Abstract: A method for the production of alcohol and other bioproducts hemicelluloses extracted from biomass prior to thermal conversion of the biomass to energy. The process can be integrated with the host plant process to minimize the energy loss from extracting hemicelluloses. Also disclosed is a Stepwise enzymatic break down of cellulose fibers from a pulping operation which is performed with the redeployment of equipment and vessels contained within typical existing pulp and paper manufacturing mills. The preferred feedstock is highly delignified pulp from acid or alkaline pulping process or from bleaching stage.

Abstract: Some variations provide a process for producing cellulosic fructose from biomass, comprising: fractionating a biomass feedstock in the presence of an acid catalyst, a solvent for lignin, and water, to produce a liquor containing cellulose-rich solids, lignin, and dissolved hemicellulose; removing the cellulose-rich solids from the liquor; hydrolyzing the dissolved hemicellulose contained in the liquor, to produce a hydrolyzed liquor comprising hemicellulosic monomers; hydrolyzing the cellulose-rich solids to produce glucose, using cellulase enzymes or an acid or base hydrolysis catalyst; enzymatically isomerizing the glucose to fructose, using glucose isomerase enzymes; and recovering the fructose in purified form or in a fructose-glucose solution. The cellulosic fructose produced by the disclosed processes has many uses.

Abstract: The invention provides a method for purifying a biomass hydrolysate comprising sugars and suspended particles, comprising centrifuging the biomass hydrolysate, thermally treating the centrifuged hydrolysate to chemically or physically agglomerate the suspended particles, and filtering the thermally treated hydrolysate to remove agglomerated suspended particles, thereby generating a purified hydrolysate (sugar syrup). The sequence of steps may be varied. Biomass hydrolysates may be provided from a wide variety of processes. Surprisingly, a 20-fold improvement in sugar purity (total suspended solids content) is demonstrated experimentally, compared to prior methods.

Abstract: A biomass-derived dietary supplement comprising an acetate salt, a hemicellulose-derived sweetener, and cellulose is provided. The formulation may originate from treatment of biomass, by converting acetic acid (from biomass) to an acetate salt and combining it with a hemicellulose-based sweetener such as xylitol and inert, non-digestive cellulose. This is formed into a powder, crystal, pill or capsule to be delivered orally as a dietary supplement. Supplemental minerals and vitamins may be added. A process for producing a biomass-derived dietary supplement is also disclosed.

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

Abstract: In some variations, this invention provides a process for producing fermentable sugars from cellulosic biomass, comprising: extracting biomass with steam or hot water to produce an extract liquor containing hemicellulose oligomers, dissolved lignin, and cellulose-rich solids; separating and washing the cellulose-rich solids; removing a portion of glucan contained in the washed cellulose-rich solids as glucose oligomers using a liquefaction-focused blend of enzymes; co-hydrolyzing glucose oligomers and hemicellulose oligomers, with enzymes or an acid catalyst, to produce glucose and hemicellulose monomers; and recovering the glucose and hemicellulose monomers as fermentable sugars. The liquefaction-focused blend of enzymes contains endoglucanases and exoglucanases. A rotating unit for high-solids enzymatic hydrolysis may be employed, with continuous liquid removal. Optionally, the glucose and the hemicellulose monomers may be recovered as separate streams.

Abstract: What is disclosed is a biorefining process to co-produce xylitol with ethanol or other products. In some variations, a process for producing ethanol and xylitol from lignocellulosic biomass, comprises: extracting hemicelluloses from lignocellulosic biomass, wherein the hemicelluloses include xylose oligomers and other sugar oligomers; hydrolyzing the xylose oligomers and the other sugar oligomers, using an acid catalyst or enzymes, to generate xylose and other sugar monomers, respectively; fermenting the other sugar monomers to ethanol using a suitable ethanol-producing microorganism; removing at least some of the ethanol (to increase concentration of xylose); fermenting the xylose to xylitol using a suitable xylitol-producing microorganism; and recovering the xylitol at high concentration.

Abstract: This invention provides processes to convert biomass into energy-dense biomass for combustion, alone or in combination with another solid fuel. Some embodiments provide processes for producing energy-dense biomass from cellulosic biomass, comprising extracting the feedstock with steam and/or hot water to produce an extract liquor containing hemicellulosic oligomers, dissolved lignin, and cellulose-rich solids; separating the extract liquor, to produce dewatered cellulose-rich solids; hydrolyzing the dewatered cellulose-rich solids, thereby removing a portion of the cellulose, to produce intermediate solids (with higher energy density) and a hydrolysate; drying the intermediate solids to produce energy-dense biomass; and optionally recovering fermentable sugars from the hydrolysate. The energy-dense biomass may be pelletized into biomass pellets, which may have a similar energy density as torrefied pellets from wood.

Abstract: A method is disclosed for the production of alcohol and other bioproducts hemicelluloses extracted from biomass prior to thermal conversion of the biomass to energy. The process can be integrated with the host plant process to minimize the energy loss from extracting hemicelluloses. Also disclosed is a stepwise enzymatic break down of cellulose fibers from a pulping operation which is performed with the redeployment of equipment and vessels contained within typical existing pulp and paper manufacturing mills. The preferred feedstock is highly delignified pulp from acid or alkaline pulping process or from bleaching stage.

Abstract: The disclosure provides a process for producing fluff pulp and ethanol from sugarcane bagasse or straw, comprising: fractionating the feedstock in the presence of an acid catalyst, a solvent for lignin, and water, to generate a solid/liquid slurry comprising cellulose-rich solids, hemicelluloses, and lignin; separating the solid/liquid slurry into a solid stream and a liquid stream; further treating the cellulose-rich solids to produce fluff pulp; hydrolyzing the hemicelluloses to generate hemicellulose monomers; and fermenting at least a portion of the hemicellulose monomers to cellulosic ethanol. Lignin is removed from the process during one or more steps and combusted to provide energy for process requirements. The process is integrated with, and provides energy to, a first-generation process that ferments sugarcane-derived sucrose to first-generation ethanol. Similar processes are possible with energy cane, corn, and other crops.

Abstract: A system or plant and method for the production of pure alcohol, acetic acid or its derivatives from the extract containing hemicelluloses filtered after extraction of woody biomass or directly extracted from woody biomass. The process can be integrated with the host plant process to minimize the effect of loss of heat value from the extracted hemicelluloses and reduce the loading to the effluent plant.

Abstract: The disclosure provides a process for separating fermentation inhibitors from a biomass-derived hydrolysate, comprising: introducing a biomass-derived liquid hydrolysate stream to a stripping column; introducing a steam-rich vapor stream to the stripping column to strip fermentation inhibitors (such as acetic acid) from the liquid hydrolysate stream; recovering a stripped liquid stream and a stripper vapor output stream; compressing the stripper vapor output stream; introducing the compressed vapor stream, and a water-rich liquid stream, to an evaporator; recovering, from the evaporator, an evaporated liquid stream and an evaporator output vapor stream; and recycling the evaporator output vapor stream to the stripping column as the steam-rich vapor stream. Other variations utilize a rectification column to recover a rectified liquid stream and a rectification column vapor stream, and recycle the rectification column vapor stream to the stripping column as the steam-rich vapor stream.

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

Abstract: A process is provided for producing a lignin-coated cellulose material, comprising: pre-extracting a lignocellulosic biomass feedstock in the presence of steam or hot water, depositing lignin from the liquid onto a surface of solids to generate a lignin-coated intermediate material; optionally drying the intermediate material; digesting the lignin-coated intermediate material in the presence of an acid, a solvent for lignin, and water, wherein the rate of delignification of surface lignin is lower than the rate of delignification of bulk lignin; and recovering a hydrophobic lignin-coated cellulose material. In some variations, part of the overall process is a combination of Green Power+® and AVAP® technologies. A cellulose-rich composition is provided, containing about 5 wt % to about 15 wt % total lignin, with particles having a higher average surface concentration of lignin compared to an average bulk (internal) concentration of lignin.

Abstract: A biorefinery process to fractionate lignocellulosic materials into cellulose, hemicelluloses and lignin using a pretreatment with mixture of alcohol, sulfur dioxide and water. Further treatment with enzymes, micro-organisms, and optionally bisulfite ion, are used to convert intermediate products to alcohol and lignin derivatives.

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

Abstract: This invention provides processes and apparatus to convert biomass, including wood and agricultural residues, into low-ash biomass pellets for combustion, alone or in combination with another solid fuel. Some embodiments provide processes for producing low-ash biomass from cellulosic biomass, comprising providing an aqueous extraction solution with acetic acid; extracting the feedstock to produce an extract liquor containing soluble ash, hemicellulosic oligomers, acetic acid, dissolved lignin, and cellulose-rich solids; dewatering and drying the cellulose-rich, lignin-rich solids to produce a low-ash biomass; hydrolyzing the hemicellulosic oligomers to produce hemicellulosic sugars, wherein additional acetic acid is generated; removing a vapor stream comprising vaporized acetic acid from the extract; and recycling the vapor or its condensate to provide some starting acetic acid for the extraction solution. The disclosed processes can produce clean power from biomass.

Abstract: An improved semichemical pulping process is disclosed to reduce washing costs and recovery process costs, while producing equivalent pulp and paper products. In some variations, the invention provides a process for producing a paper product from biomass, comprising: digesting lignocellulosic biomass in the presence of steam and/or hot water to generate an intermediate pulp material and a liquid phase containing extracted hemicelluloses; mechanically refining the intermediate pulp material, to generate a refined pulp material; and introducing the refined pulp material, the liquid phase, and optionally a separate solid material to a paper machine, to produce a paper product. The process optionally employs no washing step. When the liquid phase is washed from the intermediate pulp material or the refined pulp material using an aqueous wash solution, the wash filtrate may be introduced directly or indirectly to the paper machine.

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

Abstract: In some variations, this invention provides a process for producing fermentable sugars from cellulosic biomass, comprising: extracting biomass with steam or hot water to produce an extract liquor containing hemicellulose oligomers, dissolved lignin, and cellulose-rich solids; separating and washing the cellulose-rich solids; removing a portion of glucan contained in the washed cellulose-rich solids as glucose oligomers using a liquefaction-focused blend of enzymes; co-hydrolyzing glucose oligomers and hemicellulose oligomers, with enzymes or chemical catalyst, to produce glucose and hemicellulose monomers; and recovering the glucose and hemicellulose monomers as fermentable sugars. The liquefaction-focused blend of enzymes contains endoglucanases and exoglucanases. Optionally, the glucose and the hemicellulose monomers may be recovered as separate streams.