LIGNOCELLULOSIC BIOMASS FERMENTATION PROCESS SYRUP BINDER AND ADHESIVE

Abstract

Lignocellulosic syrup is produced as a co-product in a lignocellulosic biomass fermentation process, such as one producing ethanol from lignocellulosic biomass. The lignocellulosic syrup may be used as a binder of particulate materials. In addition, the syrup may be used as an adhesive.

Description

This application claims the benefit of U.S. Provisional Applications 61/889061, filed Oct. 10, 2013 and 62/000639, filed May 20, 2014 each of which is incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The invention relates to the field of materials comprising a binder or adhesive. More specifically, syrup that is a co-product of a lignocellulosic biomass fermentation process is effectively used as a binder or adhesive.

BACKGROUND OF THE INVENTION

Binders and adhesives are useful in many applications particularly where materials with desired properties are difficult to handle due to their particulate nature. Substances that have been used as binders, for example with coal fines, include starch and molasses (U.S. Pat. No. 5,009,671), asphaltic binder material (U.S. Pat. No. 823,025), bitumen binders (U.S. Pat. No. 3,966,427), or liquefied biomass (U.S. Pat. No. 5,916,826). Additionally lignosulfonate, a waste liquor of the sulfate pulping process of wood, is used as a binder and adhesive with various materials.

In a cellulosic ethanol process which makes use of lignocellulosic biomass as a carbon source for fermentation, whole stillage from a distillation column (beer column) is typically separated into solids (wetcake or filter cake) and liquid (thin stillage) fractions. The thin stillage is passed through evaporators producing a syrup. The filter cake and syrup are co-products of the cellulosic ethanol process. A syrup with at least about 40% solids may be burned as disclosed in commonly owned US20120102823, thereby providing energy. The filter cake may also be burned to provide energy.

There remains a need for additional materials that can effectively be used as binders and adhesives, and methods of using these materials.

SUMMARY OF THE INVENTION

In one aspect is provided a method for binding a particulate material comprising:

a) providing a lignocellulosic syrup;

b) providing at least one particulate material;

c) contacting the particulate material of (b) with the syrup of (a);

• • wherein the syrup binds the particulate material.

In another aspect is provided a method for adhering two surfaces comprising applying to at least one surface a composition comprising a lignocellulosic syrup and bringing the two surfaces into contact with each other such that the lignocellulsoic syrup is interposed between the two surfaces.

In a further aspect is provided a composition comprising lignocellulosic syrup and at least one additional particulate material,

DETAILED DESCRIPTION

The following definitions and abbreviations are to be used for the interpretation of the claims and the specification.

As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having,” “contains” or “containing,” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a composition, a mixture, process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such composition, mixture, process, method, article, or apparatus.

Further, unless expressly stated to the contrary, “or” refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

The indefinite articles “a” and “an” preceding an element or component of the invention are intended to be nonrestrictive regarding the number of instances (i.e. occurrences) of the element or component. Therefore “a” or “an” should be read to include one or at least one, and the singular word form of the element or component also includes the plural unless the number is obviously meant to be singular.

The term “invention” or “present invention” as used herein is a non-limiting term and is not intended to refer to any single embodiment of the particular invention but encompasses all possible embodiments as described in the specification and the claims.

As used herein, the term “about” modifying the quantity of an ingredient or reactant of the invention employed refers to variation in the numerical quantity that can occur, for example, through typical measuring and liquid handling procedures used for making concentrates or use solutions in the real world; through inadvertent error in these procedures; through differences in the manufacture, source, or purity of the ingredients employed to make the compositions or carry out the methods; and the like. The term “about” also encompasses amounts that differ due to different equilibrium conditions for a composition resulting from a particular initial mixture. Whether or not modified by the term “about”, the claims include equivalents to the quantities. In one embodiment, the term “about” means within 10% of the reported numerical value, preferably within 5% of the reported numerical value.

The term “fermentable sugar” refers to oligosaccharides and monosaccharides that can be used as a carbon source by a microorganism in a fermentation process.

The term “lignocellulosic” refers to a composition comprising both lignin and cellulose. Lignocellulosic material may also comprise hemicellulose.

The term “cellulosic” refers to a composition comprising cellulose and additional components, including hemicellulose.

The term “saccharification” refers to the production of fermentable sugars from polysaccharides.

The term “pretreated biomass” means biomass that has been subjected to pretreatment prior to saccharification. The pretreatment may take the form of physical, thermal or chemical means and combinations thereof.

The term “particulate material” or “particulate matter” means material that is comprised of small discrete particles of solid matter that remains individually dispersed in gas or liquid. Particulate material of the invention is generally comprised of particles of regular or irregular shape. Typical particles have diameter ranging from about 1 to about 10000 microns, although larger particles may be used as well.

The term “butanol” refers to isobutanol, 1-butanol, 2-butanol, or combinations thereof.

The term “lignocellulosic biomass” refers to any lignocellulosic material and includes materials comprising cellulose, hemicellulose, lignin, starch, oligosaccharides and/or monosaccharides. Biomass may also comprise additional components, such as protein and/or lipid. Biomass may be derived from a single source, or biomass can comprise a mixture derived from more than one source; for example, biomass could comprise a mixture of corn cobs and corn stover, or a mixture of grass and leaves. Lignocellulosic biomass includes, but is not limited to, bioenergy crops, agricultural residues, municipal solid waste, industrial solid waste, sludge from paper manufacture, yard waste, wood and forestry waste. Examples of biomass include, but are not limited to, corn cobs, crop residues such as corn husks, corn stover, grasses (including Miscanthus), wheat straw, barley straw, hay, rice straw, switchgrass, waste paper, sugar cane bagasse, sorghum plant material, soybean plant material, components obtained from milling of grains or from using grains in production processes (such as DDGS: dried distillers grains with solubles), woody material such as trees, branches, roots, wood chips, sawdust, shrubs and bushes, leaves, vegetables, fruits, flowers, empty palm fruit bunch, and energy cane.

The term “energy cane” refers to sugar cane that is bred for use in energy production. It is selected for a higher percentage of fiber than sugar.

The term “lignocellulosic biomass hydrolysate” refers to the product resulting from saccharification of lignocellulosic biomass. The biomass may also be pretreated or pre-processed prior to saccharification.

The term “lignocellulosic biomass hydrolysate fermentation broth” is broth containing product resulting from biocatalyst growth and production in a medium comprising lignocellulosic biomass hydrolysate. This broth includes components of lignocellulosic biomass hydrolysate that are not consumed by the biocatalyst, as well as the biocatalyst itself and product made by the biocatalyst.

The term “slurry” refers to a mixture of insoluble material and a liquid. A slurry may also contain a high level of dissolved solids. Examples of slurries include a saccharification broth, a fermentation broth, and a stillage.

The term “whole stillage” refers to the bottoms of a distillation. The whole stillage contains the high boilers and any solids of a distillation feed stream. Whole stillage is a type of depleted broth.

The term “thin stillage” refers to a liquid fraction resulting from solid/liquid separation of a whole stillage, fermentation broth, or product depleted fermentation broth.

The term “syrup” or “lignocellulosic syrup” will be used interchangeably and means a concentrated product produced from the removal of water, generally by evaporation, from thin stillage.

The term “target product” refers to any product that is produced by a microbial production host cell in a fermentation. Target products may be the result of genetically engineered enzymatic pathways in host cells or may be produced by endogenous pathways. Typical target products include but are not limited to acids, alcohols, alkanes, alkenes, aromatics, aldehydes, ketones, biopolymers, proteins, peptides, amino acids, vitamins, antibiotics, and pharmaceuticals.

The term “fermentation” refers broadly to the use of a biocatalyst to produce a target product. Typically the biocatalyst grows in a fermentation broth utilizing a carbon source in the broth, and through its metabolism produces a target product.

“Solids” refers to soluble solids and insoluble solids. Solids from a lignocellulosic fermentation process contain residue from the lignocellulosic biomass used to make hydrolysate medium.

“Volatiles” refers herein to components that will largely be vaporized in a process where heat is introduced. Volatile content is measured herein by establishing the loss in weight resulting from heating under rigidly controlled conditions to 950° C. (as in ASTM D-3175). Typical volatiles include, but are not limited to, hydrogen, oxygen, nitrogen, acetic acid, and some carbon and sulfur.

“Fixed carbon” refers herein to a calculated percentage made by summing the percent of moisture, percent of ash, and percent of volatile matter, and then subtracting that percent from 100.

“Ash” is the weight of the residue remaining after burning under controlled conditions according to ASTM D-3174.

“Sugars” as referred to in the lignocellulosic syrup composition means a total of monosaccharide and soluble oligosaccharides.

Production and Composition of Liqnocellulosic Syrup

The present lignocellulosic syrup is produced as a co-product from a process that uses lignocelulosic biomass as a source of fermentable sugars which are used as a carbon source for a biocatalyst. The biocatalyst uses the sugars in a fermentation process to produce a target product.

To produce fermentable sugars from lignocellulosic biomass, the biomass is treated to release sugars such as glucose, xylose, and arabinose from the polysaccharides of the biomass. Lignocellulosic biomass may be treated by any method known by one skilled in the art to produce fermentable sugars in a hydrolysate. Typically the biomass is pretreated using physical, thermal and/or chemical treatments, and saccharified enzymatically. Thermo-chemical pretreatment methods include steam explosion or methods of swelling the biomass to release sugars (see for example WO2010113129; WO2010113130). Chemical saccharification may also be used. Physical treatments for pre-processing the biomass include, but are not limited to, grinding, milling, and cutting. Physical treatments such as these may be used for particle size reduction prior to further chemical treatment. Chemical treatments include base treatment such as with strong base (ammonia or NaOH), or acid treatment (U.S. Pat. No. 8,545,633; WO2012103220). In one embodiment the biomass is treated with ammonia (U.S. Pat. No. 7,932,063; U.S. Pat. No. 7,781,191; U.S. Pat. No. 7,998,713; U.S. Pat. No. 7,915,017). These treatments release polymeric sugars from the biomass. Particularly useful is a low ammonia pretreatment where biomass is contacted with an aqueous solution comprising ammonia to form a biomass-aqueous ammonia mixture where the ammonia concentration is sufficient to maintain alkaline pH of the biomass-aqueous ammonia mixture but is less than about 12 weight percent relative to dry weight of biomass, and where dry weight of biomass is at least about 15 weight percent solids relative to the weight of the biomass-aqueous ammonia mixture, as disclosed in U.S. Pat. No. 7,932,063, which is herein incorporated by reference.

Saccharification, which converts polymeric sugars to monomeric sugars, may be either by enzymatic or chemical treatments. In one aspect, the pretreated biomass is contacted with a saccharification enzyme consortium under suitable conditions to produce fermentable sugars. Prior to saccharification, the pretreated biomass may be brought to the desired moisture content and treated to alter the pH, composition or temperature such that the enzymes of the saccharification enzyme consortium will be active. The pH may be altered through the addition of acids in solid or liquid form. Alternatively, carbon dioxide (CO₂), which may be recovered from fermentation, may be utilized to lower the pH. For example, CO₂ may be collected from a fermenter and fed into the pretreatment product headspace in the flash tank or bubbled through the pretreated biomass if adequate liquid is present while monitoring the pH, until the desired pH is achieved. The temperature is brought to a temperature that is compatible with saccharification enzyme activity, as noted below. Typically suitable conditions may include temperature between about 40° C. and 50° C. and pH between about 4.8 and 5.8.

Enzymatic saccharification of cellulosic or lignocellulosic biomass typically makes use of an enzyme composition or blend to break down cellulose and/or hemicellulose and to produce a hydrolysate containing sugars such as, for example, glucose, xylose, and arabinose. Saccharification enzymes are reviewed in Lynd, L. R., et al. (Microbiol. Mol. Biol. Rev., 66:506-577, 2002). At least one enzyme is used, and typically a saccharification enzyme blend is used that includes one or more glycosidases. Glycosidases hydrolyze the ether linkages of di-, oligo-, and polysaccharides and are found in the enzyme classification EC 3.2.1.x (Enzyme Nomenclature 1992, Academic Press, San Diego, Calif. with Supplement 1 (1993), Supplement 2 (1994), Supplement 3 (1995, Supplement 4 (1997) and Supplement 5 [in Eur. J. Biochem., 223:1-5, 1994; Eur. J. Biochem., 232:1-6, 1995; Eur. J. Biochem., 237:1-5, 1996; Eur. J. Biochem., 250:1-6, 1997; and Eur. J. Biochem., 264:610-650 1999, respectively]) of the general group “hydrolases” (EC 3.). Glycosidases useful in saccharification can be categorized by the biomass components they hydrolyze. Glycosidases useful in saccharification may include cellulose-hydrolyzing glycosidases (for example, cellulases, endoglucanases, exoglucanases, cellobiohydrolases, β-glucosidases), hemicellulose-hydrolyzing glycosidases (for example, xylanases, endoxylanases, exoxylanases, β-xylosidases, arabino-xylanases, mannases, galactases, pectinases, glucuronidases), and starch-hydrolyzing glycosidases (for example, amylases, α-amylases, β-amylases, glucoamylases, α-glucosidases, isoamylases). In addition, it may be useful to add other activities to the saccharification enzyme consortium such as peptidases (EC 3.4.x.y), lipases (EC 3.1.1.x and 3.1.4.x), ligninases (EC 1.11.1.x), or feruloyl esterases (EC 3.1.1.73) to promote the release of polysaccharides from other components of the biomass. It is known in the art that microorganisms that produce polysaccharide-hydrolyzing enzymes often exhibit an activity, such as a capacity to degrade cellulose, which is catalyzed by several enzymes or a group of enzymes having different substrate specificities. Thus, a “cellulase” from a microorganism may comprise a group of enzymes, one or more or all of which may contribute to the cellulose-degrading activity. Commercial or non-commercial enzyme preparations, such as cellulase, may comprise numerous enzymes depending on the purification scheme utilized to obtain the enzyme. Many glycosyl hydrolase enzymes and compositions thereof that are useful for saccharification are disclosed in WO 2011/038019. Additional enzymes for saccharification include, for example, glycosyl hydrolases that hydrolyze the glycosidic bond between two or more carbohydrates, or between a carbohydrate and a noncarbohydrate moiety.

Saccharification enzymes may be obtained commercially. Such enzymes include, for example, Spezyme® CP cellulase, Multifect® xylanase, Accelerase® 1500, Accellerase® DUET, and Accellerase® Trio™ (Dupont™/Genencor®, Wilmington, Del.), and Novozyme-188 (Novozymes, 2880 Bagsvaerd, Denmark). In addition, saccharification enzymes may be unpurified and provided as a cell extract or a whole cell preparation. The enzymes may be produced using recombinant microorganisms that have been engineered to express one or more saccharifying enzymes. For example, an H3A protein preparation that may be used for saccharification of pretreated cellulosic biomass is an unpurified preparation of enzymes produced by a genetically engineered strain of Trichoderma reesei, which includes a combination of cellulases and hemicellulases and is described in WO 2011/038019, which is incorporated herein by reference.

Chemical saccharification treatments may be used and are known to one skilled in the art, such as treatment with mineral acids including HCl and H₂SO₄ (U.S. Pat. No. 5,580,389; WO2011002660).

Sugars such as glucose, xylose and arabinose are released by saccharification of lignocellulosic biomass and these monomeric sugars provide a carbohydrate source for a biocatalyst used in a fermentation process. The sugars are present in a biomass hydrolysate that is used as fermentation medium. The fermentation medium may be composed solely of hydrolysate, or may include components additional to the hydrolysate such as sorbitol or mannitol at a final concentration of about 5 mM as described in U.S. Pat. No. 7,629,156, which is incorporated herein by reference. The biomass hydrolysate typically makes up at least about 50% of the fermentation medium. Typically about 10% of the final volume of fermentation broth is seed inoculum containing the biocatalyst.

The medium comprising hydrolysate is fermented in a fermenter, which is any vessel that holds the hydrolysate fermentation medium and at least one biocatalyst, and has valves, vents, and/or ports used in managing the fermentation process.

Any biocatalyst that produces a target product utilizing glucose and preferably also xylose, either naturally or through genetic engineering, may be used for fermentation of the fermentable sugars in the biomass hydrolysate made from lignocellulosic biomass. Target products that may be produced by fermentation include, for example, acids, alcohols, alkanes, alkenes, aromatics, aldehydes, ketones, biopolymers, proteins, peptides, amino acids, vitamins, antibiotics, and pharmaceuticals. Alcohols include, but are not limited to methanol, ethanol, propanol, isopropanol, butanol, ethylene glycol, propanediol, butanediol, glycerol, erythritol, xylitol, mannitol, and sorbitol. Acids may include acetic acid, formic acid, lactic acid, propionic acid, 3-hydroxypropionic acid, butyric acid, gluconic acid, itaconic acid, citric acid, succinic acid, 3-hydroxyproprionic acid, fumaric acid, maleic acid, and levulinic acid. Amino acids may include glutamic acid, aspartic acid, methionine, lysine, glycine, arginine, threonine, phenylalanine and tyrosine. Additional target products include methane, ethylene, acetone and industrial enzymes.

The fermentation of sugars in biomass hydrolysate to target products may be carried out by one or more appropriate biocatalysts, that are able to grow in medium containing biomass hydrolysate, in single or multistep fermentations. Biocatalysts may be microorganisms selected from bacteria, filamentous fungi and yeast. Biocatalysts may be wild type microorganisms or recombinant microorganisms, and may include, for example, organisms belonging to the genera of Escherichia, Zymomonas, Saccharomyces, Candida, Pichia, Streptomyces, Bacillus, Lactobacillus, and Clostridiuma. Typical examples of biocatalysts include recombinant Escherichia coli, Zymomonas mobilis, Bacillus stearothermophilus, Saccharomyces cerevisiae, Clostridia thermocellum, Thermoanaerobacterium saccharolyticum, and Pichia stipitis. To grow well and have high product production in a lignocellulosic biomass hydrolysate fermentation broth, a biocatalyst may be selected or engineered to have higher tolerance to inhibitors present in biomass hydrolysate such as acetate. For example, the biocatalyst may produce ethanol as a target product, such as production of ethanol by Zymomonas mobilis as described in U.S. Pat. No. 8,247,208, which is incorporated herein by reference.

Fermentation is carried out with conditions appropriate for the particular biocatalyst used. Adjustments may be made for conditions such as pH, temperature, oxygen content, and mixing. Conditions for fermentation of yeast and bacterial biocatalysts are well known in the art.

In addition, saccharification and fermentation may occur at the same time in the same vessel, called simultaneous saccharification and fermentation (SSF). In addition, partial saccharification may occur prior to a period of concurrent saccharification and fermentation in a process called HSF (hybrid saccharification and fermentation).

For large scale fermentations, typically a smaller culture of the biocatalyst is first grown, which is called a seed culture. The seed culture is added to the fermentation medium as an inoculum typically in the range from about 2% to about 20% of the final volume.

Typically fermentation by the biocatalyst produces a fermentation broth containing the target product made by the biocatalyst. For example, in an ethanol process the fermentation broth may be a beer containing from about 6% to about 10% ethanol. In addition to target product, the fermentation broth contains water, solutes, and solids from the hydrolysate medium and from biocatalyst metabolism of sugars in the hydrolysate medium. Typically the target product is isolated from the fermentation broth producing a depleted broth, which may be called whole stillage. For example, when ethanol is the product, the broth is distilled, typically using a beer column, to generate an ethanol product stream and a whole stillage. Distillation may be using any conditions known to one skilled in the art including at atmospheric or reduced pressure. The distilled ethanol is further passed through a rectification column and molecular sieve to recover an ethanol product. The target product may alternatively be removed in a later step such as from a solid or liquid fraction after separation of fermentation broth.

The syrup co-product of a lignocellulosic biomass fermentation process is produced from the fermentation broth or depleted fermentation broth. An example of syrup production is disclosed in commonly owned US20120102823, which is incorporated herein by reference. The broth or depleted broth, such as whole stillage, is separated into solid and liquid streams, where the liquid stream is called thin stillage. Various filtration devices may be used such as a belt filter, belt press, screw press, drum filter, disc filter, Nutsche filter, filter press or filtering centrifuge. Filtration may be aided such as by application of vacuum, pressure, or centrifugal force. To improve efficiency of filtration, a heat treatment may be used as disclosed in commonly owned and co-pending US20120178976, which is incorporated herein by reference.

Following liquid/solid separation of a lignocellulosic biomass hydrolysate fermentation broth or depleted broth, the solids fraction, or filter cake (also called wetcake), may be burned to supply energy to the production process. The filter cake may be dried prior to burning, such as by air drying, to reduce moisture.

A product stream may be removed following liquid/solid filtration of a lignocellulosic biomass hydrolysate fermentation broth. For example, the liquid stream may be extracted or distilled to generate a product stream, such as distillation to produce an ethanol product stream and a remaining liquid.

The liquid fraction is further purified by evaporation producing water that may be recycled and a syrup. Prior to evaporation, a portion of the liquid fraction may be recycled for use as back set, which may be added at any point in the process where water is needed, such as in pretreatment, saccharification, or biocatalyst seed production. Evaporation may be in any evaporation system, such as falling film, rising film, forced circulation, plate or mechanical and thermal vapor recompression systems. Evaporation may be continuous or batch and may use a multi-effect evaporator. The evaporated water may be recycled in the overall lignocellulosic biomass hydrolysate fermentation process.

The remaining material after evaporation is a syrup which is the present lignocellulosic syrup. The lignocellulosic syrup composition contains from about 40% to about 70% solids or from about 40% to about 60% solids (may have about 40%, 45%, 50%, 55%, 60%, 65%, or 70% solids), from about 10 g/l to 30 g/l of acetamide, at least about 40 g/l of sugars, a density of about 1 to about 2 g/cm³, and viscosity less than 500 SSU at 100° F. (38° C.). “SSU” is Saybolt Universal Viscosity in Seconds (Burger V L., Encycl. Ind. Chem. Anal. (1966), Volume 3, 768-74. The extent of evaporation may be modulated to achieve the desired solids content. When the pretreatment process used to prepare the biomass for saccharification is a process that uses ammonia, the lignocellulosic syrup contains at least about 5 g/l of ammonia.

Lignocellulosic Syrup as Binder

In the present method the present lignocellulosic syrup contacts at least one particulate material wherein the syrup binds the particulate material. The particulate material may be of a single substance, or it may include multiple substances. In one embodiment the lignocellulosic syrup is mixed with the particulate material. The material may include any material that is particulate, such as being powdery, dusty, or granular. In one embodiment the particulate material is not a burnable material or a soil conditioner.

The lignocellulosic syrup is mixed with the particulate material in any amount wherein the syrup acts as a binder of the particulate material. In various embodiments the syrup is between about 0.1% and about 20% by weight of the final combination of syrup particulate material. The syrup may be about 0.1%, 0.5%, 1%, 2%, 4%, 6%, 8%, 10%, 12%, 14%, 16%, 18%, or 20% of the total combined weight. In various embodiments the syrup is between about 0.1% and 20%, 0.5% and 20%, 0.5% and 10%, 0.5% and 5%, 2% and 20%, or 2% and 10% of the final composition of syrup and particulate material.

In various embodiments the particulate material is carbon black powder, fly ash, or animal feed ingredients. Carbon black is a powdery form of carbon that is typically produced by incomplete combustion of heavy petroleum products such various types of tar. It is a paracrystalline carbon with a high surface area to volume ratio. Carbon black is used as a reinforcing filler and colorant in tires and other rubber products, as well as a color pigment in plastics, paints, toners, inks, and leather, and an insulating material in electrical equipment. Binding of carbon black with lignocellulosic syrup produces a composition that is more readily handled and transported. This composition may be used in production of tires, as well as in the other applications listed above.

Fly ash is a byproduct from burning pulverized coal in electric power generating plants. It is composed of mineral impurities in the coal such as clay, feldspar, quartz and shale, that fuse during combustion. This material is present in exhaust gas. It cools and solidifies, and is collected by electrostatic precipitators or bag filters. Fly ash has cementitious properties and is used as an additive in cement. Binding of fly ash with lignocellulosic syrup produces a composition that is more readily handled and transported. This composition may be used in cement for making concrete

Feed pellets are compositions of animal feed components and a binder that holds the components together. Feed components may include such ingredients as grains, soy, milling byproducts, added vitamins, minerals, fats/oils. Grains and other components are typically hammermilled to a particulate form for use in feed pellets. Binding of animal feed components with lignocellulosic syrup produces a composition that is more readily handled and transported.

The mixture of lignocellulosic syrup and particulate material may be processed to form a conveniently handled solid material. Processing may include treatments such as heating, compressing, extruding, pelleting, molding, and/or drying. Various shapes may be formed such as briquettes, pellets, irregular shapes, and the like. For example, the mixture may be passed through an extruder at an elevated temperature, then a pelletizer, then dried, forming hardened fuel pellets. Any type of extruder that pushes or draws semisoft solids through a die may be used, as known to one of skill in the art. Extrusion may be performed at elevated temperature and/or elevated pressure. A pelletizer may be used to reduce volume and increase density of the lignocellulosic syrup and particulate material composition, either alone or combined with extrusion, and to form the material into pellets. Briquettes may be formed using a screw press or other compression apparatus. Following forming, the composition may be allowed to dry forming a solid lignocellulosic syrup composition. The moisture may be less than about 30%, 25%, 20%, 15%, 10%, or less, depending on the starting materials and the process used to produce the present solid composition.

In one embodiment the lignocellulosic syrup applied to contact the particulate material. The material may include any material that is particulate, such as being powdery, dusty, or granular. In one embodiment the particulate material is not a burnable material or a soil conditioner. In one embodiment the lignocellulosic syrup is applied to particulate material that covers a surface such as a path, dirt road, nursery, orchard, feed lots, or construction area which is not paved. Lignocellulosic syrup may be applied to any dusty surface, such that the syrup is used to control dust. A surface for lignocellulosic syrup application may first be graded and optionally wetted prior to contact with the syrup. The syrup may be mixed with soil or other spreadable material prior to application. The syrup is typically applied at a rate of 0.3-0.5 gallons per square yard. The syrup functions to bind the road surface particles together, and as water evaporates the dust particles remain aggolmerated minimizing issues that result from dusting.

Lignocellulosic Syrup as Adhesive

In various embodiments, lignocellulosic syrup may be used as an adhesive, or as a component of an adhesive. The syrup may be a partial replacement for phenol in a phenol-formaldehyde adhesive. A lignocellulosic syrup containing adhesive may be used in a dry, moist, or liquid form. A lignocellulosic syrup containing adhesive may be a plasticizer. Lignocellulosic syrup adhesives may be used in applications such as in particleboard, plywood, spot-glueing palletized bags together to keep them from shifting during storage, handling and shipping, linoleum cements, re-wettable gum tapes and palletized containers.

Claims

1. A method for binding a particulate material comprising:

a) providing a lignocellulosic syrup;

b) providing at least one particulate material contacting the particulate material of (b) with the syrup of (a);

wherein the syrup binds the particulate material.

2. The method of claim 1 wherein the contacting of (c) is mixing the syrup of (a) with the particulate material of (b).

3. The method of claim 2 wherein the particulate material is selected from the group consisting of animal feed ingredients, carbon black, and fly ash.

4. The method of claim 1 wherein the contacting of (c) is applying the syrup of (a) to the particulate material of (b).

5. The method of claim 4 wherein the particulate material of (b) covers a path, road, nursery, orchard, or construction area.

6. A method for adhering two surfaces comprising: a) applying to at least one surface a composition comprising a lignocellulosic syrup; and b) bringing the two surfaces into contact with each other such that the lignocellulosic syrup is interposed between the two surfaces.

7. The method of claim 6 wherein the composition is selected from cement, and rewettable gum tape.

8. The method of claim 1 or 6 wherein the lignocellulosic syrup is a co-product of a process for the production of alcohol from a lignocellulosic biomass.

9. The method of claim 8 wherein the lignocellulosic biomass is selected from the group consisting of corn cobs, corn stover, grasses, wheat straw, barley straw, hay, rice straw, switchgrass, waste paper, sugar cane bagasse, sorghum plant material, soybean plant material, woody plants, vegetables, fruits, and flowers.

10. The method of claim 1 or 6 wherein the lignocellulosic syrup is a co-product of a process that employs ammonia for the pretreatment of a lignocellulosic biomass.

11. The method of claim 10 wherein the lignocellulosic syrup comprises:

a) from about 40% to about 70% solids;

b) from about 10 g/l to about 30 g/l of acetamide; and

c) at least about 40 g/l of sugars;

wherein the cellulosic syrup has a density of about 1 to about 2 g/cm3 and a viscosity of less than 500 SSU at 100° F. (38° C.).

12. A composition comprising lignocellulosic syrup and at least one additional particulate material.

13. The composition of claim 12 wherein the lignocellulosic syrup is a co-product of a process for the production of alcohol from a lignocellulosic biomass.

14. The composition of claim 13 wherein the lignocellulosic biomass is selected from the group consisting of corn cobs, corn stover, grasses, wheat straw, barley straw, hay, rice straw, switchgrass, waste paper, sugar cane bagasse, sorghum plant material, soybean plant material, woody plants, vegetables, fruits, flowers, empty palm fruit bunch, and energy cane.

15. The composition of claim 12 wherein the lignocellulosic syrup is a co-product of a process that employs ammonia for the pretreatment of a lignocellulosic biomass.

16. The composition of claim 15 wherein the syrup comprises:

a) from about 40% to about 70% solids;

b) from about 10 g/l to about 30 g/l of acetamide; and

c) at least about 40 g/l of sugars;

wherein the cellulosic syrup has a density of about 1 to about 2 g/cm3 and a viscosity of less than 500 SSU at 100 ° F. (38° C.).