces, ula and Pichia, and fungi ofthe dematioid genus Torula.

Commercially available yeasts include, for example, Red Star®/Lesaffre Ethanol Red (available from Red Star/Lesaffre, USA), FALI® (available from Fleischmann’s Yeast, a division of Burns Philip Food Inc, USA), SUPERSTART® (available from Alltech, now Lalemand), GERT STRAND® (available from Gert Strand AB, Sweden) and FERMOL® (available from DSM Specialties).

Antibiotics While it is generally preferred to have a high sugar concentration in the saccharified solution, lower trations may be used, in which case it may be ble to add an antimicrobial additive, e.g., a broad spectrum antibiotic, in a low concentration, e.g., 50 to 150 ppm. Other suitable antibiotics include amphotericin B, ampicillin, chloramphenicol, ciprofloxacin, icin, hygromycin B, kanamycin, ,neomycin, penicillin, puromycin, streptomycin. Antibiotics will inhibit growth of microorganisms during transport and storage, and can be used at appropriate concentrations, e.g., n 15 and 1000 ppm by , e.g., between 25 and 500 ppm, or between 50 and 150 ppm. If desired, an antibiotic can be included even ifthe sugar concentration is relatively high.

Surfactants The addition of surfactants can enhance the rate of saccharification. Examples of surfactants include non-ionic surfactants, such as a Tween® 20 or Tween® 80 hylene glycol surfactants, ionic surfactants, or eric tants. Other suitable surfactants include octylphenol ethoxylates such as the TRITONTM X series nonionic tants commercially available from Dow Chemical. A surfactant can also be added to keep the sugar that is being produced in on, particularly in high concentration solutions.

Saccharification Medium In one embodiment, the medium has the following concentrations of components: PHYSICAL TREATMENT OF FEEDSTOCK Physical Preparation In some cases, methods can include a physical preparation, e.g., size reduction of materials, such as by cutting, grinding, shearing, pulverizing or chopping. For example, in other cases, material is first pretreated or processed using one or more of the methods described herein, such as radiation, sonication, oxidation, pyrolysis or steam explosion, and then size reduced or further size reduced. ng first and then size ng can be advantageous. Screens and/or magnets can be used to remove oversized or undesirable objects such as, for e, rocks or nails from the feed stream. In some cases no pre- processing is ary, for example when the initial recalcitrance of the biomass is low, and wet milling is sufficiently effective to reduce the recalcitrance, for e, to prepared the material for further processing, e.g., saccharification.

Feed preparation systems can be configured to e streams with specific characteristics such as, for example, specific maximum sizes, specific length-to-width,or specific surface areas ratios. Physical preparation can increase the rate of reactions or reduce the processing time required by opening up the materials and making them more accessible to processes and/or reagents, such as ts in a on. The bulk density of feedstocks can be controlled (e. g., sed). In some situations, it can be desirable to prepare a high or higher bulk density al, e.g., by densifying the material (e. g., densification can make it easier and less costly to transport to r site) and then reverting the material to a lower bulk density state. The material can be densified, for example from less than 0.2 g/cc to more than 0.9 g/cc (e.g., less than 0.3 to more than 0.5 g/cc, less than 0.3 to more than 0.9 g/cc, less than 0.5 to more than 0.9 g/cc, less than 0.3 to more than 0.8 g/cc, less than 0.2 to more than 0.5 g/cc). For example, the material can be densified by the methods and equipment disclosed in US. 7,932,065 and WO 2008/073186, the full disclosures of which are incorporated herein by reference. ed materials can be processed by any of the methods described herein, or any al processed by any of the methods bed herein can be subsequently densified.

In some cases, the al can be densified prior to wet milling. Wet milling can re-open densified al.

Size Reduction In some embodiments, the material to be processed is in the form of a fibrous material that includes fibers provided by shearing a fiber source. For example, the shearing can be performed with a rotary knife cutter.

For example, a fiber source, e.g., that is recalcitrant or that has had its recalcitrance level reduced, can be sheared, e.g., in a rotary knife cutter, to provide a first fibrous material. The first fibrous material is passed through a first screen, e.g., having an average opening size of 1.59 mm or less (1/16 inch, 0.0625 inch), provide a second fibrous material. If desired, the fiber source can be cut prior to the shearing, e.g., with a shredder. For example, when a paper is used as the fiber source, the paper can be first cut into strips that are, e.g., 1/4— to l/2-inch wide, using a shredder, e.g., a counter-rotating screw shredder, such as those manufactured by Munson (Utica, NY). As an alternative to shredding, the paper can be reduced in size by cutting to a desired size using a guillotine cutter. For example, the guillotine cutter can be used to cut the paper into sheets that are, e.g., 10 inches wide by 12 inches long.

In some embodiments, the shearing of the fiber source and the passing of the resulting first fibrous material through a first screen are performed concurrently. The shearing and the passing can also be performed in a type process.

For example, a rotary knife cutter can be used to concurrently shear the fiber source and screen the first fibrous material. A rotary knife cutter includes a hopper that can be loaded with a shredded fiber source prepared by shredding a fiber source. The shredded fiber source In some implementations, the feedstock is physically treated prior to saccharification and/or fermentation. al treatment processes can e one or more of any of those described , such as ical treatment, chemical treatment, irradiation, sonication, ion, sis or steam explosion. ent methods can be used in combinations of two, three, four, or even all of these technologies (in any order). When more than one treatment method is used, the s can be applied at the same time or at different times. Other processes that change a molecular structure of a biomass feedstock may also be used, alone or in combination with the ses disclosed herein.

Mechanical Treatments In some cases, methods can include mechanically treating the biomass feedstock.

Mechanical treatments include, for example, cutting, milling, pressing, ng, shearing and chopping. Milling may e, for example, ball milling, hammer milling, rotor/stator dry or wet milling, freezer milling, blade milling, knife milling, disk milling, roller milling or other types of milling. Other mechanical treatments include, e.g., stone grinding, cracking, mechanical ripping or tearing, pin grinding or air attrition milling.

Mechanical treatment can be advantageous for “opening up,9’ (Sstressing,” breaking and shattering the cellulosic or lignocellulosic materials, making the cellulose of WO 70707 the materials more susceptible to chain scission and/0r reduction of crystallinity. The open materials can also be more susceptible to oxidation when irradiated.

In some cases, the mechanical treatment may e an initial preparation of the feedstock as received, e.g., size reduction of materials, such as by cutting, grinding, shearing, pulverizing or chopping. For example, in some cases, loose feedstock (e.g., recycled paper, starchy materials, or switchgrass) is prepared by shearing or shredding.

Alternatively, or in addition, the feedstock material can first be physically treated by one or more of the other physical treatment methods, e.g., al treatment, radiation, sonication, oxidation, pyrolysis or steam explosion, and then mechanically treated. This sequence can be advantageous since materials treated by one or more of the other treatments, e. g., irradiation or sis, tend to be more e and, therefore, it may be easier to further change the molecular structure of the material by mechanical treatment.

In some embodiments, the feedstock material is in the form of a fibrous material, and mechanical treatment includes shearing to expose fibers of the fibrous material.

Shearing can be performed, for example, using a rotary knife cutter. Other methods of ically treating the feedstock e, for example, milling or ng. Milling may be performed using, for e, a hammer mill, ball mill, d mill, conical or cone mill, disk mill, edge mill, Wiley mill or grist mill. Grinding may be performed using, for example, a stone grinder, pin grinder, coffee r, or burr grinder. Grinding may be provided, for example, by a reciprocating pin or other element, as is the case in a pin mill. Other mechanical treatment methods include mechanical ripping or tearing, other methods that apply pressure to the material, and air attrition milling. Suitable mechanical ents further include any other technique that changes the lar structure of the feedstock.

If desired, the mechanically treated material can be passed through a screen, e.g., having an average opening size of 1.59 mm or less (1/16 inch, 0.0625 inch). In some embodiments, shearing, or other mechanical treatment, and screening are performed concurrently. For example, a rotary knife cutter can be used to concurrently shear and screen the feedstock. The feedstock is sheared between stationary blades and rotating blades to provide a sheared material that passes through a screen, and is captured in a bin.

The cellulosic or lignocellulosic material can be mechanically treated in a dry state (e. g., having little or no free water on its surface), a hydrated state (e.g., having up to ten percent by weight absorbed water), or in a wet state, e.g., having between about 10 percent and about 75 percent by weight water. The fiber source can even be mechanically treated while partially or fully submerged under a liquid, such as water, ethanol or isopropanol.

The fiber cellulosic or lignocellulosic material can also be ically treated under a gas (such as a stream or atmosphere of gas other than air), e. g., oxygen or nitrogen, or steam.

If desired, lignin can be removed from any of the fibrous materials that include lignin. Also, to aid in the own of the materials that include ose, the material can be treated prior to or during mechanical treatment or irradiation with heat, a chemical (e.g., mineral acid, base or a strong oxidizer such as sodium hypochlorite) and/or an enzyme. For example, grinding can be performed in the presence of an acid. ical treatment systems can be configured to produce streams with specific morphology characteristics such as, for example, surface area, porosity, bulk density, and, in the case of fibrous feedstocks, fiber teristics such as length—to-width ratio.

In some embodiments, a BET e area of the mechanically d material is greater than 0.1 mZ/g, e.g., greater than 0.25 mZ/g, greater than 0.5 mZ/g, greater than 1.0 mz/g, greater than 1.5 mZ/g, greater than 1.75 mz/g, greater than 5.0 mZ/g, greater than 10 mz/g, greater than 25 mZ/g, greater than 35 mz/g, greater than 50m2/g, greater than 60 mz/g, greater than 75 mz/g, r than 100 mZ/g, greater than 150 mZ/g, greater than 200 mz/g, or even greater than 250 mZ/g.

A porosity of the mechanically treated material can be, e.g., r than 20 percent, greater than 25 percent, greater than 35 percent, greater than 50 percent, greater than 60 t, greater than 70 percent, r than 80 percent, greater than 85 percent, greater than 90 percent, greater than 92 percent, greater than 94 percent, greater than 95 percent, greater than 97.5 percent, greater than 99 percent, or even greater than 99.5 percent. a In some ments, after mechanical treatment the material has a bulk density ofless than 0.25 g/cm3, e.g., 0.20 g/cm3, 0.15 g/cm3, 0.10 g/cm3, 0.05 g/cm3 or less, e.g., 2012/041382 0.025 g/cm3. Bulk density is determined using ASTM D1895B. Briefly, the method involves filling a measuring cylinder of known volume with a sample and obtaining a weight of the sample. The bulk density is calculated by dividing the weight of the sample in grams by the known volume of the er in cubic centimeters.

If the feedstock is a fibrous material the fibers ofthe fibrous materials mechanically treated al can have a vely large average length-to-diameter ratio (e.g., greater than 20-to-1), even if they have been sheared more than once. In addition, the fibers of the fibrous materials bed herein may have a relatively narrow length and/or -to—diameter ratio distribution.

As used herein, average fiber widths (e.g., diameters) are those determined optically by randomly ing approximately 5,000 fibers. Average fiber lengths are corrected length—weighted lengths. BET (Brunauer, Emmet and Teller) e areas are multi-point surface areas, and porosities are those determined by mercury porosimetry.

If the second feedstock is a fibrous material 14 the average length-to-diameter ratio of fibers of the mechanically treated material can be, e.g. greater than 8/1, e.g., greater than 10/1, greater than 15/ 1, greater than 20/1, greater than 25/1, or greater than 50/1. An average fiber length of the mechanically d material 14 can be, e.g., between about 0.5 mm and 2.5 mm, e.g., between about 0.75 mm and 1.0 mm, and an average width (e. g., diameter) of the second fibrous material 14 can be, e.g., between about 5 um and 50 um, e.g., between about 10 um and 30 pm.

In some embodiments, if the feedstock is a fibrous material, the standard ion of the fiber length of the mechanically treated material can be less than 60 percent of an average fiber length of the mechanically treated material, e.g., less than 50 t of the average length, less than 40 percent of the average , less than 25 percent of the average length, less than 10 percent of the average length, less than 5 percent of the average length, or even less than 1 percent of the average length.

Treatment to Solubilize, Reduce Recalcitrance or Functionalize Materials that have or have not been physically prepared can be treated for use in any production process described herein. One or more of the production processes described below may be ed in the recalcitrance reducing operating unit discussed 2012/041382 above. Alternatively, or in addition, other processes for reducing recalcitrance may be included.

Treatment processes utilized by the recalcitrance reducing operating unit can include one or more of irradiation, sonication, oxidation, pyrolysis or steam explosion.

Treatment s can be used in combinations of two, three, four, or even all of these logies (in any order).

Radiation Treatment One or more radiation processing sequences can be used to process materials from the feedstock, and to provide a wide variety of different sources to extract useful substances from the feedstock, and to provide partially degraded structurally modified material which functions as input to further processing steps and/or sequences.

Irradiation can, for example, reduce the molecular weight and/or crystallinity of feedstock. Radiation can also sterilize the materials, or any media needed to bioprocess the al.

In some embodiments, energy deposited in a material that releases an on from its atomic orbital is used to irradiate the als. The radiation may be provided by (1) heavy charged particles, such as alpha particles or protons, (2) electrons, produced, for example, in beta decay or electron beam accelerators, or (3) omagnetic radiation, for example, gamma rays, x rays, or ultraviolet rays. In one approach, ion produced by radioactive substances can be used to irradiate the feedstock. In some embodiments, any combination in any order or concurrently of(1) through (3) may be utilized. In another approach, electromagnetic radiation (e.g., produced using electron beam rs) can be used to irradiate the feedstock. The doses applied depend on the desired effect and the particular feedstock.

In some instances when chain scission is desirable and/or polymer chain functionalization is desirable, particles heavier than electrons, such as protons, helium nuclei, argon ions, n ions, neon ions, carbon ions, phosphorus ions, oxygen ions or nitrogen ions can be utilized. When ring-opening chain scission is d, positively charged particles can be utilized for their Lewis acid ties for enhanced ring- opening chain scission. For example, when maximum oxidation is desired, oxygen ions can be ed. and when maximum nitration is desired, nitrogen ions can be utilized.

The use of heavy particles and positively charged particles is described in US. 7,931,784, the full disclosure of which is incorporated herein by nce.

In one method, a first material that is or includes cellulose having a first number average molecular weight (Mm) is irradiated, e.g., by treatment with ionizing radiation (e.g., in the form of gamma ion, X-ray radiation, 100 nm to 280 nm ultraviolet (UV) light, a beam of ons or other charged particles) to provide a second material that includes cellulose having a second number average molecular weight (Mm) lower than the first number average molecular weight. The second material (or the first and second material) can be combined with a microorganism (with or without enzyme treatment) that can utilize the second and/or first material or its constituent sugars or lignin to produce an intermediate or a product, such as those described .

Since the second material includes cellulose having a reduced lar weight relative to the first material, and in some instances, a reduced llinity as well, the second material is generally more dispersible, swellable and/or soluble, e.g., in a solution containing a microorganism and/or an enzyme. These properties make the second material easier to process and more susceptible to chemical, enzymatic and/or biological attack relative to the first material, which can greatly improve the production rate and/or production level of a desired product, e. g., ethanol. Radiation can also sterilize the materials or any media needed to bioprocess the material.

In some embodiments, the second material can have a level of oxidation (02) that is higher than the level of oxidation (01) of the first material. A higher level of oxidation of the material can aid in its sability, swellability and/or lity, further enhancing the material’s tibility to chemical, enzymatic or biological attack. In some embodiments, to increase the level of the oxidation of the second al ve to the first material, the irradiation is performed under an oxidizing environment, e.g., under a blanket of air or oxygen, ing a second material that is more oxidized than the first material. For example, the second material can have more hydroxyl groups, aldehyde groups, ketone , ester groups or carboxylic acid groups, which can increase its hydrophilicity. 2012/041382 Ionizing Radiation Each form of radiation ionizes the -containing material via particular interactions, as determined by the energy of the radiation. Heavy charged particles ily ionize matter via Coulomb scattering; furthermore, these interactions produce energetic electrons that may further ionize matter. Alpha particles are identical to the nucleus of a helium atom and are produced by the alpha decay of various radioactive nuclei, such as isotopes of bismuth, polonium, astatine, radon, francium, radium, several actinides, such as actinium, thorium, uranium, neptunium, curium, californium, americium, and ium.

When particles are utilized, they can be neutral (uncharged), positively charged or negatively charged. When d, the charged particles can bear a single positive or negative charge, or multiple charges, e.g., one, two, three or even four or more charges.

In instances in which chain scission is desired, positively charged particles may be desirable, in part due to their acidic nature. When particles are utilized, the particles can have the mass ofa resting electron, or greater, e.g., 500, 1000, 1500, 2000, 10,000 or even 100,000 times the mass ofa resting electron. For example, the particles can have a mass of from about 1 atomic unit to about 150 atomic units, e.g., from about 1 atomic unit to about 50 atomic units, or from about 1 to about 25, e.g., 1, 2, 3‘, 4, 5, 10, 12 or 15 amu. Accelerators used to accelerate the particles can 'be ostatic DC, electrodynamic DC, RF linear, magnetic induction linear or uous wave. For example, ron type rators are available from IBA, m, such as the Rhodotron® system, while DC type accelerators are available from RDI, now IBA Industrial, such as the tron®. Ions and ion accelerators are discussed in Introductory Nuclear Physics, h S. Krane, John Wiley & Sons, Inc. (1988), Krsto Prelec, FIZIKA B 6 (1997) 4, 177—206, Chu, William T., “Overview of Light-Ion Beam Therapy” Columbus-Ohio, ICRU-IAEA Meeting, 18—20 March 2006, Iwata, Y. et al., “Altemating-Phase—Focused IH-DTL for Heavy-Ion Medical Accelerators” Proceedings of EPAC 2006, Edinburgh, Scotland and Leaner, C.M. et al., “Status ofthe Superconducting ECR Ion Source Venus” Proceedings of EPAC 2000, Vienna, Austria.

In some embodiments, a beam of electrons is used as the radiation source. A beam of electrons has the advantages of high dose rates (e.g., 1, 5, or even 10 Mrad per second), high hput, less containment, and less confinement equipment. Electrons can also be more efficient at causing chain scission. In addition, electrons having energies of 4-10 MeV can have a penetration depth of 5 to 30 mm or more, such as 40 mm. In some cases, multiple electron beam devices (e.g., multiple heads, often ed to as “horns”) are used to deliver multiple doses of electron beam radiation to the material. This high total beam power is usually achieved by utilizing multiple accelerating heads. For example, the electron beam device may include two, four, or more rating heads. As one example, the electron beam device may include four accelerating heads, each of which has a beam power of 300 kW, for a total beam power 1O of 1200 kW. The use of multiple heads, each of which has a relatively low beam power, ts excessive temperature rise in the material, thereby preventing g of the material, and also increases the uniformity of the dose through the thickness of the layer of material. Irradiating with multiple heads is disclosed in US. Application Serial No. 13/276,192 filed Oct 18, 201 1, the complete disclosure of which is orated herein by reference.

Electron beams can be generated, e.g., by electrostatic generators, cascade generators, ormer generators, low energy accelerators with a scanning system, low energy accelerators with a linear cathode, linear accelerators, and pulsed accelerators.

Electrons as an ionizing radiation source can be useful, e.g., for relatively thin piles of als, e.g., less than 0.5 inch, e.g., less than 0.4 inch, 0.3 inch, 0.2 inch, or less than 0.1 inch. In some embodiments, the energy of each electron of the electron beam is from about 0.3 MeV to about 2.0 MeV (million electron volts), e.g., from about 0.5 MeV to about 1.5 MeV, or from about 0.7 MeV to about 1.25 MeV.

Electron beam irradiation devices may be procured commercially from Ion Beam Applications, Louvain-la-Neuve, Belgium or the Titan ation, San Diego, CA.

Typical electron energies can be 1 MeV, 2 MeV, 4.5 MeV, 7.5 MeV, or 10 MeV.

Typical electron beam irradiation device power can be 1 kW, 5 kW, 10 kW, 20 kW, 50 kW, 100 kW, 250 kW, or 500 kW. The level of merization of the ock depends on the electron energy used and the dose applied, while exposure time depends on the power and dose. Typical doses may take values of 1 kGy, 5 kGy, lO kGy, 20 kGy, 50 kGy, 100 kGy, or 200 kGy. In a some embodiments energies between 0.25-10 WO 70707 MeV (e.g., 0.5—0.8 MeV, 0.5-5 MeV, 0.8-4 MeV, 0.8-3 MeV, 0.8-2 MeV 0r 0.8-1.5 MeV) can be used.

Electromagnetic Radiation In embodiments in which the irradiating is performed with omagnetic radiation, the electromagnetic radiation can have, e.g., energy per photon (in electron volts) of greater than 102 eV, e.g., greater than 103, 104, 105, 106, or even greater than 107 eV. In some embodiments, the electromagnetic radiation has energy per photon of between 104 and 107, e.g., between 105 and 106 eV. The electromagnetic radiation can have a frequency of, e.g., greater than 10‘6 Hz, greater than 10'7 Hz, 10”, 1019, 1020, or even greater than 1021 Hz. In some embodiments, the electromagnetic radiation has a frequency of between 1018 and 1022 Hz, e.g., between 10'9 to 102' Hz.

Doses In some embodiments, the irradiating (with any ion source or a combination of sources) is performed until the material receives a dose of at least 0.25 Mrad, e.g., at least 1.0, 2.5, 5.0, 8.0, 10, 15, 20, 25, 30, 35, 40, 50, or even at least 100 Mrad. In some embodiments, the irradiating is performed until the al receives a dose of between 1.0 Mrad and 6.0 Mrad, e.g., between 1.5 Mrad and 4.0 Mrad, 2 Mrad and 10 Mrad, 5 Mrad and 20 Mrad, 10 Mrad and 30 Mrad, 10 Mrad and 40 Mrad, or 20 Mrad and 50 Mrad.

In some embodiments, the ating is performed at a dose rate of between 5.0 and 1500.0 kilorads/hour, e.g., between 10.0 and 750.0 kilorads/hour or between 50.0 and 350.0 kilorads/hours.

In some embodiments, two or more radiation sources are used, such as two or more ionizing radiations. For example, samples can be treated, in any order, with a beam of electrons, ed by gamma radiation and UV light having wavelengths from about 100 nm to about 280 nm. In some embodiments, samples are treated with three ionizing radiation sources, such as a beam of electrons, gamma radiation, and energetic UV light.

Sonication, Pyrolysis and Oxidation In addition to radiation ent, the feedstock may be treated with any one or more of sonication, pyrolysis and oxidation. These ent ses are described in US. Serial No. 12/417,840 filed April 3, 2009, the disclosure of which is incorporated by reference herein.

Other Processes To Solubiliz_e, Reduce Recalcitrance Or To Functionalize Any of the ses ofthis paragraph can be used alone without any of the processes bed herein, or in combination with any of the processes described herein (in any order): steam explosion, chemical treatment (e.g., acid treatment (including concentrated and dilute acid treatment with mineral acids, such as sulfuric acid, hloric acid and organic acids, such as trifluoroacetic acid), and/or base treatment (e.g., treatment with lime or sodium hydroxide», UV treatment, screw extrusion treatment, solvent treatment (e.g., treatment with ionic liquids) and freeze milling. Some of these processes, for example, are described in US. Series Nos. 12/417,723 filed April 3, 2009; 13/099,151 filed May 2, 2011; and 12/502,629 filed July 14, 2009, the disclosures of which are incorporated herein.

PRODUCTION OF FUELS ACIDS ESTERS AND/OR OTHER PRODUCTS After one or more of the processing steps discussed above have been performed on the biomass, the complex carbohydrates contained in the ose and llulose fractions can be processed into fermentable sugars using a saccharification process, as discussed above.

After the resulting sugar solution has been transported to a manufacturing facility, the sugars can be converted into a y of products, such as alcohols, e.g., ethanol, or organic acids. The product obtained depends upon the microorganism utilized and the conditions under which the bioprocessing occurs. These steps can be performed, for example, utilizing the ng ent of the com-based ethanol manufacturing facility.

The mixing processes and equipment discussed herein may also be used during bioprocessing, if desired. ageously, the mixing systems described herein do not impart high shear to the liquid, and do not significantly raise the l temperature of the . As a result, the microorganisms used in cessing are maintained in a viable condition throughout the process. Mixing may enhance the reaction rate and improve the efficiency of the process. lly, fermentation utilizes various microorganisms. The sugar solution produced by saccharification of lignocellulosic materials will generally n xylose as well as glucose. It may be desirable to remove the xylose, e.g., by chromatography, as some commonly used microorganisms (e.g., yeasts) do not act on xylose. The xylose may be collected and utilized in the manufacture of other products, e.g., animal feeds and the sweetener Xylitol. The xylose may be d prior to or after delivery of the sugar solution to the manufacturing facility where fermentation will be performed.

The microorganism can be a natural microorganism or an engineered microorganism, e.g., any ofthe microorganisms discussed in the als section herein.

The optimum pH for yeast is from about pH 4 to 5, while the optimum pH for Zymomonas is from about pH 5 to 6. Typical fermentation times are about 24 to 96 hours with temperatures in the range of 26 °C to 40 °C, however thermophilic microorganisms prefer higher temperatures.

Carboxylic acid groups lly lower the pH of the fermentation solution, tending to inhibit fermentation with some microorganisms, such Pichia stipitis.

Accordingly, it is in some cases desirable to add base and/or a buffer, before or during fermentation, to bring up the pH of the on. For example, sodium hydroxide or lime can be added to the fermentation medium to elevate the pH of the medium to range that is optimum for the microorganism ed.

Fermentation is generally conducted in an aqueous growth medium, which can n a nitrogen source or other nutrient source, e.g., urea, along with vitamins and trace minerals and metals. It is generally preferable that the growth medium be sterile, or at least have a low microbial load, e.g., ial count. Sterilization of the growth medium may be accomplished in any desired manner. However, in preferred implementations, sterilization is accomplished by irradiating the growth medium or the dual components of the growth medium prior to mixing. The dosage of radiation is generally as low as possible while still obtaining adequate results, in order to minimize energy consumption and resulting cost. For example, in many instances, the growth medium itself or components Of the growth medium can be treated with a radiation dose ofless than 5 Mrad, such as less than 4, 3, 2 or 1 Mrad. In specific instances, the growth medium is treated with a dose of between about 1 and 3 Mrad.

In some embodiments, all or a portion of the fermentation process can be interrupted before the low molecular weight sugar is completely converted to l. The intermediate tation products include high concentrations of sugar and carbohydrates. These intermediate fermentation products can be used in ation of food for human or animal consumption. Additionally or alternatively, the intermediate fermentation products can be ground to a fine particle size in a stainless-steel tory mill to produce a flour-like substance.

Mobile ferrnentors can be utilized, as described in US. Series No. 12/374,549 filed Jan 21, 2009, now Published International Application No. WO 11598.

Similarly, the saccharification equipment can be mobile. Further, saccharification and/or fermentation may be performed in part or entirely during transit.

POST-PROCESSING After fermentation, the resulting fluids can be distilled using, for example, a “beer column” to separate ethanol and other alcohols from the majority of water and residual solids. The vapor exiting the beer column can be, e. g., 35% by weight ethanol and can be fed to a cation column. A e of nearly azeotropic (92.5%) ethanol and water from the rectification column can be purified to pure (99.5%) ethanol using vapor-phase molecular sieves. The beer column s can be sent to the first effect ofa three-effect evaporator. The rectification column reflux condenser can provide heat for this first effect. After the first effect, solids can be separated using a centrifuge and dried in a rotary dryer. A portion (25%) of the centrifuge effluent can be ed to fermentation and the rest sent to the second and third evaporator effects. Most of the evaporator condensate can be returned to the process as fairly clean condensate with a small portion split off to waste water treatment to prevent build-up of low—boiling compounds.

INTERMEDIATES AND PRODUCTS Using the processes described herein, the treated s can be converted to one or more products, such as energy, fuels, foods and materials. Specific examples of products include, but are not limited to, en, sugars (e.g., e, xylose, ose, mannose, galactose, fructose, disaccharides, oligosaccharides and polysaccharides), alcohols (e.g., dric alcohols or dihydric alcohols, such as ethanol, n-propanol, isobutanol, sec-butanol, tert-butanol or n-butanol), hydrated or hydrous alcohols, e.g., containing greater than 10%, 20%, 30% or even greater than 40% water, l, biodiesel, organic acids, hydrocarbons (e.g., methane, ethane, propane, isobutene, pentane, n-hexane, biodiesel, bio-gasoline and mixtures thereof), co- products (e.g., proteins, such as cellulolytic proteins (enzymes) or single cell proteins), and mixtures of any of these in any combination or relative concentration, and optionally in combination with any additives, e.g., fuel additives. Other examples include carboxylic acids, salts ofa carboxylic acid, a mixture of carboxylic acids and salts of carboxylic acids and esters of carboxylic acids (e.g., methyl, ethyl and n-propyl esters), ketones (e.g., acetone), aldehydes (e.g., acetaldehyde), alpha, beta unsaturated acids, such as acrylic acid and olefins, such as ethylene. Other alcohols and l derivatives include propanol, propylene glycol, tanediol, opanedi01, sugar alcohols (e.g., erythritol, glycol, glycerol, sorbitol threitol, arabitol, ribitol, mannitol, dulcitol, fucitol, iditol, isomalt, ol, ol, l and other polyols), methyl or ethyl esters of any of these alcohols. Other products include methyl acrylate, methylmethacrylate, lactic acid, citric acid, formic acid, acetic acid, nic acid, butyric acid, succinic acid, valeric acid, caproic acid, 3-hydroxypropionic acid, palmitic acid, stearic acid, oxalic acid, c acid/glutaric acid, oleic acid, linoleic acid, glycolic acid, oxybutyric acid, and mixture thereof, a salt ofany of these acids, or a mixture of any of the acids and their respective salts. a salt of any ofthe acids and a e of any of the acids and respective salts.

Other intermediates and products, including food and pharmaceutical products, are described in US. Serial No. 12/417,900 filed April 3, 2009, the full disclosure of which is hereby incorporated by reference herein.

OTHER EMBODIMENTS A number of embodiments have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope ofthe disclosure.

In some implementations, the systems discussed herein, or components of these systems, may be portable, e.g., in the manner of the mobile processing equipment described in U.S. Serial No. 12/374,549 filed June 2, 2009 and International Application No. , the full disclosures of which are incorporated herein by reference.

While tanks have been referred to herein, the process may take place in any type of vessel or container, including lagoons, pools, ponds and the like. If the container in which mixing takes place is an in-ground structure such as a lagoon, it may be lined. The ner may be covered, e.g., if it is outdoors, or uncovered.

In an alternate embodiment, the dispersing system 134 can be omitted in the systems shown in FIGS. 2A and 2B, and a pump can be used to draw liquid from the tank and deliver it h outlet pipe 137 to wet the feedstock material, which is then dispersed by the mixing action of the jet mixer 144. In such implementations, the pump would preferably be a low shear pump, e.g., a positive displacement pump such as the progressive cavity pumps available from SEEPEX and lobe pumps from Waukesha. It is also preferred that the pump be capable of pumping high viscosity fluids, since the viscosity of the liquid will increase as more feedstock is added.

While s feedstocks have been described herein, other feedstocks and es of s feedstocks with other feedstocks may be used. For example, some implementations may utilize es of biomass feedstocks with hydrocarboncontaining feedstocks such as those disclosed in U.S. Series No. 13/293,985 filed November 10, 2011, the full disclosure of which is incorporated by reference herein.

Accordingly, other embodiments are within the scope of the ing claims.

Throughout the specification and claims, unless the context requires otherwise, the word “comprise” or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated integer or group of integers but not the ion of any other integer or group of integers.

Claims (16)

WHAT IS CLAIMED IS:

1. A method of processing lignocellulosic material, the method comprising: a. wet milling a reduced recalcitrance lignocellulosic material and 5 applying a jet mixer during wet milling; b. adding an enzyme to the reduced recalcitrance lignocellulosic material after wet milling; and c. adding a microorganism to the reduced recalcitrance lignocellulosic material after wet g has been ted.

2. The method of claim 1 wherein the reduced recalcitrance lignocellulosic al has been exposed to an electron beam.

3. The method of claim 1 or claim 2, wherein the lignocellulosic material 15 is ed from the group ting of wood, particle board, sawdust, agricultural waste, sewage, silage, grasses, rice hulls, bagasse, cotton, jute, hemp, flax, bamboo, sisal, abaca, straw, wheat straw, corn cobs, corn stover, switchgrass, alfalfa, hay, coconut hair, seaweed, algae, and mixtures thereof.

4. The method of any one of claims 1-3 further comprising ying the 20 reduced recalcitrance lignocellulosic material prior to wet milling.

5. The method of any one of claims 1-4, wherein wet milling is performed using a rotor/stator head comprising a rotor and a stator.

6. The method of claim 5 wherein the rotor and stator include nesting 25 rings of teeth.

7. The method of claim 5 or claim 6, wherein the stator ses two or more concentric rings of teeth. 30

8. The method of claim 5 wherein the rotor comprises a ring of teeth configured to fit between adjacent rings of teeth of the stator.

9. The method of claim 5 or claim 6 n the clearance between the rotor and stator is from about 0.25 to 6.4 mm.

10. The method of clai m 5 wherein the spacing between the teeth in each 5 ring of teeth is from about 2.5 to 7.6 mm.

11. The method of claim 5 wherein wet milling is performed using a plurality of rotor/stator heads. 10

12. The method of any one of claims 1-11, wherein wet milling is performed at a shear rate of from about 30,000 sec-1 to 50,000 sec-1.

13. The method of any one of claims 1-12, wherein wet milling is performed in-line.

14. The method of any one of claims 1-13, wherein wet milling is performed in a batch process.

15. The method of any one of claims 1-14, wherein the microorganism 20 converts the reduced recalcitrance lignocellulosic material to a t selected from the group consisting of: an alcohol, an organic acid, a sugar, a hydrocarbon, and a mixture thereof.

16. The method of claim 15 wherein a jet mixer is operated while the 25 microorganism converts the d recalcitrance ellulosic material to the product.