Non-Pressurised Pre-Treatment, Enzymatic Hydrolysis And Fermentation Of Waste Fractions

Abstract

The present invention relates to a process for production of fermentation products, including bioethanol by non-pressurised pre-treatment, enzymatic hydrolysis and fermentation of waste fractions containing mono- and/or polysaccharides, having a relatively high dry matter content. The process in its entirety, i.e. from non-pressurised pre-treatment over enzymatic hydrolysis and fermentation to sorting of fermentable and non-fermentable solids can be processed at a relatively high dry matter content in a single vessel or similar device using free fall mixing for the mechanical processing of the waste fraction.

Claims

1. A process for the production of fermentation products from mono- and/or polysaccharide containing waste fractions having a dry matter content above 20% involving subjecting said waste fractions to; non-pressurised pre-treatment enzymatic hydrolysis fermentation wherein non-pressurised pre-treatment and enzymatic hydrolysis are carried out in a single vessel or similar device using free fall mixing for the mechanical processing of the waste.

2. A process according to claim 1, wherein the said fermentation, or part of it is carried out in the same said vessel used for non-pressurised pre-treatment and enzymatic hydrolysis.

3. A process according to claim 2, wherein recovery of the resulting fermentation products is performed in the same said vessel used for non-pressurised pre-treatment, enzymatic hydrolysis and fermentation by applying heat and/or vacuum to the vessel.

4. A process according to any of claims 2 or 3, wherein a sorting/separation of the non-fermentable solids from the fermented mash is performed in the same said vessel used for non-pressurised pre-treatment, enzymatic hydrolysis and fermentation.

5. A process according to claim 3, wherein said recovery in the same said vessel is only done from the solid part of the fermented mash after separation/removal of the liquid part.

6. A process according to any of the claims 1 to 5, wherein the said mono- and/or polysaccharide containing waste fractions are derived from households such as e.g. unsorted municipal solid waste (MSW), MSW processed in some central sorting, shredding or pulping device, source sorted waste from households, organic fractions and paper rich waste fractions, RPF (Refuse-Derived-Fuel) fractions.

7. A process according to any of the claims 1 to 5, wherein the said mono- and/or polysaccharide containing waste fractions are derived from the industry such as e.g. general industry waste fractions containing paper or other organic fractions, waste fractions from paper industry e.g. recycling facilities, waste fractions from food and feed industry, waste fractions from the medicinal industry.

8. A process according to any of the claims 1 to 5, wherein the said mono- and/or polysaccharide containing waste fractions are derived from agriculture or farming related sectors such as e.g. waste fractions from processes including sugar or starch rich product such as potatoes and beet, contaminated or in other ways spoiled agricultural products such as grain, potatoes and beet not exploitable for food or feed purposes, manure, or manure derived products.

9. A process according to any of the claims 1 to 5, wherein the said mono- and/or polysaccharide containing waste fractions are derived from municipal, county or state related or regulated activities such as e.g. sludge from waste water treatment plants, fibre or sludge fractions from biogas processing, general waste fractions from the public sector containing paper or other organic fractions.

10. A process according to any of the claims 1 to 9, wherein the non-pressurised pre-treatment is performed using steam.

11. A process according to claim 10, wherein the treatment time of the non-pressurised pre-treatment is between 0-120 min. with a temperature ranging between 60-110 C. and a steam admission of 0-2 kg/kg dry matter.

12. A process according to any of the claims 1 to 9, wherein the enzymatic hydrolysis of the mono- and/or polysaccharide containing waste fraction is performed with hydrolytic enzymes, supplied in either native form or in form of microbial organisms giving rise to the accumulation of such enzymes.

13. A process according to claim 12, wherein said enzymatic hydrolysis lasts for 0-96 hours and with a temperature ranging from 20-105 C.

14. A process according to any of the claims 1 to 9, wherein said fermentation is performed by the action of standard, cultivated or manipulated yeast and/or bacteria or any other microorganism capable of producing ethanol or other specific biochemicals.

15. A process according to claim 14, wherein said fermentation last for 1-150 hours with a temperature ranging from 20-105 C.

16. A process according to any of the claims 1 to 9, wherein the mixing of the mono- and/or polysaccharide containing waste fraction is performed with free fall mixers such as drum mixers, tumble mixers or similar mixing devices.

17. Use of a material produced by a process according to any of the claims 1 to 16, in a process for bioethanol or/and any other fermentation product processing.

18. Use of a process according to any of claims 1-16 as part of a process for the production of bioethanol or/and any other fermentation product.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0073] FIG. 1 shows a schematic diagram of the principle of the invention. In the example shown, waste is placed in a vessel wherein non-pressurised pre-treatment, hydrolysis, fermentation and separation are performed by the addition of steam, enzymes and yeast/microorganisms. The ethanol beer is optionally removed for further processing while the solid waste is discharged.

[0074] FIG. 2 shows an example of a gravity mixer suitable for the present invention. A perforated inner-drum separates the fermentable and non-fermentable waste fractions. The process according to the present invention can be performed using the following preferred technical parameters.

[0075] For all waste fractions, the particle size is no limitation for processing the waste. Only the dimension of the equipment could limit the maximum particle size of the waste. It is therefore possible to handle and utilise un-sorted un-shredded waste with e.g. particles of 1000 mm throughout the total process.

[0076] Composition of the Mono- and/or Polysaccharide Containing Waste Fraction

[0077] Mono and/or polysaccharide containing waste fractions according to the present invention include any materials containing polymeric and/or monomeric sugars e.g. in the form of starch as well as refined starch, cellulose, hemicellulose and/or di- and/or monosaccharides. Treatment of the below-characterised material can be performed without supplementary addition of water or mechanical shredding.

[0078] Relevant types of mono- and/or polysaccharide containing waste may include:

[0079] waste fractions derived from households such as e.g.: [0080] Unsorted municipal solid waste (MSW) [0081] MSW processed in some central sorting, shredding or pulping device such as e.g. Dewaster or reCulture [0082] Solid waste sorted from households, including both organic fractions and paper rich fractions. [0083] RDF (Refuse-Derived-Fuel) fractions.

[0084] Waste fractions derived from the industry such as e.g.: [0085] General industry waste fractions containing paper or other organic fractions now being treated as household waste. [0086] Waste fraction from paper industry, e.g. from recycling facilities [0087] Waste fractions from food and feed industry [0088] Waste fraction from the medicinal industry

[0089] Waste fractions derived from agriculture or farming related sectors such as e.g.: [0090] Waste fractions from processes including sugar or starch rich products such as potatoes and beet. [0091] Contaminated or in other ways spoiled agriculture products such as grain, potatoes and beet not exploitable for food or feed purposes. [0092] Garden refuse [0093] Manure, or manure derived products

[0094] Waste fractions derived from municipal, county or state related or regulated activities such as e.g.: [0095] Sludge from waste water treatment plants [0096] Fibre or sludge fractions from biogas processing [0097] General waste fractions from the public sector containing paper or other organic fractions [0098] The dry matter content of the mono- and/or polysaccharide containing waste fraction in the enzymatic hydrolysis and fermentation processes is above 20%, preferably 20-80%, more preferably 20-50%, even more preferably 20-45% and most preferably 20-40%

[0099] Free Fall Mixer Device

[0100] If a vessel based on the free fall mixing concept in the form of a drum mixer is utilised, the following technical data are preferred: [0101] Rotational speed: 0-30 rpm, preferably 0-20 rpm, more preferably 0-15 rpm even more preferably 0-10 rpm and most preferably 0-5 rpm. [0102] Rotation with periodically alternated rotating direction, [0103] Rotation in pre-defined intervals.

[0104] As will be evident the optimal rotational speed will depend on the volume of the vessel, the preferred rotational speed may thus be relatively high when the process is carried out in a relatively small vessel, while it may be relatively low when the process is carried out in a relatively large vessel.

[0105] Non-Pressurised Pre-Treatment of Waste Fractions

[0106] If a thermal pre-treatment is chosen the following technical data is preferred: [0107] Pre-treatment temperature: 60-110 C., preferably 65-105 C., more preferably 70-105 C., even more preferably 75-105 C. and most preferably 80-100 C. [0108] Pre-treatment time: 0-120 min, preferably 5-100 min, more preferably 10-90 min, even more preferably 20-80 min and most preferably 30-60 min. [0109] Pre-treatment steam admission: 0-2 kg/kg dry matter, preferably 0.01-1.5 kg/kg dry matter, more preferably 0.02-1.0 kg/kg dry matter, even more preferably 0.03-0.8 kg/kg dry matter and most preferably 0.05-0.5 kg/kg dry matter.

[0110] Enzymatic Hydrolysis of Waste Fractions [0111] Enzymes for hydrolysis of various waste fractions: [0112] Cellulases [0113] Cellobiases [0114] Memicellulases [0115] Alpha amylases [0116] Glyco amylases (AMG) [0117] Oxidative enzymes [0118] Optionally proteolytic enzymes and lipases [0119] Treatment time for enzymatic hydrolysis; 0-98 hours, preferably 0-72 hours, more preferably 0-48 hours, even more preferably 0-24 hours and most preferably 5-15 hours [0120] Temperature for enzymatic hydrolysis (adjusted with reference to the optimum temperatures of the applied enzymes): 20-105 C., preferably 20-100 C., more preferably 20-90 C., more preferably 20-80 C., even more preferably 25-70 C. and most preferably 30-70 C. [0121] pH of waste mash (adjusted with reference to the optimum pH of the applied enzymes): 3-12, preferably 4-11, such as 5-10, more preferably 4-9, such as 6-9, even more preferably 4-8, such as 7-8 and most preferably 4-5.

[0122] Fermentation of hydrolysed waste fraction [0123] Microorganisms for fermentation of various waste fractions. [0124] Standard bakers yeast (dry, fresh or in any other form) [0125] Any kind of genetically or otherwise modified yeast [0126] Any kind of thermophilic bacteria [0127] Any kind of fungus capable of producing the desired product. [0128] Treatment time for fermentation: 1-150 hours, preferably 10-90 hours, more preferably 20-80 hours, even more preferably 30-75 hours and most preferably 40-70 hours. [0129] Temperature for fermentation (adjusted with reference to the optimum temperatures of the applied microorganisms): 20-105 C., preferably 20-100 C., more preferably 20-90 C., more preferably 20-80 C., even more preferably 25-70 C. and most preferably 30-70 C. [0130] pH of waste mash. Adjusted with reference to the optimum pH of the applied micro organisms: 3-12, preferably 4-11, such as 5-10, more preferably 4-9, such as 6-9, even more preferably 4-8, such as 7-8 and most preferably 4-5

Example 1: Experiments with High Cellulase Loading Conducted in a Cement Mixer

[0131] 1) Ethanol Production from Untreated Municipal Solid Waste

[0132] 12.2 kg of unsorted and untreated municipal solid waste from Odense Kraftvarmevrk's waste pit, corresponding to an estimated amount of 8.5 kg dry matter, was loaded into a conventional rotary cement mixer, with a horizontal axis tilted about 10 degrees. The mixer consisted of two internal ribs along the long axis in order to ensure proper mixing of the material. A lid was mounted on the opening in order to keep the waste fraction inside the drum and to reduce evaporation from the mixer. The mixer drum rotated along the horizontal axis with a speed of 29 rpm.

[0133] A steam generator was connected to the rotating drum. Approximately 4.5 kg of saturated steam at 3 barg was added during a period of 35 minutes, of which 20 minutes was used to heat up the waste fraction and the remaining 15 minutes was retention time at 90-96 c.

[0134] The cement mixer was cooled down to 40 C. by removing the steam connection and a fan heater was mounted in order to keep a constant temperature in the range of 40-45 C. Two litres of water was added resulting in a dry matter content of the mash of 45%.

[0135] 1275 ml of Celluclast1.5 FG L, 255 ml of Novozym 188 and 8.5 ml of AMG were added to the waste mash. The Celluclast 1.5 FG L and Novozym 188 enzyme addition corresponded to approximately 15 FPU/g DM.

[0136] The cement mixer was heated to 40-45 C. by use of a fan heater. The mixing/hydrolysis of the material was performed over 9 hours and was interrupted every hour in order to measure the pH level and adjust it to 4-5. The pH of the mash was adjusted by adding citric acid granulates to the drum. The process resulted in a more or less muddy mash containing large non-converted particles, such as plastic containers, tins and pieces of glass. Samples were taken.

[0137] In order to determine the sugar content of the resulting samples, they were centrifuged for 15 min at 2500 rpm after which the supernatant was filtered through a 0.45 m filter and analysed for sugars on HPLC. After 9 hours of enzymatic hydrolysis at an enzyme load of 15 FPU/g DM the supernatant contained 51 g/kg of glucose and 10 g/kg of xylose.

[0138] After 9 hours of hydrolysis at 40-45 C. the saccharification and fermentation processes were performed simultaneously by adding yeast to the cement mixer. The temperature was allowed to cool down below 35 C. after which 170 g of compressed yeast (Baker's yeast, De Danske Spritfabrikker) was added. The saccharification and fermentation processes were continued for 37 hours at 30-35 C. only interrupted once for pH adjustment after 16 hours.

[0139] The simultaneous saccharification and fermentation resulted in 32 g/kg of ethanol equivalent to 4.5 vol. % of ethanol.

[0140] The fermented mash was sieved and the solid fraction dried. The dry solid fraction made up 4.6 kg. The dry matter of the liquid fraction was not further analysed.

[0141] 2) Ethanol Production from Source Sorted Organic Solid Household Waste

[0142] 25.7 kg of source sorted municipal solid waste from deposal area Klintholm I/S corresponding to an estimated amount of 10.3 kg dry matter was handled in the same way as described above. The steam admission resulted in a dry matter content of the mash at approximately 30%.

[0143] 1545 ml of Celluclast 1.5 FG L, 309 ml of Novozym 188, 10 mL of Spirizyme plus FG (glyco amylase) and 10 ml of Liquozyme sc ds (alpha amylase) were added to the waste mash. The Celluclast1.5 FG L and Novozym 188 enzyme addition corresponded to approximately 15 FPU/g DM.

[0144] The cement mixer was heated to 40-45 C. by use of a fan heater. The mixing/hydrolysis of the material was performed for 6 hours and was interrupted every hour in order to measure and adjust the pH to 4-5. The pH of the mash was adjusted by adding citric acid granulates to the drum. The process resulted in semi-liquid mud containing minor amounts of non-converted particles such as pieces of plastic, tins and glass.

[0145] The samples were centrifuged for 15 min at 2500 rpm. The supernatant was filtered through a 0.45 m filter and analysed for sugars on HPLC. After 6 hours of hydrolysis and at an enzyme load of 15 FPU/g DM, the supernatant contained 53 g/kg of glucose and 12 g/kg of xylose.

[0146] After 6 hours of hydrolysis at 40-45 C. the saccharification and fermentation processes were performed simultaneously by the addition of yeast to the cement mixer. The temperature was allowed to cool down below 35 C. and 200 g of compressed yeast (Baker's yeast, De Danske Spritfabrikker) was added. The saccharification and fermentation processes were continued for 39 hours at 30-35 C. only interrupted once after 13 hours for pH adjustment.

[0147] The simultaneous saccharification and fermentation resulted in 37 g/kg of ethanol equivalent to 5.2 vol. % of ethanol.

[0148] After sieving of the fermented mash the wet solid fraction made up 6.0 kg. The dry matter of the liquid fraction was not further analysed,

Example 2: Experiment with High Cellulase Loading Conducted in Pilot Scale Reactor (FIG. 2)

[0149] Ethanol Production (Including Vacuum Stripping) from Source Sorted Organic Solid Household Waste and Paper

[0150] 49.6 kg of source sorted municipal solid waste from deposal area Klintholm I/S and 16.7 kg paper (newspapers and advertising circulars) corresponding to an estimated amount of approximately 33.3 kg dry matter was loaded into the pilot reactor. The pilot reactor is consisting of a stationary drum with a perforated inner drum as can be seen on FIG. 2, the perforated inner drum can rotate along the horizontal axis (in alternating directions with a speed of 0-18 rpm). The reactor is equipped with a cooling/heating jacket for temperature control, which is connected to an electrical heating element and to cooling water: The reactor can also be connected to a vacuum stripper for ethanol recovery.

[0151] Approximately 21 kg of saturated steam at 4 barg was added during a period of 60 minutes while mixing30 min heating and 30 min pre-treatment at 90 C. To further lower the dry matter content of the waste mash 15 l of water was added, which resulted in a dry matter content of 30-32%.

[0152] After the pre-treatment the reactor and content was cooled to approximately 40 C. with cooling water in the cooling jacket of the reactor and addition of small amounts of pressurised air to the drum.

[0153] Prior to addition of enzymes the pH of the waste fraction was adjusted to approximately 5. After this 5 l of Celluclast 1.5 FG, 1 l Novozym 188, 33 ml Spirizyme plus FG and 33 ml Liquozyme sc ds was added. The amount of Celluclast 1.5 FG and Novozym 188 corresponds to an enzyme dose of approximately 15 FPU pr. g dry matter.

[0154] During enzymatic hydrolysis the pH of the waste mash was continuously adjusted by addition of solid citric acid to the drum. Hydrolysis changed the consistency of the waste mash from a solid to a semi liquid mud containing minor amounts of non-converted particles such as pieces of plastic, nutshells and small sticks.

[0155] After 6 hours of hydrolysis at 40-45 C. the waste mash was cooled to 36 C. with cooling water in the cooling jacket and small amounts of pressurised air in the drum. After cooling 666 g compressed Baker's yeast (De Dansk Spritfabrikker) was added to the drum. The simultaneous saccharification and fermentation (SSF) processes were continued for 39 hours at 30-35 C.

[0156] The hydrolysis and the subsequent SSF process, i.e. after 45 hours in total, resulted in 28.8 g/kg of ethanol equivalent to 4.0 vol. % of ethanol.

[0157] After SSF some the ethanol in the reactor was recovered by connecting a vacuum pump and a cooled condenser to the reactor.

Example 3: Experiment with Low Cellulase Loading Conducted in Pilot Scale Reactor (FIG. 2)

[0158] Ethanol Production from Unsorted Municipal Solid Waste and Paper

[0159] 32.1 kg of MSW from two families in one week was added in closed waste bags and 8.1 kg additional paper (newspapers and advertising circulars) corresponding to an estimated amount of approximately 30 kg dry matter was loaded into the pilot reactor, To lower the dry matter content of the waste 12.5 l water was added. For detailed description see example 2.

[0160] After loading the waste was heated to 90 C. with the heating jacket and additional steam (4 barg) to the reactor chamber. When 90 C. (also checked manually by a handheld thermometer inside the drum) was reached, the temperature was kept there for 30 minutes while mixing. Afterwards the mixture was cooled to approximately 50 C. with the cooling jacket while the pH was adjusted to approximately 5 by addition of solid citric acid.

[0161] At correct temperature and pH, enzymes were added in the form of: 1.15 l Celluclast 1.5 FG, 0.25 l Novozym 188, 30 g amylase (NS50033, from Novozymes), 15 g Resinase A 2 and 15 g Alcalase 2.5 L. The amount of Celluclast 1.5 FG and Novozym 188 corresponds to an enzyme dose of approximately 7 FPU pr. g dry matter.

[0162] During the enzymatic hydrolysis the pH of the waste mash was continuously adjusted by addition of solid citric acid to the drum.

[0163] Approximately 24 hours after addition of enzymes the now viscous waste was further chilled to 33 C. and the yeast was added. Soon after the addition of yeast carbon dioxide formation could be observed as bubbles in the yeast lock. During SSF, pH of the mash was adjusted by addition of solid sodium carbonate. The process continued for one week.

[0164] After 24 hours of pre-hydrolysis followed by seven days of SSF the result was 22.8 g/kg of ethanol equivalent to 3.2 vol. % of ethanol.

Example 4: Yields (Waste to Ethanol) for Different Types of Waste

[0165] Several experiments have been conducted with different types of waste. Yields are shown below (volume of ethanol produced pr. tonne dry matter).

TABLE-US-00001 High cellulase Low cellulase loading loading L ethanol/ton L ethanol/ton Type of waste dry matter dry matter Unsorted MSW 60-75 60 Source sorted organic MSW 110-140 Garden refuse (mainly 10-20 lignocellulose), pre-treated at atmospheric pressure Garden refuse (mainly 112 lignocellulose), pre-treated at high pressure Drained manure 20 Waste from potato flour 235 production

[0166] Results demonstrate that considerable amounts of ethanol can be produced from MSW even at low enzyme loadings in this process. Having in mind, that sorting after fermentation is the strength of this process, results also illustrate that source sorting will increase the yield pr tan dry matter. The experiments with garden refuse illustrates the importance of high temperature pre-treatment for waste fractions mainly consisting of lignocellulose, and stresses that this process aiming at converting easy accessible monosaccharides into ethanol or other fermentation products. Even though, it is possible to reach an ethanol concentration of around 4 vol. % in the fermentation broth, which is necessary keeping economy in the distillation. This is possible because of the high dry matter content this process is operated in.

CITED LITERATURE

[0167] Giovannozzi-Sermanni, G., D'Annibale, A., Perani, C., Porri, A., Falesiedi, G. (2002). Solid-state bioreactors for the sustainability. Internet address [0168] reCulture: EP 0921858, EP 87935926.2 [0169] Dewaster: http://www.ewoc.dk/ [0170] U.S. Pat. No. 4,342,820 A [0171] U.S. Pat. No. 4,093,516 A [0172] CZ 9,602,835 A3 [0173] U.S. Pat. No. 4,094,740 A [0174] U.S. Pat. No. 5,637,502