Biomass fractionation and extraction apparatus

A biomass fractionation apparatus includes a vessel having a processing chamber, an inlet configured to receive a biomass into the processing chamber, and an outlet configured to discharge processed biomass from the chamber. A bed plate is movably positioned within the processing chamber and includes a plurality of elongated fins extending outwardly therefrom in substantially parallel spaced-apart relationship. A cylindrical rotor is rotatably secured within the processing chamber in adjacent, spaced-apart relationship with the bed plate. The rotor has a plurality of elongated blades extending radially outwardly therefrom in circumferentially spaced-apart relationship. Upon rotation of the rotor, the blades are configured to accelerate a biomass within the processing chamber against the fins of the bed plate and to cause the bed plate to pulsate against the rotor.

FIELD OF THE INVENTION

The present invention relates generally to biomass and, more particularly, to biomass processing.

BACKGROUND

Natural cellulosic feedstocks are typically referred to as “biomass”. Many types of biomass, including wood, paper, agricultural residues, herbaceous crops, and lignocellulosic municipal and industrial solid wastes have been considered as feedstocks for the production and preparation of a wide range of goods. Plant biomass materials are comprised primarily of cellulose, hemicellulose, other sugars, and lignin, bound together in a complex gel-like structure along with amounts of extractives, pectins, proteins and ash. Thus, successful commercial use of biomass as a feedstock or its components directly may depend on the separation of the various constituents.

Many steps are often required in production, harvesting, storage, transporting, and processing of biomass to yield useful products. One step in the processing is the separation, or fractionation, of biomass into its major components: extractives, hemicellulose, lignin, other sugars, and cellulose. Many approaches have been investigated for disentangling this complex structure. Once this separation has been achieved, a variety of paths are opened for further processing of each component into marketable products. For example, the possibility of producing products such as biofuels, polymers and latex replacements from biomass has recently received much attention. This attention is due to the availability of large amounts of cellulosic feedstock, the need to reduce burning or landfilling of waste cellulosic materials, and the usefulness of sugar and cellulose as raw materials substituting for oil-based products. Other biomass constituents, such as isolated extractives and lignins from the biomass, may also have potential market value.

The difficulty is efficiently and in an environmentally friendly manner separating the components from each other. Thus there continues to be a need for improved systems and methods for separating solid biomass into its constituent components that take into consideration factors such as environmental and energy concerns, efficiency and cost-effectiveness.

SUMMARY

According to some embodiments of the present invention, a biomass fractionation apparatus includes a vessel having a processing chamber, an inlet configured to receive biomass into the processing chamber, and an outlet configured to discharge processed biomass from the chamber. A cylindrical rotor is rotatably secured within the processing chamber, and a motor is operably connected to the rotor and is configured to rotate the rotor. A bed plate is movably positioned within the processing chamber adjacent to the rotor. A pump is in fluid communication with the vessel inlet, for example via tubing, and is configured to feed biomass into the processing chamber. In some embodiments, the pump is configured to feed the biomass into the processing chamber at a rate of between about 10 gallons per minute (gpm) and about 20 gpm.

The rotor has a plurality of elongated blades extending radially outwardly therefrom in circumferentially spaced-apart relationship. Each rotor blade has a longitudinal direction that is substantially parallel with the rotational axis of the rotor. The bed plate includes a plurality of elongated fins extending outwardly therefrom in substantially parallel spaced-apart relationship. A biasing mechanism is configured to urge the bed plate towards the rotor against an opposite force caused by the biomass flowing through the processing chamber between the rotor and the bed plate.

In some embodiments, the biasing mechanism includes a counterweight located external to the vessel. The counterweight is connected to the bed plate via one or more articulating linkages. In other embodiments, the biasing mechanism may include at least one pneumatic cylinder, at least one spring, etc.

Upon rotation of the rotor via the motor, the rotor blades are configured to accelerate the biomass within the processing chamber against the fins of the bed plate. The force of the biomass against the bed plate and the opposite force of the biasing mechanism against the bed plate causes the bed plate to pulsate rapidly against the rotor with the biomass therebetween.

In some embodiments, each rotor blade has a substantially rectangular cross-sectional configuration. In some embodiments, each rotor blade has a width of about 0.375 inch. In some embodiments, each rotor blade has a distal free end that is spaced from the rotor by about 0.50 inch. Rotation of the rotor blades relative to the bed plate fins causes the biomass within the vessel to accelerate from about 4 feet per second (fps) to about 40 fps.

In some embodiments, a longitudinal direction defined by each bed plate fin is skewed relative to a longitudinal direction defined by each rotor blade. This prevents the rotor blades and bed plate fins from becoming engaged (i.e., interdigitated) which may damage the apparatus. In some embodiments, each bed plate fin has a distal free end with an arcuate configuration.

In some embodiments, the vessel inlet is located above the rotor and is oriented at an angle that is transverse to a rotational axis of the rotor. In some embodiments, the vessel outlet is positioned adjacent to the bed plate.

The processing chamber may be formed from various materials including, but not limited to, carbon and alloy steel, stainless steel, cast iron, brass, copper and polymeric materials. Similarly, the bed plate may be formed from various materials including, but not limited to, carbon and alloy steel, brass, stainless steel, cast iron, and polymeric materials. The rotor may be formed from various materials including, but not limited to, carbon and alloy steel, stainless steel, cast iron, brass, copper and polymeric materials.

According to some embodiments of the present invention, a method for fractionating biomass includes a pretreatment step wherein the biomass is converted to a fluidized or flowable form and may include chopping, cutting, attrition, crushing, or the like, and/or contact with a solvent (e.g., ethanol, aqueous ethanol, water, short chain alcohol, glycerin, or any combination thereof, etc.), for example, to produce a fluidized biomass; and subjecting the fluidized biomass to pulse and shear forces within a processing chamber while avoiding denaturing the individual components to produce a first fraction and a fractionated biomass. An exemplary fraction is a component such as lignin, extractives, pectins, cellulose, sugars, fibers, proteins and hemicellulose, or any combination thereof.

The processing chamber includes a cylindrical rotor having a plurality of elongated blades extending radially outwardly therefrom in circumferentially spaced-apart relationship, and a bed plate movably positioned within the processing chamber adjacent the rotor. The bed plate includes a plurality of elongated fins extending outwardly therefrom in substantially parallel spaced-apart relationship. The rotor is rotated to accelerate the fluidized biomass against the fins of the bed plate and to cause the bed plate to pulsate against the rotor with the fluidized biomass therebetween. For example, in some embodiments, the rotor may be rotated such that the bed plate pulsates against the rotor at a frequency of at least 1000 pulses per second.

In some embodiments, the fractionated biomass is subjected to a compression force while in contact with additional solvent to provide a second fraction separated from the previously fractionated biomass and then the first fraction and the second fraction may be combined together, further separated in combined form or separated apart from each other. The combination of the first fraction and the second fraction may be filtered to remove any solid materials therefrom.

In some embodiments, each of the steps is conducted at ambient temperature.

According to other embodiments of the present invention, a biomass fractionation system includes a biomass fiber disassembly station, a fractionation apparatus, a press, and a screen. The fiber disassembly station is configured to provide a fluidized biomass wherein the fibers have been mechanically disassembled while maintaining the overall chemistries of each of the fiber components. The fractionation apparatus is configured to subject the fluidized biomass to shear forces and pulsation within a processing chamber while avoiding denaturing the individual components to produce a first fraction and a fractionated biomass. The processing chamber includes a cylindrical rotor having a plurality of elongated blades extending radially outwardly therefrom in circumferentially spaced-apart relationship, and a bed plate movably positioned within the processing chamber adjacent the rotor. The bed plate includes a plurality of elongated fins extending outwardly therefrom in substantially parallel spaced-apart relationship. The rotor is rotated in a manner to accelerate the biomass against the fins of the bed plate and to cause the bed plate to pulsate against the rotor with the biomass therebetween. The press is configured to subject the fractionated biomass to a compression force while in contact with additional solvent to provide a second fraction separated from the previously fractionated biomass. The screen is configured to filter the combination of the first fraction and the second fraction to remove any solid materials, particularly fiber fragments. The biomass fractionation system may also include a separator (e.g., membranes, etc.) for separating each of the components. For example, in some embodiments, the separator is configured to separate the fractionated biomass into two or more product streams, such as a lignin/extractives product stream and a sugars/hemicellulose product stream, etc.

DETAILED DESCRIPTION

The present invention will now be described more fully hereinafter with reference to the accompanying figures, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Like numbers refer to like elements throughout. In the figures, certain components or features may be exaggerated for clarity, and broken lines may illustrate optional features or elements unless specified otherwise. In addition, the sequence of operations (or steps) is not limited to the order presented in the figures and/or claims unless specifically indicated otherwise. Features described with respect to one figure or embodiment can be associated with another embodiment or figure although not specifically described or shown as such.

It will be understood that although the terms first and second are used herein to describe various features or elements, these features or elements should not be limited by these terms. These terms are only used to distinguish one feature or element from another feature or element. Thus, a first feature or element discussed below could be termed a second feature or element, and similarly, a second feature or element discussed below could be termed a first feature or element without departing from the teachings of the present invention.

The term “about”, as used herein with respect to a value or number, means that the value or number can vary by +/− 20%, 10%, 5%, 1%, 0.5%, or even 0.1%.

The term “biomass” includes any non-fossilized, i.e., renewable, organic matter. Types of biomass include, but are not limited to, plant biomass, animal biomass (any animal by-product, animal waste, etc.) and municipal waste biomass (residential and light commercial refuse with recyclables such as metal and glass removed).

The term “fluidized”, as used herein with respect to biomass, means causing a biomass to acquire the characteristics of a fluid by suspending the disassembled fibers in air, gas, or liquid.

The term “plant biomass” or “ligno-cellulosic biomass” includes virtually any plant-derived organic matter (woody or non-woody) available for energy on a sustainable basis. “Plant-derived” necessarily includes both sexually reproductive plant parts involved in the production of seed (e.g., flower buds, flowers, fruit and seeds) and vegetative parts (e.g., leaves, roots, leaf buds and stems). Plant biomass can include, but is not limited to, agricultural crop wastes and residues such as corn stover, wheat straw, rice straw, sugar cane bagasse, flax, hemp, oat straw, esparto, kenaf, and the like. Plant biomass further includes, but is not limited to, woody energy crops, wood wastes and residues such as trees, softwood forest thinnings, barky wastes, sawdust, paper and pulp industry waste streams, wood fiber, herbal plant material and the like. Additionally grass crops, such as switchgrass, wheat grass and the like have the potential to be produced in large-scale amounts and to provide a significant source of another plant biomass. For urban areas, a potential plant biomass feedstock comprises yard waste (e.g., grass clippings, leaves, tree clippings, brush, etc.) and vegetable processing waste.

The components of the biomass may include, but are not limited to, lignin, extractives for use as pharmaceuticals or nutraceuticals, cellulose, hemicellulose, other sugars, pectins, proteins, fibers, and other materials obtained from the leaves, stems, flowers, buds, roots, tubers, seeds, fruit and the like of a plant. It is noted that specific biomasses may be higher in such components. For example, woody and grassy biomasses are high in hemicelluloses, cellulose, sugars, and lignins. Herbal materials are high in extractives. Leaf buds and flowers are high in protein.

“Ambient to slightly elevated temperature” includes the temperature of the surroundings in which embodiments of the present invention take place. Ambient to slightly elevated temperature may include, but is not limited to, “room temperature,” and temperatures within the range of about 10° C. to about 100° C. (64° F. to 212° F.).

“Water” includes, but is not limited to, deionized water, spring water, distilled water, tap water and well water, and mixtures thereof.

Referring toFIGS. 1-3, a biomass fractionation apparatus10, according to some embodiments of the present invention, is illustrated. The illustrated apparatus10includes a frame12that supports a vessel14. The vessel14has a processing chamber16(FIG. 3) with an inlet18configured to receive a biomass into the processing chamber16, and an outlet20configured to discharge processed biomass from the chamber16. In the illustrated embodiment, the inlet18is located above the rotor (40,FIG. 3) within the processing chamber16and may be oriented at an angle that is transverse to the rotational axis A1(FIG. 3) of the rotor40. In the illustrated embodiment, the processing chamber16has a volume of about two (2) quarts. However, embodiments of the present invention are not limited to the processing chamber16having any particular size or volume. Moreover, the vessel14may have various shapes and configurations and the inlet and outlet18,20nozzles may have different orientations, for example as illustrated inFIGS. 10-12.

The illustrated vessel14includes a top14tthat is pivotably secured to the vessel14via a hinge14hand is movable between open (FIG. 3) and closed positions (FIGS. 1 and 2). The top14tis maintained in a closed position during biomass processing via locking device15. Various types of locking devices may be utilized and embodiments of the present invention are not limited to the illustrated locking device15. For example, in other embodiments, the vessel14may include a top that is secured thereto via fasteners, etc.

A fluidized biomass is pumped into the processing chamber16via a pump22that is in fluid communication with the vessel inlet18via a hose24. The fluidized biomass is subjected to fractionation within the processing chamber16, as will be described below, and exits the processing chamber16via the vessel outlet20. The fractionated biomass leaving the processing chamber16is directed to a tank or to further downstream processing via a hose26connected to the vessel outlet20.

In some embodiments, the pump22is configured to feed a fluidized biomass into the processing chamber16at a rate of between about 10 gallons per minute (gpm) and about 20 gpm. However, other feed rates may be utilized. An exemplary pump is a pharmaceutical Fristam pump, available from Fristam Pumps USA, Middleton, Wis. However, various types of pumps may be utilized in accordance with embodiments of the present invention.

Referring toFIG. 3, the top14tof the vessel14has been pivoted to an open position to reveal the processing chamber16and an elongated, cylindrical rotor40rotatably secured therewithin. The illustrated processing chamber16has a generally arcuate internal wall16awhich facilitates the flow of a fluidized biomass through the chamber16during processing. The rotor40is secured to a shaft52and the shaft52is rotatably secured to opposite end walls14wof the vessel via bearings, as would be understood by one skilled in the art. The shaft52is connected to a motor50via a coupling device50C, as would be understood by one skilled in the art of the present invention. Exemplary coupling devices that may be utilized include flex couplings manufactured by Lovejoy, Inc., Downers Grove, Ill. In some embodiments, the motor50is configured to rotate the rotor40up to about 1,500 rotations per minute (rpm). However, embodiments are not limited to any particular motor size or rpm range. Moreover, the motor50may be a fixed or variable speed motor.

As will be described further below, an elongated bed plate30(FIGS. 4-6) is movably positioned within the processing chamber16beneath the rotor40. The bed plate30has a length that is substantially the same length of the rotor40. However, other lengths are possible, including lengths greater or lesser than the length of the rotor40. The processing chamber16includes an elongated opening16b(FIG. 4) formed in the bottom thereof and the bed plate30is movably and sealably positioned within the opening16b. As will be described below, the bedplate30is configured to pulse rapidly against the rotor40as the rotor40is rotated via the motor50and a fluidized biomass is pumped into the chamber16via the pump22. A seal (not shown) prevents the biomass being processed within the processing chamber16from leaking out of the chamber16around the bed plate30.

In the illustrated embodiment, the rotor40includes a plurality of elongated blades42that extend radially outwardly in circumferentially spaced-apart relationship. The rotational axis of the rotor40defines an axial direction A1(FIG. 3). Each rotor blade42is elongated in a direction that is substantially parallel with direction A1. In addition, each illustrated rotor blade42has a substantially rectangular cross-sectional configuration with generally parallel opposing side walls42a,42b, and a distal free end42c(FIGS. 4, 7). In some embodiments, each elongated blade42has a width W1(FIG. 4) of about 0.375 inch, and each rotor blade has a height H1(FIG. 4) of about 0.50 inch. In the illustrated embodiment, the rotor40has a diameter of about 8.0 inches and a length of about 6.0 inches. The illustrated rotor40includes thirty two (32) blades extending radially outwardly in circumferentially spaced-apart relationship. However, embodiments of the present invention are not limited to any particular number of blades42or to any particular dimensions of the rotor40or blades42. Moreover, the rotor blades42may have other shapes and configurations and are not limited to the illustrated shape and configuration.

Referring toFIGS. 5 and 6, the illustrated bed plate30includes a plurality of elongated fins32in substantially parallel spaced-apart relationship. Each pair of adjacent fins32defines a respective slot34. In the illustrated embodiment, each fin32has generally parallel opposing side walls32a,32b, and an arcuate distal free end32c. In some embodiments, each elongated fin has a width W2(FIG. 4) of about ¼ inch. As illustrated inFIG. 6, the height H2of the outermost fins32is greater than the height H3of the inner two fins32. The difference in height of the fins32along with the arcuate distal ends32callows each rotor blade distal end42cto be spaced apart from each fin distal free end32cby about the same amount during rotation of the rotor40, as illustrated inFIG. 7.

The bed plate30is movably positioned within the processing chamber and can move back and forth (i.e., float) relative to the rotor40as a biomass is accelerated against the fins32thereof. For example, in the illustrated embodiment, the bed plate30moves up and down relative to the rotor40. A biasing mechanism60is operably associated with the bed plate30and is configured to urge the bed plate30towards the rotor40against an opposite force caused by the biomass being pumped through the processing chamber16. In the illustrated embodiment, the biasing mechanism60includes one or more counterweights62that are connected to the bed plate via articulating linkages64a,64b. In the illustrated embodiment, the one or more counterweights62are located external to the vessel14(FIG. 2) and are placed on a platform64cthat is connected to the bed plate30via linkages64a,64b.

A locking mechanism66is provided in the illustrated embodiment to disengage the biasing mechanism60from the bed plate30during non-operational times.

However, embodiments of the present invention are not limited to the illustrated configuration of the linkages64a,64band the counterweight platform64c. For example, a single arm may be used to connect platform64cto the bed plate.

Embodiments of the present invention are not limited to the illustrated biasing mechanism60. Other ways of urging the bed plate30towards the rotor40against an opposite force caused by a biomass being pumped through the processing chamber16may be utilized. For example, in some embodiments, one or more springs may be operably associated with the bed plate30to urge the bed plate30towards the rotor40. In other embodiments, as illustrated inFIGS. 10-12, a biasing mechanism may include one or more pneumatic (or other fluid actuated) cylinders70that are configured to urge the bed plate30towards the rotor40.

As illustrated inFIG. 5, the elongated bed plate fins32extend along a direction A2. The bed plate30and rotor40are positioned within the processing chamber16such that direction A2is skewed or transverse to the direction A1(i.e., the rotational axis of the rotor40and the longitudinal direction defined by each of the rotor blades42). The skewed orientation of the bed plate fins32relative to the rotor blades42prevents the rotor blades42from becoming stuck in the slots34between the bed plate fins32(i.e., interdigitated), which may damage the rotor40and/or the bed plate30.

In operation, a biomass typically has a residence time within the processing chamber16of between about 1.5-3.0 seconds. However, the residence time can be varied by adjusting the biomass flow rate via the pump22. In this amount of time, the rotor40will cause the bed plate to pulsate relative to the rotor between about 900 and about 3600 times inside the processing chamber16. These pulsations and the rapid acceleration of the biomass, for example, from about 4.0 feet per second (fps) −8.0 fps in the inlet hose24to about 40 fps in the processing chamber16, cause the cellular structure of the biomass to release its components without denaturing or altering the chemistry of the individual components, namely fractionation into each of the various components.

In some embodiments of the present invention, the processing chamber inner surface16amay be formed of materials such as carbon and alloy steel, brass, stainless steel, cast iron, and polymeric materials. In some embodiments of the present invention, the rotor40and rotor blades42may be formed of materials such as carbon and alloy steel, stainless steel, cast iron, brass, copper, and polymeric materials. Similarly, in some embodiments of the present invention, the bed plate30and bed plate fins32may be formed of materials such as carbon and alloy steel, stainless steel, cast iron, brass, copper, and polymeric materials.

Referring now toFIGS. 10-12, fractionation apparatus10according to other embodiments of the present invention are illustrated. Referring initially toFIGS. 10 and 11, the illustrated fractionation apparatus10includes a vessel14having a processing chamber16and a rotor40rotatably secured therewithin, as described above. The rotor40is secured to a shaft52and the shaft52is rotatably secured to the vessel14via bearings53. In addition, sealing glands54(e.g., Teflon® brand sealing glands, etc.) are provided around the shaft52on both sides of the vessel14to prevent leakage of biomass from the processing chamber via the openings in the vessel14for the shaft52.

In the illustrated embodiment, a pair of pneumatic cylinders70are provided that serve as a biasing mechanism to urge the bed plate30towards the rotor40and cause rapid pulsations thereof when the rotor40is rotated and biomass is pumped into the chamber16. Each pneumatic cylinder70includes a piston74that is actuated via air through air inlet72. Each piston74pushes against the bed plate30when the pneumatic cylinder is pressurized with air. The illustrated fractionation apparatus10also includes a bed plate stop adjustment76that is utilized to set the distance the bed plate30can move relative the rotor40.

The fractionation apparatus10illustrated inFIGS. 9 and 10is configured such that the bed plate30is positioned to one side of the rotor40(as opposed to beneath the rotor40, as is the case with the embodiment illustrated inFIGS. 1-4). In addition, the inlet18and outlet20are located on the opposite side of the rotor40, as illustrated.

FIG. 11illustrates a fractionation apparatus10according to other embodiments of the present invention and wherein the bed plate30is positioned above the rotor40, and the inlet18and outlet20are located on the opposite side of the rotor40(i.e., beneath the rotor40), as illustrated.

In each of the embodiments illustrated inFIGS. 10 and 11, a mid feather17is positioned within the processing chamber16. The mid feather17is an elongated member that reduces the ability of a biomass to bypass the bed plate30and flow directly from the inlet18to the outlet20. The rotational direction of the rotor40in each embodiment is illustrated by arrow R. The mid feather17in each embodiment thereby helps direct the biomass around the rotor40in the direction of rotation R.

Referring now toFIG. 8A, operations for the fractionation and extraction of various biomasses, according to some embodiments of the present invention, will be described. At ambient temperature, and optionally while in contact with a solvent, a pretreatment step (Block90) may be conducted. The biomass may be subjected to a pre-soak step (Block100) and/or a disassembly step (Block110) in which the fibers are mechanically disassembled, followed by being subjected to high frequency pulses and high shear forces (Block120) to fractionate or extract the biomass via the biomass fractionation apparatus10ofFIG. 1-7 or 9-11. The fractionated or extracted biomass may then be subjected to filtration (Block125), followed by a compression force (Block130), and then followed by additional filtration and/or separation (Block140). The fractions then may be used to provide a desired product stream (Block150). It is noted that an initial fraction or extraction product may be collected at earlier points of the method and such previously collected fraction combined with the fraction or extract product stream.

In the initial pre-soak step (Block100) of the pretreatment step (Block90), the biomass may be contacted with a solvent such as with an alcohol, an aqueous alcohol, water or glycerin or co-solvent or mixture thereof in order to begin the fractionation or extraction of the biomass. The biomass may swell during this pretreatment step (Block100). The biomass may be disassembled (Block110) such as by chopping, cutting, attrition, or crushing prior to extraction. In a particular embodiment, if the biomass is, for example, fresh plant biomass or herbal plant material, the material may be extracted with alcohol. If the biomass is dried plant biomass or herbal plant material, it may be extracted with an aqueous alcoholic solution. Aqueous alcoholic fractionation or extraction may be performed in aqueous alcohol at different concentrations. Suitable alcohols may be short chain alcohol, such as, but not limited to, methanol, ethanol, propanol, isopropanol, butanol and isobutanol. In a particular embodiment, the alcohol is ethanol. The alcohol may be a co-solvent mixture such as a mixture of an alcohol and water. The aqueous alcoholic solution may comprise from about 0-100% (v/v) alcohol. More particularly, the aqueous alcoholic solution may comprise from about 25-95% (v/v) alcohol. In a particular embodiment, the aqueous alcoholic solution is about 25% (v/v) or more alcohol. In another particular embodiment, the aqueous alcohol may be about 60% (v/v) alcohol. In another embodiment, the aqueous alcoholic solution may be about 70% (v/v) alcohol. In yet another embodiment, the aqueous alcoholic solution may be about 86% or more (v/v) alcohol. In yet other embodiments, the process for fractionating or extracting biomass may comprise contacting the biomass with glycerin or an aqueous glycerin solution. In yet another embodiment, the process for extracting biomass may comprise contacting the biomass with water. Typically, in other embodiments of the invention, the ratio of biomass/solids contacted with a solvent/liquids used may be about 1:1 to 1:10 of solids to liquid.

Embodiments of the present invention are not limited to a pretreatment step involving a solvent. In some embodiments, fibers can be caused to “open up” without the use of a solvent by cutting, fraying, refining via various devices and in a dry condition.

In some embodiments, the pretreatment step (Block90) may take place for any period of time that is sufficient for the fractionation or extraction process and may take place in any vessel, container or mixer suitable for contacting the biomass with a solvent. In some embodiments, the pretreatment step may be any length of time between, for example, 15 minutes, 30 minutes, 1 hour, 24 hours, 72 hours, etc. In another embodiment, the pretreatment step may be 15 minutes or less. The pretreatment step (Block90) may be one minute or less. In the pretreatment step (Block90), the biomass in contact with the solvent may optionally be subjected to a compressive force, which can result in absorption of the solvent into the biomass. The compression in the pretreatment step (Block90) may take place according to any technique that will be appreciated by one of skill in the art. In an embodiment of the invention, compression during the pretreatment step may be affected by a screw press. However, as discussed above, the pretreatment step (Block90) does not require the use of a solvent

The biomass, after being subjected to pre-soaking in solvent (Block100), may be further subjected to a disassembly step (Block110). The material may be disassembled such as by processing in a mechanical high consistency fluidization machine such as a refiner or disk mill available from, for example, Sprout Waldron, Beloit Jones, and Andritz. By utilizing a refiner or disk mill, the biomass and particularly the fibrous material thereof may be altered without destroying the fibrous nature of the fibrous material so that the high frequency pulses and shear forces of the fractionation apparatus are accessible to the fibrous material. The processing may take place for any amount of time necessary as would be understood by one of skill in the art as necessary to affect this step. In a particular embodiment, the disassembly process is performed for one minute or less. The biomass may be subjected to additional compression in the presence of a solvent. Alternatively, the biomass may be subjected to centrifugation or the like to separate the liquid fraction from the solid fraction.

Following disassembly of the fibers (Block110), the material may be subjected to fractionation (Block120) using high frequency pulses and shear forces, for example via the apparatus10ofFIG. 1-7 or 9-11, to fractionate or extract the biomass using shear forces and high frequency pulses. It will be appreciated that in a particular embodiment, pulsation and shear forces are used to avoid denaturing or altering the chemical properties of the individual components. Because the biomass may be in a fluidized form, a portion of the fractions or extracts may be separated from the biomass. The subjecting of the biomass shear forces and to high frequency pulses (Block120) may take place for any amount of time necessary as would be appreciated by one of skill in the art as necessary to affect this step. In a particular embodiment, subjecting the biomass to shear forces and high frequency pulses (Block120) takes place for one minute or less. In operation, the biomass is rapidly accelerated from about 4 mph to about 120 mph under greater than 1000 pulses per second of energy while avoiding fragmentation or attrition of the biomass particles. This facilitates the ability of the cellular structure of the biomass to release its various fractions or constituents from the complex and entangled structure of the biomass without substantially denaturing or altering any of the biomass components and the chemistry thereof.

The biomass material may then be subjected to a filtration or separation step with or without agitation (Block125) and then to a compression force (Block130) e.g., a crushing or macerating force, optionally in the presence of a solvent, wherein the compression force removes liquid for collection while discharging a low liquid solids cake. The compression force can be applied according to various techniques, as would be understood by one of skill in the art. In a particular embodiment, the compression force is affected by screws of a screw press that macerate the previously extracted biomass. A second fraction or extract separated from the previously fractionated or extracted biomass may be provided from this compression step. In another embodiment of the invention, the biomass contacted with additional solvent subjected to a compression force may be subjected again to compression to provide the second extract. The compression of this step may take place for any amount of time necessary as would be appreciated by one of skill in the art as necessary to affect this step.

At this time, the first fraction or extract from the previous steps may be combined and filtered (Block140) to remove any remaining fibers. The filtering/screening of the extracts may be performed by any method known to one of skill in the art with any device that is suitable for filtering and removing any remaining solid matter from the extract and may include agitation. The fractions or extracts provided from the process according to some embodiments of the present invention may be used to provide a desired fraction or extractive product stream (Block150). The product stream provided will be dependent upon the solvent used in the fractionation or extraction process. For example, in an embodiment of the invention, fractionation or extraction of lignins or medicinals may be provided if the solvent is ethanol or aqueous ethanol. In another embodiment, fractionation or extraction of sugars or hemicelluloses may be provided if the solvent is water. The fractions or extracts may be further separated isolated or purified using membranes, centrifugation, precipitation and the like. In one embodiment, membranes that separate components based on molecular weight may be used.

Referring now toFIG. 8B, operations for the fractionation and extraction of various biomasses, according to some embodiments of the present invention, will be described. The biomass, for example, herbal material, is subjected to an activation step which may include an additional disassembly step (e.g., maceration) (Block210) followed by being subjected to high frequency pulses (Block220) to fractionate or extract the biomass using high shear forces and high frequency pulses via the biomass fractionation apparatus10ofFIGS. 1-7 and 9-11. The fractionated or extracted biomass may then be filtered via one or more screens (Block240) and then subjected to crushing (Block230), for example, via a screw press. The fractions or extracts then may be used to provide a desired product stream (Block250). It is noted that an initial fraction or extraction product may be collected at earlier points of the method and such previously collected fraction combined with the fraction or extract product stream. Also, the screened liquids may either be recirculated through the screen (Block240) or may be used again in the activation step (Block210).

The separated, isolated or purified individual components may be used in a wide variety of ways. Lignin provided in accordance with embodiments of the present invention may be used in the preparation of products such as coatings and adhesives. In a further embodiment, fractionation or extraction provides sugars and/or hemicelluloses. Sugars, cellulose and/or hemicelluloses provided in accordance with embodiments of the present invention may further be used in the preparation of biofuels such as ethanol or the preparation of polymers/plastics. The fraction may be used as a feedstock to provide additional products or used directly. For example, another embodiment is the fermentation of the provided fractions to produce the ethanol. In another embodiment, the polymer is polylactic acid (PLA). In another embodiment the lignin may be further separated for further processing. Because the lignin has not been submitted to high temperatures, its functional groups have not chemically reacted and the isolated lignin may be more reactive. In an embodiment, the further refining and processing may provide pulp (cellulose) suitable for paper products and/or paper coatings. In yet another embodiment, the fractions or extractives provided may be used in paint additives. In yet another particular embodiment, the biomass is herbal plant material. The herbal plant material for extraction is provided in the form of whole leaf, stem, stalk, root and the like, and is ground or cut prior to treatment. The herbal plant material may be organic, cultivated, or wild. Suitable herbal plant materials include, but are not limited to, kava kava, echinacea, St. John's wort, valerian root, milk thistle seed, Siberian ginseng, nettle leaf, ginkgo, gotu kola, ginkgo/gotu kola supreme, astragalus, goldenseal, dong quai, ginseng, St. John's wort supreme, echinacea/goldenseal supreme, bilberry, green tea, hawthorne, ginger, turmeric, black cohosh, cats claw, chamomile, dandelion, chaste tree berry, feverfew, garlic, horse chestnut, licorice, eyebright, yohimbe, astragalus supreme, valerian poppy supreme, and serenity elixir. In some embodiments of the present invention, herbal plant material or teas may be extracted at ambient temperature without heating.