TH96776A - Two-container reactor system And methods for hydrolysis And digesting wood chips with chemically enhanced washing methods - Google Patents

Abstract

The DC60 reactor system consists of: a primary reactor containing the hydrolysate and an extraction barrier. The first section, located above the extraction barrier, is maintained at conditions that aid the hydrolysis reaction in the cellulose material. The second section, located below the extraction barrier, is where hydrolysis is effectively stopped. A flushing fluid inlet is located below the extraction barrier, providing flushing fluid at a temperature below the hydrolysis temperature; a transport pipe with an inlet matched to the material discharge section of the primary reactor and an outlet matched to the secondary reactor; and a secondary reactor including a fluid discharge section that extracts a portion of the liquid from the secondary reactor and directs it to the primary reactor or to the transport pipe. The transport pipe has an inlet matched to the material discharge section of the first reactor vessel and an outlet matched to the second reactor vessel. The second reactor vessel includes a liquid discharge section that extracts a portion of the liquid from the second reactor vessel and directs it to the first reactor vessel or to the transport pipe.

Claims (56)

Revised 10/09/2015 1. Process system for cellulose material conversion. The system consists of: a first pressurized reactor vessel (10) operating at a pressure higher than atmospheric pressure; the first reactor vessel (10) includes: a material inlet that receives the cellulose material and a material outlet (56) for the material, where the cellulose material flows from the material inlet to the material outlet (56); a thermal energy inlet in the upper part of the first reactor vessel (10); an extraction baffle (48) with outlets for extracting hydrolysates and liquids from the first reactor vessel (10); the first section of the first reactor vessel (10) between the material inlet and the liquid extraction baffle (48), where the first section is maintained at the hydrolysis temperature of the cellulose material; a flushing liquid inlet (52) to the first pressurized reactor vessel (10) and below the extraction baffle (48), where the flushing liquid inlet (52) is connected to a flushing liquid source including 1. A process system as in claim 1 where the inlet of the washing fluid (50) is at the bottom of the second section of the first reactor vessel (10) between the extraction partition (48) and the waste section (56), where the temperature is below the hydrolysis temperature and the hydrolysis reactor is literally stopped, a transport pipe (62) providing a flow pipe from the waste section (56) to the second reactor vessel (12), which is the continuous digestion vessel, and the continuous digestion vessel (12) which receives the cellulose material discarded from the first reactor vessel (10). 2. A process system as in claim 1 where the inlet of the washing fluid (52) is at the bottom of the second section of the first reactor vessel (10). 3. A process system as in claim 1 or 2 where the volume of sodium hydroxide and the sulfur-free white fluid is literally in the washing fluid. 4. A process system as in one of the preceding claims in which the first reactor (10) is literally vertical at a height of at least 100 ft, the inlet is in the upper part of the vessel and the discharge (56) is near the lower part of the vessel (10). 5. A process system as in one of the preceding claims in which the heated inlet is positioned and constructed to receive steam (72) at a pressure greater than atmospheric pressure. 6. A process system as in one of the preceding claims which also includes a temporary tank (30) that receives the liquid extracted from the extraction baffle (48) and provides steam to the first reactor (10) at or above the first vessel and is intended to be discharged. 7. A process system as in claim 6 in which a temporary tank (30) contains a liquid disposal section which provides liquid for the scraping section of the system. 8. A process system as in one of the preceding claims in which a second reactor (12) includes a liquid disposal section which extracts a portion of the liquid from the second reactor (12) and directs that portion of the liquid to at least one of the lower inlet sections of the first reactor (10) or to a transport pipe (62). 9. A process system as in claim 8 which also includes an upper separation section (57) in the second reactor (12) and the extracted portion of the liquid is extracted from the upper separation section (57). 10. A process system as in one of the preceding claims. It also includes a pH monitor (78) that monitors the pH level of the viscous cellulose material in the transport tube (62). 11. The method for performing the hydrolysis of the cellulose material is included: feeding the cellulose material into the upper intake section of the first reactor vessel (10), where the material moves down through the vessel (10); hydrolysis of the cellulose material in the upper section of the first reactor vessel (10) by adding pressure and heat to the vessel (10) and by keeping the cellulose material above the hydrolysis temperature; extraction of the hydrolysate from the cellulose material through the extraction baffle (48) under the upper section of the first reactor vessel (10); cooling the cellulose material under the extraction baffle (48) to a temperature below the hydrolysis temperature by adding the rinsing fluid under the extraction baffle (48), where the rinsing fluid 11. The method of claim 11 in which the amount of sodium hydroxide and white liquid is not more than five percent by volume of water in the washing fluid and/or is in the range of 0.01 percent to 5 percent of the volume of cellulose material flowing through the first reactor vessel (10). 12. The method of claim 11 in which the amount of sodium hydroxide and white liquid is not more than five percent by volume of water in the washing fluid and/or is in the range of 0.01 percent to 5 percent of the volume of cellulose material flowing through the first reactor vessel (10). 13. The method as in claim 11 or 12 in which the washing fluid is 10°C to 70°C cooler than the hydrolysis temperature. 14. The method as in any one of claims 11 through 13 in which the washing fluid flows. 15. A method as in any of the claims 11 through 14 in which the washing fluid has a pH of 3 to 7, of which 3 to 4 is desirable. 16. A method as in any of the claims 11 through 15 in which the cellulose material in the lower part of the first reactor vessel (10) is maintained at a temperature of at least ten degrees Celsius below the hydrolysis temperature, of which 10°C to 70°C is desirable, cooler than the hydrolysis temperature. 17. A method as in any of the claims 11 through 16 in which the hydrolysis temperature is at least 170°C, of which 150°C to 175°C is desirable. 18. A method as in any of the claims 11 through 17 in which the hydrolysis step This occurs while the cellulose material is at a pH in the range of 1 to 6. 19. A method as in any of the claims 11 through 18, which also includes the addition of steam (72) into the first reactor vessel (10) to increase the pressure of the vessel and to add heat energy to the vessel. 20. A method as in any of the claims 11 through 19, which also includes the supply of the discarded cellulose material from the outlet (56) of the first reactor vessel (10) to the inlet of the second reactor vessel (12) and the supply of the heating fluid to the top of the second reactor vessel (12) to digest the cellulose material to produce the substance. 21. A method of claim 20, which also includes the extraction of the fluid from the vessel. Second reactor (12) and supply of extracted fluid to the bottom of the first reactor vessel (10). 22. The method of claim 21, which also includes the measurement of the pH of the extracted fluid and the addition of a rinsing fluid flow to the bottom of the first reactor vessel if the measured pH is greater than the previously measured pH level. -------------------------------------------------------------------------------------- 1. The reactor vessel system consists of: the first reactor vessel, with a material inlet section to receive cellulose material and a material discharge section for cellulose material, where cellulose material flows through the first reactor vessel from the inlet section to the discharge section; the hydrolysate and liquid extraction barrier in the first reactor vessel; the first section of the first reactor vessel, between the material inlet section and the liquid extraction barrier, where this first section is maintained at conditions that support the hydrolysis reaction in the cellulose material; the second section of the first reactor vessel, between the extraction barrier and the discharge section, where hydrolysis is effectively stopped; a flushing liquid inlet for supplying flushing liquid below the extraction barrier, flowing through the second section to the extraction barrier, where the flushing liquid is supplied at the extraction temperature, and the flushing liquid stops the second section of hydrolysis; and a transport pipe with an inlet matched to the material discharge section of the first reactor vessel and an outlet matched to the second reactor vessel. Where the cellulose material flows from the material discharge section, through the transport pipe to the second reactor vessel, and the second reactor vessel uses the heating fluid to cool the cellulose material in the second reactor vessel, and the second reactor vessel includes a liquid discharge section that extracts a portion of the liquid from the second reactor vessel and directs it to at least one type of lower inlet of the first reactor vessel or to the transport pipe, and where the washing fluid is a mixture of water and at least one type of sodium hydroxide and, essentially, a sulfur-free white liquid. 2. The reactor vessel system as described in Claim 1, where at least one type of sodium hydroxide, and at least a sulfur-free white liquid, is present in the range of 0.01 percent to 0.01 percent of the amount of cellulose material flowing through the vessel. 3. A reactor vessel system as described in Claim 1, where hydrolysis is performed at hydrolysis temperatures of 150 °C and 175 °C. 4. A reactor vessel system as described in Claim 1, where hydrolysis in the vessel is performed at pH 1 to 6. 5. The reactor vessel system as described in claim 3, where the washing fluid is 10°C to 70°C cooler than the hydrolysis temperature. 6. The reactor vessel system as described in Claim 1, where the washing fluid has a pH in the range of 3 to 7. 7. The reactor vessel system described in Claim 1 subsequently comprises an upper separation section in a second reactor vessel, and the extracted liquid portion is extracted from the upper separation section. 8. The reactor vessel system described in Claim 1 herein comprises a pH monitoring section that measures the pH level of the viscous cellulose material in the transport pipes. 9. The reactor vessel system as described in Claim 1 subsequently comprises temporary tanks that receive the fluid extracted from the extraction baffle and provide steam to the first reactor vessel at or above the first vessel. 10. The reactor vessel system as described in claim 9, whereby temporary tanks shall have a liquid discharge section provided with liquid for the system's waste disposal section. 11. The reactor vessel system consists of: the first reactor vessel, with an upper material inlet receiving the cellulose material and a lower material discharge for the cellulose material, through which the cellulose material flows from the inlet to the discharge; the hydrolysate and liquid extraction baffle in the first reactor vessel; the upper part of the first reactor vessel, between the material inlet and the liquid extraction baffle, which is maintained at or above the hydrolysis temperature where the hydrolysis reaction occurs in the cellulose material; the thermal energy inlet for supplying heated fluid to the cellulose material in the upper part of the first reactor vessel; the lower part of the first reactor vessel, between the extraction baffle and the lower discharge, where hydrolysis is effectively stopped; and the flushing fluid inlet in the lower part of the first reactor vessel, for supplying sufficient flushing fluid to the vessel, so the flushing fluid flows up through the lower part to the extraction baffle. Where the washing fluid is supplied at the hydrolysis temperature, and the washing fluid cools and stops the hydrolysis reaction in the second section of the reactor; the transport pipe has an inlet matched to the material discharge section of the first reactor and an outlet matched to the second reactor, where the cellulose material flows from the bottom material discharge section to the second reactor, and the second reactor includes the heating fluid applied to the cellulose material, and the second reactor includes a liquid discharge section that extracts a portion of the liquid from the second reactor and directs it to at least one of the lower inlets of the first reactor or to the transport pipe, and where the washing fluid is a mixture of water and at least one type of sodium hydroxide and, essentially, a sulfur-free white liquid. 12. The reactor vessel system as described in claim 11, where at least one type of sodium hydroxide, and necessarily a sulfur-free white liquid, shall be in the range of 0.01 percent to 5 percent of the volume of cellulose material flowing through the vessel. 13. The reactor vessel system as described in claim 11, where hydrolysis is performed in vessels at hydrolysis temperatures of 150 °C and 175 °C. 14. The reactor vessel system as described in claim 11, where hydrolysis in the vessel occurs in the pH range of 1 to 6. 15. The reactor vessel system as described in claim 11, where the washing fluid is cooled 10 °C to 70 °C below the hydrolysis temperature. 16. The reactor vessel system as described in Claim 11, where the washing fluid has a pH in the range of 3 to 7. 17. The reactor vessel system as described in Claim 11 subsequently comprises an upper separation section in a second reactor vessel, and the extracted liquid portion is extracted from the upper separation section. 18. The reactor vessel system as described in claim 11 subsequently includes a pH monitoring component that measures the pH level of the viscous cellulose material in the transport pipes. 19. The reactor vessel system as described in Claim 11 subsequently comprises temporary tanks that receive the fluid extracted from the extraction baffle and provide steam to the first reactor vessel at or above the first vessel. 20. The reactor vessel system as described in claim 19, whereby temporary tanks shall have a liquid discharge section provided with liquid for the system's scraping section. 21. Process System for Cellulose Material Conversion into Hydrolyzate. The system consists of: a first-stage pressurized reactor operating at a pressure higher than atmospheric pressure; the first-stage reactor comprises: an inlet section receiving cellulose material and a discharge section where cellulose material flows from the inlet to the discharge; a thermal energy inlet in the upper part of the first-stage reactor; the first section of the first-stage reactor between the inlet and the liquid extraction baffle, where the first section is maintained at a hydrolysis temperature of at least 150 °C in the cellulose material; an extraction baffle with an outlet for extracting hydrolysate and liquid from the first-stage reactor; and the second section of the first-stage reactor between the extraction baffle and the discharge section, where the temperature is lower than the hydrolysis temperature, and the hydrolysis reactor is effectively stopped, with the discharge section of the first-stage reactor being lower than the second section; a transport pipe providing flow from the discharge section to the continuous digestion pipe; and a continuous digestion vessel receiving the cellulose material discharged from the first-stage reactor. 22. The reactor vessel system as described in claim 21 subsequently consists of a liquid inlet for rinsing the initial-pressure reactor vessel and below the compression barrier, where the rinsing liquid inlet is connected to a source of rinsing fluid, and the rinsing fluid includes at least one type of sodium hydroxide and, necessaryly, a sulfur-free white liquid in the range of 0.01 percent to 5 percent of the volume of cellulose material flowing through the vessel. 23. The reactor vessel system as described in claim 21, where the washing fluid has a pH in the range of 3 to 7. 24. A reactor vessel system as described in claim 21, where the hydrolysis temperatures are in the range of 150 °C and 175 °C. 25. The reactor vessel system as described in claim 21, where the cellulose material in the first section of the first reactor vessel has a pH in the range of 1 to 6. 26. The reactor vessel system as described in claim 21, where the temperature in the second section of the first reactor vessel is 10 °C to 70 °C cooler than the hydrolysis temperature. 27. The reactor vessel system as described in Claim 21, where the first reactor vessel is truly vertical, shall have a height of at least 100 feet, the inlet section shall be at the top of the vessel, and the discharge section shall be near the bottom of the vessel. 28. The reactor vessel system as described in claim 21, whereby the first reactor vessel, whereby the heat energy input is steam at a pressure higher than atmospheric pressure. 29. The reactor vessel system as described in Claim 21 subsequently consists of temporary tanks receiving the fluid extracted from the extraction baffle and supplying steam to the first reactor vessel, at or above the first vessel, and the discharge of hydrolysates to the hydrolysate recovery system. 30. The process system described in claim 29 subsequently comprises a washing fluid inlet at the lower section of the second section, where the washing fluid inlet is coupled to a source of chilled washing fluid. 31. The process system as described in Reputation 21, where the sources of washing fluid include a chilled washing water source and a source of at least one type of sodium hydroxide and a truly sulfur-free white liquid, where the amount of sodium hydroxide and the truly sulfur-free white liquid does not exceed five percent by volume of water in the washing fluid. 32. The method for producing meat from cellulose material consists of: supplying cellulose material to the upper intake section of the first reactor; hydrolyzing the cellulose material in the upper section of the first reactor by applying pressure and heat to the vessel; extracting the hydrolysate from the cellulose material through the lower extraction baffle of the upper section and into the first reactor; supplying rinsing fluid to the lower section of the first reactor, which stops the hydrolysis of the cellulose material in the lower section, and the rinsing fluid flows up through the cellulose material to the extraction baffle; discarding the cellulose material from the lower outlet of the first reactor; supplying the discarded cellulose material to the second reactor; and supplying heating fluid to the uppermost section of the second reactor to further digest the cellulose material to produce meat. 33. The method as described in claim 32, whereby the washing fluid includes an amount of at least one type of sodium hydroxide and a purely sulfur-free white liquid in the range of 0.01 percent to 5 percent of the volume of cellulose material flowing through the initial reactor vessel. 34. The method as described in claim 32, where hydrolysis is performed at hydrolysis temperatures of 150 °C and 175 °C. 35. The method as described in claim 34, where the washing liquid is cooled to 70°C below the hydrolysis temperature. 36. The method as described in claim 32, where hydrolysis is performed while the cellulose material has a pH in the range of 1 to 6. 37. The method as described in claim 32, where the washing liquid has a pH in the range of 3 to 7. 38. The method described in claim 32, whereby the cellulose material in the supernatant is treated at a temperature above the hydrolysis temperature to aid hydrolysis and the cellulose material in the supernatant is treated at a temperature at least ten degrees Celsius below the hydrolysis temperature. 39. The method as described in claim 38, where the hydrolysis temperature is at least 170 degrees Celsius. 40. The procedure described in claim 32 subsequently involves extracting the fluid from the second reactor vessel and supplying the extracted fluid to the bottom of the first reactor vessel. 41. The procedure described in claim 40 subsequently involves measuring the pH of the extracted fluid and increasing the flow of rinsing fluid to the lower section if the measured pH is greater than the previously measured pH. 42. The procedure described in claim 32 subsequently involves steaming the first reactor vessel to provide pressure and heat to the vessel. 43. The method as described in claim 32, where the washing liquid is a mixture of water and at least one type of sodium hydroxide and a truly sulfur-free white liquid, where the amount of sodium hydroxide and the truly sulfur-free white liquid shall not exceed five percent by volume of water in the washing liquid. 44. Methods to stop the hydrolysis of the cellulose material include: supplying the cellulose material at the top inlet of the first reactor vessel, with the material moving down through the vessel; adding steam above atmospheric pressure to the first reactor vessel; maintaining a temperature above the hydrolysis temperature of the cellulose material in the upper section of the first reactor vessel; extracting the hydrolysate from the cellulose material through the lower-upper extraction baffle in the first reactor vessel; cooling the cellulose material below the extraction baffle to a temperature below the hydrolysis temperature; and draining the cellulose material from the bottom outlet of the first reactor vessel. 45. The reactor vessel system as described in claim 44, whereby the cooling procedure includes the addition of a bottom flushing fluid for the extraction baffle and a flushing fluid including at least one type of sodium hydroxide and a sulfur-free white liquid, in the amount of 0.01 percent to 5 percent of the volume of cellulose material flowing through the first reactor vessel. 46. A reactor vessel system as described in claim 44, where the hydrolysis temperature is in the range of 150 °C to 175 °C. 47. The reactor vessel system as described in claim 46, whereby the cooling procedure includes the addition of a flushing fluid to the first reactor vessel below the extraction baffle, whereby the flushing fluid is cooled 10 °C to 70 °C below the hydrolysis temperature. 48. The reactor vessel system as described in claim 46, where the washing fluid has a pH of 3 to 7. 49. A reactor vessel system as described in claim 44, where the hydrolysis step occurs when the cellulose material is at a pH in the range of 1 to 6. 50. The method of claim 44, whereby the cooling of the cellulose material shall include the supply of a washing fluid to the bottom of the first reactor vessel and the supply of the washing fluid to flow up to the extraction baffle. 51. Method of claim 44 where the washing liquid is a mixture of water and at least one kind of sodium hydroxide and a purely sulfur-free white liquid. 52. The method of claim 44, where the amount of sodium hydroxide and white liquid shall not exceed five percent of the water in the washing liquid. 53. Method of claim 44 where the hydrolysis temperature is at least 170 degrees Celsius. 54. The procedure of claim 44 subsequently involves supplying the discarded cellulose material from the lower outlet of the first reactor to the inlet of the second reactor, and extracting the fluid from the second reactor, and supplying the extracted fluid to the lower section of the first reactor. 55. The procedure of claim 54 subsequently involves checking the pH of the extracted fluid and increasing the flow of rinsing fluid to the bottom section. If the checked pH exceeds the previously checked pH level, 56. The procedure of claim 44 subsequently involves adding steam to the first reactor vessel to provide pressure and heat to the vessel.