Processes for converting biomass into high-value products
Inventors
Holtzapple, Mark • Lonkar, Sagar • Darvekar, Pratik • Roy, Samarpita • Granda, Cesar • Benefield, Trent • Seidel, Jeremy • Ehlinger, Victoria • Wellington, Scott • Mann, Tyler
Assignees
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Publication Number
US-12553022-B2
Publication Date
2026-02-17
Expiration Date
Abstract
A biomass processing system is disclosed whereby a counter flow path is provided for recovering yielded product from at least two fermentation stages. In certain configurations, the counter flow path is associated with respective extraction stages that correspond to each respective fermentation stages. To enhance product recovery, certain configurations also disclose mechanical grinding of biomass between fermentation stage to enhance a surface area for further subsequent processing of the biomass. To yet further enhance the system, certain configurations discloses a cell recovery sub-system that agitates processed biomass to separate cells from undigested residues. The recovered cells may be recycled to fermentation stages in the system.
Core Innovation
The invention relates to a biomass processing system that converts biomass into a desired product using multiple fermentation stages and associated separation and recovery stages. A first and second fermentation stage each yield a desired product, where the first fermentation stage yields a higher concentration of the desired product than the second fermentation stage. A first separator associated with the first fermentation stage separates a combination of solids and liquids from the first fermentation stage so that liquids are sent to a first extraction stage and solids are sent to the second fermentation stage.
To connect the stages in a countercurrent manner, the system includes a second extraction stage associated with an output of the second fermentation stage, and the second extraction stage has an output that feeds the first fermentation stage. A countercurrent flow path, separate from the output of the second extraction stage that feeds the first fermentation stage, extends from the second extraction stage to the first extraction stage. The second separator associated with the second fermentation stage separates a combination of solids and liquids from the second fermentation stage such that liquids are sent along a first path to the second extraction stage and solids are sent along a second path, separate from the first path, to a third fermentation stage.
In related embodiments, the countercurrent processing is implemented using ion exchange resin beds instead of an extraction stage. A first and second ion exchange resin bed are associated with the first and second fermentation stage, and a countercurrent flow path extends from the second ion exchange resin bed to the first fermentation stage without passing through the first ion exchange resin bed.
Claims Coverage
The independent claims are clm-00001, clm-00007, and clm-00009. Across these claims, the main inventive features comprise countercurrent multi-stage fermentation paired with upstream/downstream extraction or ion exchange, solids/liquids separation with distinct routing paths, and concentration relationships between fermentation stages.
Countercurrent extraction and fermentation stage routing with solids/liquids separation
A biomass processing system with a first and second fermentation stage yielding a desired product with the first fermentation stage yielding a higher concentration than the second; first and second extraction stages associated with outputs of the first and second fermentation stages; the second extraction stage having an output that feeds the first fermentation stage; and a countercurrent flow path extending from the second extraction stage to the first extraction stage, separate from the output that feeds the first fermentation stage, while first and second separators separate solids and liquids to send liquids to extraction and solids to downstream fermentation stages.
Countercurrent ion exchange resin beds between fermentation stages
A biomass processing system with a first and second fermentation stage yielding a desired product with the first fermentation stage yielding a higher concentration than the second; a first ion exchange resin bed associated with the first fermentation stage and a second ion exchange resin bed associated with the second fermentation stage; a countercurrent flow path extending from the second ion exchange resin bed to the first fermentation stage without passing through the first ion exchange resin bed; and first and second separators configured to send liquids to the ion exchange resin beds while routing solids to subsequent fermentation stages.
Countercurrent extraction routing that prevents a specified flow from passing through an earlier extraction stage
A biomass processing system with a first and second fermentation stage yielding a desired product with the first fermentation stage yielding a higher concentration than the second; first and second extraction stages associated with outputs of the first and second fermentation stages; the second extraction stage having a first output feeding the first fermentation stage and a second output with a countercurrent flow path extending from the second extraction stage to the first extraction stage, wherein the flow from the first output does not pass through the first extraction stage; and first and second separators configured to route liquids to extraction stages and solids to downstream fermentation stages.
The independent claims consistently require two fermentation stages with a higher-concentration first stage, paired separation of solids and liquids, and a countercurrent interconnection that routes liquids through extraction or ion exchange in a way that supports downstream-to-upstream flow while independently routing solids to later fermentation stages. Additional optional third stages can extend the countercurrent arrangement.
Stated Advantages
Documented Applications
No documented applications found
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