# US 8,784,513 B2 · Method and apparatus for production of bio-ethanol and other fermentation products > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,784,513 B2 - Document ID: US8784513B2 - Status: Granted - Kind: B2 - Application number: 11/777,558 - Filed: 2008-03-14 - Published: 2008-09-25 - Granted: 2014-07-22 - Earliest claimed: 2006-07-14 - Assignees: Altaca Insaat ve dis Ticaret A.S. - Applicants: Steen Brummerstedt Iversen; Tommy Larsen; Corinne Mallol - Inventors: Steen Brummerstedt Iversen; Tommy Larsen; Corinne Mallol - Web page: https://patentgrep.com/patent/US8784513B2 ## CPC - C12P 7/06: Ethanol, i.e. non-beverage - C12M 21/12: {for producing fuels or solvents (C12M21/04 takes precedence; liquid carbonaceous fuels C10L1/00, solid fuels C10L5/00)} - C12M 43/02: {Bioreactors or fermenters combined with devices for liquid fuel extraction; Biorefineries} - C12P 5/02: acyclic {(C12P5/007 takes precedence)} - Y02E 50/10: Biofuels, e.g. bio-diesel - C12P: FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE {(brewing of beer C12C; producing vinegar C12J; producing specific peptides or proteins C07K; producing enzymes C12N9/00; DNA or RNA concerning genetic engineering, vectors, e.g. plasmids, or their isolation, preparation or purification C12N15/00; measuring or testing processes involving enzymes or microorganisms C12Q; measuring or testing processes involving nucleic acid amplification reactions C12Q1/6844; fermentation processes to form a food composition, A21 or A23; compounds in general, see the relevant compound class, e.g. C01, C07)} - C12M: APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; {APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS} - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION ## Abstract The present invention relates to a method and apparatus for converting organic material into a burnable substance, typically a hydrocarbon fuel, such as ethanol. ## Claims ### Claim 1 A method for converting organic material into a hydrocarbon fuel, the method comprising: (i) conducting a fermentation process that results in the fermentation of an organic material and which fermentation process results in the production of a fermented fluid material comprising a fermentation broth which contains a hydrocarbon fuel: (ii) conducting a separation process whereby the resultant fluid fermented material is separated into a hydrocarbon fuel and a residual product; (iii) conducting a conversion process wherein at least part of the separated residual product is converted into energy, wherein said conversion process is effected in a high pressure fluid comprising a pressure of at least 50 bar, and further wherein said high pressure fluid is selected from water, or alcohols and combinations thereof, and still further wherein said conversion process includes a hydrothermal conversion, solvothermal conversion or both a hydrothermal and solvothermal conversion, and further wherein at least one homogeneous catalyst, or one heterogeneous catalyst or combination thereof is present in said high pressure fluid; and (iv) distributing or recirculating at least some of the energy produced by the conversion process to the fermentation process, comprising directly or indirectly converting sugar(s) contained in the fermentation broth comprising hydrocarbon fuel(s) by the use or addition of one or more microbia. ### Claim 2 (depends on 1) The method of claim 1, wherein the separation process in (ii) comprises separating out a first stream comprising oils and a second stream comprising water soluble organics. ### Claim 3 (depends on 2) The method of claim 2, wherein water soluble salts are separated out in the first stream, in the second stream, or in both the first and second stream. ### Claim 4 (depends on 1) The method of claim 1, wherein the separation process in (ii) comprises filtration. ### Claim 5 (depends on 3) The method of claim 3, wherein the separation process in (ii) comprises filtration. ### Claim 6 (depends on 1) The method according to claim 1, wherein said conversion process that converts the residual material generates thermal energy or heat. ### Claim 7 (depends on 1) The method according to claim 1, wherein the pretreatment steps comprise a liquefaction step, wherein the organic material is liquefied by the addition of enzymes. ### Claim 8 (depends on 1) The method according to claim 1, wherein the pretreatment steps include a saccharification step, wherein the organic material is saccharified by the addition of enzymes. ### Claim 9 (depends on 1) The method according to claim 1, wherein in step (iv) at least 50% of the energy required for said pre-treatment process is supplied by distributing some of the energy produced by the conversion process (iii) to the fermentation process. ### Claim 10 (depends on 1) The method according to claim 1, wherein the fermentation process of step (i) takes place in a fluid. ### Claim 11 (depends on 10) The method according to claim 10, wherein the fluid comprises water. ### Claim 12 (depends on 1) The method according to claim 1, further comprising directly or indirectly converting sugar(s) contained in the fermentation broth comprising hydrocarbon fuel(s) by the use or addition of one or more microbia. ### Claim 13 (depends on 12) The method according to claim 12, wherein said one or more microbia include yeast and bacteria. ### Claim 14 (depends on 12) The method according to claim 12, wherein said one or more microbia include thermolabile bacteria. ### Claim 15 (depends on 1) The method according to claim 1, wherein the fermentation process (i) is effected at a temperature ranging from 24-36 degrees C. for 24-96 hours at a pH of about 4-5. ### Claim 16 (depends on 1) The method according to claim 1, wherein the separation process in (ii) comprises distilling the fermentation broth thereby separating at least a part of the hydrocarbon fuel from the remainder of the fermentation broth (residual product). ### Claim 17 (depends on 16) The method according to claim 16, wherein substantially all of the hydrocarbon fuel present in the fermentation broth is separated from the remainder of the fermentation broth (residual product) by distillation. ### Claim 18 (depends on 1) The method according to claim 1, wherein at least 50% of the energy required for said separation process in step (ii) is supplied by distributing at least some of the energy generated by the conversion process in step (iii) to the fermentation process of step (i). ### Claim 19 (depends on 1) The method according to claim 1, wherein at least 50% of the energy required for said pre-treatment process, fermentation process in step (i), and separation process of step (ii) is supplied by said energy distribution process in step (iv). ### Claim 20 (depends on 1) The method according to claim 1, wherein said conversion process in step (iii) comprises a gasification and/or pyrolysis process. ### Claim 21 (depends on 1) The method according to claim 1, wherein said conversion process in step (iii) comprises a combustion process. ### Claim 22 (depends on 1) The method according to claim 1, wherein said conversion process in step (iii) is conducted in a high pressure fluid at a pressure of least 100 bar. ### Claim 23 (depends on 1) The method according to claim 1, wherein said conversion process in step (iii) is conducted in a high pressure fluid at a pressure of least 150 bar. ### Claim 24 (depends on 1) The method according to claim 1, wherein said conversion process in step (iii) is conducted in a high pressure fluid at a pressure of least 200 bar. ### Claim 25 (depends on 1) The method according to claim 1, wherein said conversion process in step (iii) is conducted in a high pressure fluid at a pressure of least 250 bar. ### Claim 26 (depends on 1) The method according to claim 1, wherein said conversion process is effected by at least one method selected among supercritical water oxidation, wet gasification, or liquefaction or a combination of any of the foregoing methods. ### Claim 27 (depends on 1) The method according to claim 1, wherein said at least one homogeneous catalyst, heterogeneous catalyst, or combination thereof used in the conversion process of step (iii) comprises at least one compound which contains at least one element from group I of the periodic table, or at least one compound which contains at least one element from group IV of the periodic table, or comprises a combination of any of the foregoing. ### Claim 28 (depends on 1) The method according to claim 1, wherein said at least one homogeneous or heterogeneous catalyst or combination thereof is contained in the ash fraction of said substances being fed to said conversion step. ### Claim 29 (depends on 1) The method according to claim 1, wherein the conversion process in step (iii) comprises the following steps: (1) pressurizing said residual product in the fluid to a pressure above 225 bar, (2) heating said residual product in said fluid to a temperature above 200 C in the presence of a homogeneous catalyst comprising a compound which contains at least one element of group IA of the periodic table of elements, and (3) contacting said residual product in said fluid with a heterogeneous catalyst comprising a compound which contains at least one element of group IVB of the periodic table, or alpha-alumina or a combination thereof. ### Claim 30 (depends on 29) The method according to claim 29, further comprising ensuring that said fluid initially has a pH value of above 7. ### Claim 31 (depends on 30) The method according to claim 30, wherein said fluid initially is adjusted to have an initial pH value above 7 prior to the conversion process in step (iii). ### Claim 32 (depends on 29) The method according to claim 29, further comprising the step of maintaining the pH value of said fluid containing said residual product in the range 7-14. ### Claim 33 (depends on 29) The method according to claim 29, further comprising the step of maintaining the pH value of said fluid containing said residual product in the range 7-12. ### Claim 34 (depends on 29) The method according to claim 29, further comprising the step of maintaining the pH value of said fluid containing said residual product in the range 7-10. ### Claim 35 (depends on 29) The method according to claim 29, further comprising the step of maintaining the pH value of said fluid containing said residual product in the range 8-10. ### Claim 36 (depends on 29) The method according to claim 29, further comprising pre-treating the residual product at a pressure of 4-15 bar at the temperature of 100-170 degrees C. for a period of 0.5-2 hours. ### Claim 37 (depends on 29) The method according to claim 29, which further comprises separating the water and water soluble organics in the fluid fermented material from the oil and water soluble salts using a first separation unit, and further wherein the water soluble organics comprise up-concentrated methanol which is re-circulated to the organic material which is pre-treated prior to fermentation step (i). ### Claim 38 (depends on 29) The method according to claim 29, wherein the step (3) of contacting the residual product in the fluid with a heterogeneous catalyst is effected while the temperature is maintained substantially constant. ### Claim 39 (depends on 29) The method according to claim 29, wherein the temperature in the step of contacting ranges from 200-650 degrees C. ### Claim 40 (depends on 29) The method according to claim 29, wherein the temperature in the step of contacting ranges from 200-450 degrees C. ### Claim 41 (depends on 29) The method according to claim 29, wherein the temperature in the step of contacting ranges from 200-374 degrees C. ### Claim 42 (depends on 29) The method according to claim 29, wherein the temperature in the step of contacting ranges from 250-374 degrees C. ### Claim 43 (depends on 29) The method according to claim 29, wherein the temperature in the step of contacting ranges from 275-350 degrees C. ### Claim 44 (depends on 29) The method according to claim 29, wherein the pressure used to effect said conversion ranges from 225-600 bars. ### Claim 45 (depends on 29) The method according to claim 29, wherein the pressure used to effect said conversion ranges from 225-400 bars. ### Claim 46 (depends on 29) The method according to claim 29, wherein the pressure used to effect said conversion ranges from 225-350 bars. ### Claim 47 (depends on 29) The method according to claim 29, wherein the pressure used to effect said conversion ranges from 240-300 bars. ### Claim 48 (depends on 29) The method according to claim 29, wherein said heterogeneous catalyst in step (3) is in the form selected from a suspended particle, tablet, pellet, ring, cylinder, a honey comb structure, or a fibrous structure or a combination of any of the foregoing. ### Claim 49 (depends on 29) The method according to claim 29, further comprising the step of re-circulating carbonates, or hydrogen carbonates or a combination thereof. ### Claim 50 (depends on 29) The method according to claim 29, further comprising the step of re-circulating at least one alcohol. ### Claim 51 (depends on 29) The method according to claim 29, further comprising the step of re-circulating a fluid containing hydrogen. ### Claim 52 (depends on 29) The method according to claim 29, further comprising the step of re-circulating at least one carboxylic acid. ### Claim 53 (depends on 29) The method according to claim 29, further comprising the step of re-circulating at least one aldehyde, or at least one ketone, or a combination of the foregoing. ### Claim 54 (depends on 29) The method according to claim 29, wherein said fluid comprises water and the water concentration is at least 5% by weight of said fluid. ### Claim 55 (depends on 54) The method according to claim 54, wherein the water concentration is at least 10% by weight of said fluid. ### Claim 56 (depends on 54) The method according to claim 54, wherein the water concentration is at least 20% by weight of said fluid. ### Claim 57 (depends on 54) The method according to claim 54, wherein the water concentration is at least 30% by weight of said fluid. ### Claim 58 (depends on 54) The method according to claim 54, wherein the water concentration is at least 40% by weight of said fluid. ### Claim 59 (depends on 29) The method according to claim 29, wherein said residual product is selected from the group consisting of sludge, sewage sludge, liquid manure, corn silage, clarifier sludge, black liquor, residues from fermentation, residues from juice production, residues from edible oil production, residues from fruit and vegetable processing, residues from food and drink production, leachate, and seepage water or a combination thereof. ### Claim 60 (depends on 29) The method according to claim 29, wherein said residual product is selected from lignocelulotic materials which are selected from the group consisting of biomass, straw, grasses, stems, wood, bagasse, wine trash, sawdust, wood chips, and energy crops or a combination thereof. ### Claim 61 (depends on 29) The method according to claim 29, wherein said residual product is a waste material selected from house hold waste, municipal solid waste, paper waste, auto shredder waste, plastics, polymers, rubbers, scrap tires, cable wastes, CCA treated wood, halogenated organic compounds, PCB bearing transformer oils, electrolytic capacitors, halones, medical waste, risk material from meat processing, meat and bone meal, liquid streams, or process or waste water streams containing dissolved and/or suspended residual product. ### Claim 62 (depends on 29) The method according to claim 29, wherein the concentration of said residual product in said fluid is at least 5% by weight. ### Claim 63 (depends on 29) The method according to claim 29, wherein the concentration of said residual product in said fluid is at least 10% by weight. ### Claim 64 (depends on 29) The method according to claim 29, wherein the concentration of said residual product in said fluid is at least 15% by weight. ### Claim 65 (depends on 29) The method according to claim 29, wherein the concentration of said residual product in said fluid is at least 20% by weight. ### Claim 66 (depends on 29) The method according to claim 29, wherein the concentration of said residual product in said fluid is at least 30% by weight. ### Claim 67 (depends on 29) The method according to claim 29, wherein the concentration of said residual product in said fluid is at least 50% by weight. ### Claim 68 A method for converting organic material into a hydrocarbon fuel, the method comprising: (i) conducting a fermentation process that results in the fermentation of an organic material and which fermentation process results in the production of a fermented fluid material comprising a fermentation broth which contains a hydrocarbon fuel: (ii) conducting a separation process whereby the resultant fluid fermented material is separated into a hydrocarbon fuel and a residual product; (iii) conducting a conversion process wherein at least part of the separated residual product is converted into energy, wherein said conversion process is effected in a high pressure fluid comprising a pressure of at least 50 bar, and further wherein said high pressure fluid is selected from water, or alcohols and combinations thereof, and still further wherein said conversion process includes a hydrothermal conversion, solvothermal conversion or both a hydrothermal and solvothermal conversion, and further wherein at least one homogeneous catalyst, or one heterogeneous catalyst or combination thereof is present in said high pressure fluid; and (iv) distributing or recirculating at least some of the energy produced by the conversion process to the fermentation process, wherein the process further includes a pre-treatment process comprising one or more pre-treatment steps and wherein the pretreatment steps comprise a liquefaction step, wherein the organic material is liquefied by the addition of enzymes. ### Claim 69 A method for converting organic material into a hydrocarbon fuel, the method comprising: (i) conducting a fermentation process that results in the fermentation of an organic material and which fermentation process results in the production of a fermented fluid material comprising a fermentation broth which contains a hydrocarbon fuel: (ii) conducting a separation process whereby the resultant fluid fermented material is separated into a hydrocarbon fuel and a residual product; (iii) conducting a conversion process wherein at least part of the separated residual product is converted into energy, wherein said conversion process is effected in a high pressure fluid comprising a pressure of at least 50 bar, and further wherein said high pressure fluid is selected from water, or alcohols and combinations thereof, and still further wherein said conversion process includes a hydrothermal conversion, solvothermal conversion or both a hydrothermal and solvothermal conversion, and further wherein at least one homogeneous catalyst, or one heterogeneous catalyst or combination thereof is present in said high pressure fluid; and (iv) distributing or recirculating at least some of the energy produced by the conversion process to the fermentation process, wherein the process further includes a pre-treatment process comprising one or more pre-treatment steps, and wherein the pretreatment steps include a saccharification step, wherein the organic material is saccharified by the addition of enzymes. ### Claim 70 (depends on 1) The method of claim 1, wherein the hydrocarbon fuel comprises ethanol. ### Claim 71 A method for converting organic material into a hydrocarbon fuel, the method comprising: (i) conducting a fermentation process that results in the fermentation of an organic material and which fermentation process results in the production of a fermented fluid material comprising a fermentation broth which contains a hydrocarbon fuel: (ii) conducting a separation process whereby the resultant fluid fermented material is separated into a hydrocarbon fuel and a residual product; (iii) conducting a conversion process wherein at least part of the separated residual product is converted into energy, wherein said conversion process is effected in a high pressure fluid comprising a pressure of at least 50 bar, and further wherein said high pressure fluid is selected from water, or alcohols and combinations thereof, and still further wherein said conversion process includes a hydrothermal conversion, solvothermal conversion or both a hydrothermal and solvothermal conversion, and further wherein at least one homogeneous catalyst, or one heterogeneous catalyst or combination thereof is present in said high pressure fluid; and (iv) distributing or recirculating at least some of the energy produced by the conversion process to the fermentation process, wherein the fermentation process (i) is effected at a temperature ranging from 24-36 degrees C. for 24-96 hours at a pH of about 4-5.