AU2017228592A1 - Conversion systems for biomass - Google Patents

Abstract

Conversion Systems for Biomass srrE i SITE 2 TRANSPORTING SITE 3 TRANSPORTING The efficient production of ethanol from low-cost biomass (e.g., corn, sugar beets, sugar cane, switchgrass and/or paper) has become increasingly important in making ethanol competitive with gasoline and decreasing the United States' dependence on foreign oil. For example, to reduce the cost of transporting biomass to ethanol production facilities, mobile systems for producing ethanol from biomass are provided. Also provided are small-scale ethanol production facilities. For example, instead of transporting biomass to the production facility, the facility is transported to the biomass or is located nearby the source of the biomass. The ethanol production facilities or components thereof may be transported via land, water, or air. Production of other products, such as hydrocarbons, natural gas, hydrogen gas, plastics, polymers, and proteins, can also be made by the methods and facilities. Any product described herein can be made in finished form or un-finished form and moved, e.g., to a fixed facility, e.g., fixed production facility.

Description

ι 2017228592 13 Sep 2017

CONVERSION SYSTEMS FOR BIOMASS

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of Australian Patent Application No. 2015264869, which claims priority from U.S. Provisional Patent Application No. 60/832,735, filed on July 21, 2006. The contents of both of these are incorporated herein by reference in their entirety.

TECHNICAL FIELD

The present invention relates to a system for producing energy (e.g., ethanol, hydrocarbons, gasoline, methane, natural gas, and biodiesel), electricity, nutrients (human and animal), pharmaceuticals (human and veterinary) (e.g., medicines, and drugs), fertilizer, or other co-products from biomass. In particular, the invention relates to mobile, portable, and modular facilities for producing energy (e.g., ethanol, hydrocarbons, gasoline, methane, natural gas, and biodiesel), electricity, nutrients (human and animal), pharmaceuticals (human and veterinary) (e.g., medicines, drugs), fertilizer, or other co-products, by fermentation or other process from biomass (e.g., crops, agricultural waste, and municipal solid waste).

BACKGROUND

Ethanol has a variety of uses, including as an industrial chemical and solvent, fuel additive, and straight liquid fuel. Ethanol is a clean burning fuel that can be produced from renewable sources such as crops (e.g., com, and sugar cane), wood waste, agricultural waste, or other biomass. Ethanol not only reduces air emissions, but it also improves engine performance. Also, as a renewable fuel, ethanol reduces the United States’ dependence on foreign fossil fuels. Recently, ethanol production in the United States has grown from 175 million gallons in 1980 to 3.4 billion gallons in 2004. There are currently 101 ethanol production facilities on-line in the U.S., and 30 more are under construction. Therefore, the production of ethanol in coming years is expected to increase.

The majority of ethanol made in the U.S. is derived from com; however, ethanol can also be produced from other crops high in starches and sugars, such as grain sorghum, wheat, barley, potatoes, sugar cane, or sugar beets. The production of ethanol starts with breaking

AH26(13605316_1):RTK 2017228592 13 Sep 2017 o down the complex sugars (e.g.t amylose, cellulose) foundjn these plants into-simpler fermentable sugars (e,g., dextrose). This first step can be accomplished using enzymes, acid, water, and/or heat Once the stopfer sugars are obtained, yeast or other fermenting microorganisms are added to covert die sugar to ethanol. The ethanol is then removed from the 5 iemieniation by distillation. Water may fee removed from the ethanol by dehydration, tod the ethanol may be denatured to make it unfit for human consumption by adding a small amount of gasoline or other alcohol teg:, methanol).

The production of ethanol as a fuel supplement has many benefits including boosting the economy, creating jobs, benefiting agriculture, aiding rural economic development providing energy security and independence, reducing greenhouse gas emissions, and reducing emissions of other pollutants including carbon monoxide, particulate matter, oxides of nitrogen, and other ozone-forming pollutants.

Joseph DePardo in an article entitled “Outlook for Biomass Ethanol Production tod of 15 ethanol from corn is a mature technology that is not 1 ikel y to see signifieant reductions in production costs. He hypothesixes that the ability to produce ethanol from other low cost biomass will be important to making ethanol competitive as a fuel additive. Therefore, a need remains lor improving the production of ethanol from crops as well as other biomass including toon-virgin” biomass such as municipal solid waste. 20

SUMMARY OF THE INVENTION

The present invention provides for the production of energy (eg., ethanol, hydroeadxms, gasol ine, natural gas, .methane, biodiesel, and hydrogen gas), electricity,.plastics, polymers, nutrients (human and animal), proteins, biomolecules, pharmaceuticals (human and 25 veterinary), -fertilizer, or other products from biomass using, a mobile or portable proditetlon taeility of small-scale facility. The invention stems, at. least in part, from the recognition that it may to more efficient, economical, and/or convenient to move the production facility or to have a small-scale facility nearby rather 'than moving the biomass used as the starting material in the process or the product such: as ethanol produced by the facility. In certain embodiments, 30 the inventive facilities allow the use of local supplies of biomass and other materials needed in the process such as water, electricity, natural gas, gasoline, and sewer, lit the case of mobile 2 2017228592 13 Sep 2017 faculties, the site may include certain infrastructure (e&, a foundation (e.g., concrete slab)) for the tacility* walk roof, building, piping, wiring, sewer lines, gas lines, and lighting). The inventive facilities also allow for the use of biomass traditionally not thought of as usefol for producing energy (e.g., ethanol, hydrocarbons, gasoline, natural gas, methane, biodiesel, and 5 hydrogen gas), electricity, plastics, polymers, nutrients (human and animal),proteins, biomoiecules, pharmaceuticals (human and veterinary), fertilizer, or other products, such as algae, aquatic plants, agricultural waste, and human waste. The inventive systems have 'personal, commercial, governmental, agricultural, and military applications.

In one aspect, the invention provides mobile production facilities for processing 10 biomass to produce any. of the desired products described herein. The mobile faci lities, of the invention arc easily transported, or components of the facility are easily transportable. Transporting the production facility or components of the facility rather than the biomass Starting material is particularly useful and economical given that many of the crops used to produce energy %e.g., bioethanol, gasoline, hydrogen, natural gas) or other desired products are 15 seasonal. Therefore, a production facility only needs to he operational In the area when crops or other biomass is available for processing. Alter the processing is done, the facility or certain components of the facility can travel to another area with biomass available tor conversion to a desired product The in ventive facilities of components thereof may he transported by water, air, land, or any combination thereof The inventive facilities may include parts of the facility 20 or infrastructure that is not transportable or mobile. For example, the inventive production facility or components thereof may he transportable on a boat, barge, ship, or other nautical vessel. Such facilities are particularly useful for producing ethanol or other products from, aquatic biomass such as algae (e.g., Sargamm) or aquatic plants. These facilities are also useful in traveling on abody of water to different areas with biomass suitable for .the 25 production of the desired product (e.g,, traveling on a river or: on the ocean and docking at an area with: suitable biomass for processing). The portable facilities or components thereof may also be transported on land. For example, the facility may be transported by a car, a truck, tractor frailer, and railroad ear(s). Again, the land vehicle with foe portable facility can travel to areas with biomass suitable for the-production of the desired product Finally, the facilities 30 may be transported by air. The facility may be transported by plane, helicopter; and blimp. Air transportation of the facility allows for the use of biomass typically too for away from 3 2017228592 13 Sep 2017 production 'facilities to be used The facility may be on -the plane* or ike facility or components may be dropped from a plane or delivered by plane. The mobile facility is typically conveniently -sized and organized to pro vide for easy transportation of the facility and/or Its individual compoaents. In the case of land transport; the transportation vehicles are typically 5 able to travel roads and highways used by cars, tracks, and tractor; trailers. In the-case of ssa: transport, the facility or components are typically carried by a boat or barge which is moved by a boat In the case of air transport, the facility or components Is sized to St in a plane (e.g., cargo plane) or helicopter.

The inventive mobile facilities or facilities constructed from .-mobile components may 10 include any or all of tire following: apparatuses useful in producing the desired product (e.g. , ethanol): pre-processing means for the biomass, mills, cookers, cooling explainers, holding containers, fermenters, distillation apparatuses, columns, piping transfer containers, and mixing containers. In certain embodiments, the different stages of the production facilities -ate linked together efficiently so that it user can easily transfer materials from one stage of the production 1.5 process to another. The facilities may also include any reagents needed in the production process including yeast or other microorganisms (including genetically engineered microorganisms):, enzymes (e.g.,,amylase, and eellulase), acids {e.g,, .sulfuric acid, hydrochloric acid), bases (eg., sodium hydroxide), chemical-reagents, water, salts, molecular sieves, and columns. In certain embodiments, when ethanol is being produced, the facility includes 20 denaturants such as gasoline or other alcohols for denaturing.the. ethanol.. The inventive facilities can include all the necessary equipment and reagents conveniently stored in the iacility making for easy use of the facility. In certain embodiments* the facility produces enough ethanol or other energy souive to supply the energy needs of a factory, town, village, and island. In certain embodiments, the ethanol production facility produces less than 5 million 25 gallons of ethanol per year. The facility may also optionally include any equipment mandated by international, federal, state, or local law including, for example, safety equipment necessary to ptovent or handle spills, fires, or other emergencies.

As will be appreciated by one of skill in this art, the production facility may be assembled from various--transportable-components. These components may include pre-30 processing means for the biomass, mills, cookers, cooling containers, holding containers, fermenters, distillation apparatuses, columns, piping transfer containers, and mixing containers, 4 2017228592 13 Sep 2017

In certain embodiments, the component comprises a combination of two or more of any of the above. The facility may include-nonrtransportable components. These components of an ethanol production facility are designed for easy assembly of the working .facility at the site.

The components may be pre-fabncated The components may he interchangeable and may 5 provide far scalability of the facility, in certain eases, the components system allows the facility to be easily assembled and broken apart for case of portability. The various components of the facility may be'brought to the site using any combination of transport, means air, water, and land). In certain embodiments, flic components are brought to a site with certain Mrastmctuto which may include electricity, shelter, foundation, .-sewer, water, and 10 natural gas lines. All or some of the components may be -late disssseoibl ed and moved to a new site. In certain embodiments, particular components: and/or the infrastructure may remain at the-Site to be optionally used again.

In some cases, the mobile production facility or components thereof are disposable so that: after it has: served its purpose-a portion or all of the facility is abandoned temporarily or 15 permanently. In other embodiments, the facility or components thereof are meant to be re-used ami am therefore hansported from place to place with suitable biomass. The facility may be completely self-sufficieni requiring only the addition of biomass, or the facility may require other materials or utilities such as water, electricity, natural gas. gasoline, and sewer. For example, the ethanol or other energy produced by the mobile facility may be used to power a 20 generator to supply electricity te the facility, or the ethanol or other energy source may be burned to provide the heat to break down the biomass in a cooker or to run a distillation. The ethanol or other energy may also be used to power the vehicle used to transport the facility or components thereof. in another aspect, the invention also provides small-scale ethanol production facilities 25 (e.gi, producing less than 5 million gallons of ethanol), in certain embodiments, the inventive small-scale facilities produce less than 1 million gallons of ethanol These small-scale facilities may be portable or components of the system may be portable as described above. These facilities may include any or ail of the following apparatuses useful in producing bioethanol: pre-processing means for the biomass, nulls, cookers, cooling containers, holding containers, 3.0 fermenters, distillation apparatuses, columns, piping transfer containers, and mixing containers.

In certain embodiments, the different stages of the production facilities are linked together

S efficiently so that a user can easily transfer materials from one stage of the ethanol production process toanother, The facilities may also inchide any reagents needed in the ethanol production process including yeast or other microorganisms (including genetically engineered microorganisms), enzymes (e.g., amylase, and bellulase), acids (e,g,> sulfuric acid, and hydrochloric acid), bases («ag., sodium hydroxide), water, sads, molecular sieves, gasoline or other alcohols for denaturing the ethanol, and any other reagents. The Inventive facilities can, e.g., include all the necessary equipment and reagentsconveniently stored in the mobile facility making for easy use of the facility. In certain embodiments, the facility produces enough ethanol to supply the ethanol needs of a factory, town, village, and island. In certain embodiments, the facility produces less than 5 million gallons of ethanol per year. The facility may also optionally include any equipment. mandated by international, federal, state, or local law ineludmg, for example, safety equipment necessary to prevent or handle spills, fires, or other emergencies. Other products as described herein may also be produced by the small-scale production facilities.

The present invention also providesprocesses for producing a desired product using an inventive facility. The process uses biomass from a local area ixvan inventive production facility to produce the desired product locally. The locally produced product ,{&g.f ethanol, gasoline, natural gas, hydrogen gas, and hydrocarbons) is then preferably'.used locally to avoid the cost of the transporting both the biomass and the final product. Preferably, a local water source is used in the production process. Other reagents needed for the process may be provided by the facility or provided locally. The waste or co-products from the production process, e.g., the distillers grain, can be used locally as a highly nutritious livestock feed or as a fertilizer. Other waste products or co-products from the process such as biomolecules, carbohydrates, protein, and polymers may also be packaged, used, and/or sold.

The mobile component-based ethanol production facilities and small-scale production facili ties complement larger-Scale ethanol production facilities (ie:, facilities that produce over 10-20 million gallons of ethanol per year). In some cases, the inventive facilities may eliminate the need for large-scale ethanol production facilities in some areas. The portable nature of certain systems works .especially well given the cyclical nature of crops and other biomass in various geographic areas. These inventive facilities also allow for the economical production of ethanol from low cost biomass, which will aid making ethanol a competitive fuel additive. 6 2017228592 13 Sep 2017

In certain <mibodim.ettts, the inventive system uses biomass that is not com, sugarcane, or sugarbeet, or includes a; small portion of these crops.

In one aspect, the invention features a faeiiliy for producing ethanol from biomass..

Such a facility includes at least one component that is portable. 5 In some embodiments, the component performs at least one step in the process of converting biomass to ethanol. for example, the component can pre-processes the biomass, ferment the biomass, or purify ethanol produced from tire biomass,

In some embodiments, the facility is capable of only producing less than about 1 million gallons of ethanol per year, or less than about 5 million gallons of ethanol per year, 10 In some instances, the facility includes at least two portable components.

In another aspect, the invmrion features a portable facility for producing ethanol from biomass.

In .another aspect, the invention features a portable facility for producing ethanol from 'biomass. Sued a facility includes a means for transporting the facility and a fermenter for 15 eortverting sugars derived from biomass info ethanol.

For example, the faeiiliy cast be transported by land. For example, foe facility can be transported by railroad.

For example, foe facility can be transported by water, such as by using a boat, barge or other nautical vessel 20 For example, the facility can. be transported by air, such as by using an airplane or helicopter.

For example, more than one mode of iranspoitation can be used. For example, any one or more of air, land or nautical modes may be utilized. For example, train in combination with barge or boat, or blimp in combination with train. 25 For example, the facility can further include a means for converting complex sugars of biomass into ampler, more fermentable sugars.

For example, the facility am also include a means for purifying the ethanol produced in the fermenter, such as one or more distillation columns.

In another aspect, foe invention features a portable facility for producing ethanol born 30 biomass that includes a means for transporting foe facility, a mill for grinding the biomass, a 2017228592 13 Sep 2017 cooker for liquefying the biomass, a fermenter for converting sugars deri ved from biomass into ethanol and a·distillation apparatus.

In another aspect, the invention features «.method of producing ethanol from biomass that includes providing biomass; providing a portable ethanol production facility; and 5 producing ethanol from the biomass using the portable ethanol production facility.

In another aspect, the invention features methods of producing ethanol from biomass, e.g;, one or more cellulosic and/or lignoceilulosic materials (e.g., switchgrass and/or paper), that include' producing ethanol from biomass at a first site with a-resetor .or a converter, :e.g., a fermenter; transporting the reactor or converter to a second site; and producing; ethafcol from 10 biomass at. the second site with the reactor or converter.

For example, the biomass can be or can include any cellulosia or lignqcelluiosie material such as com, sugar cane, sugar beets, trees, shrubs, grasses, phytoplankton, zooplankton, algae, macroalgae, seaweed, com husks, bushes, lumber, wood waste, pulp, cotton, wool, linen, paper, newspapers, corrugated containers, mixed paper, computer printouts, IS white office paper, printing plant scraps, leaves, twigs, grass, plant cuttings, branches, frees, vines, sewage, agricultural waste. Mixtures of any of these can also be utilized.

For example, transporting can be performed with a nautical vessel, e.g., a boat, a barge, a ship, dock or a fioating platform. For example, transporting can be performed with a land vehicle, such as a ear, truck, tractor trailer of train. For example,'' transporting can be performed 20 with an airborne vehicle, such as a plane, helicopter or blimp. in some embodiments, transporting is performed by more than a single mode, such as by a land vehicle and a water vehicle. in some embodiments, the producing is performed while transporting, hi some embodiments, the system uses fixed resources, such as piping aud/br electricity 25 a given site.

In some embodiments, the reactor or converter fonns part of a system and the system also includes a component such as cutters, shearing devices, measuring devices, flow devices, mills, mixers, pumps, wiring, cookers, .heaters, coolers, aerators, containers, holding containers, distillation columns, piping, or mixtures of these, 8 2017228592 13 Sep 2017 15 25 3(3

Spacing between a first site and a second site can be small or relatively large. For example,- the sites can be physically beside one another. For example, the ethanol can be produced while the system is. being carried by a moving train. in other embodiments, the first site and second site are spaced apart by a distance of about 25 miles or more. e.g., about 50 miles or mote, about 75 miles or more, about 100 miles or more, about 150 miles or more, about 250 or more miles, or even about 500 mites or more.

In some embodiments, producing ethanol from biomass at the first and/or second site includes hydrolyzing the biomass, and then fermenting the biomass.

The methods can further include, e.g., transporting the system to a third site, and then producing ethanol at the third site. The methods can include also a fourth, fifth, sixth, seventh, eighth or more sites. Producing can occur at airy number of these sites.

In some embodiments, prior to producing ethanol δοτή biomass at the first and/or second site with the system, the system is assembled.

For example, the producing ethanol from biomass can include eqntactins the biomass with· one or .more microorganisms, such as a one or more species of yeast and/or bacteria, disposed in the fermenter. Combinations of different organisms may be used, e.g., combinations of yeast and bacteria or different species of yeast or bacteria.

For example, the one or more microorganisms can include one or more genetically engineered bacteria.

In another aspect, the invention features methods of producing energy iforn biomass that include' producing a first energy source from biomass at a first site with a reactor or a converter; transporting the reactor or a convert® to a second site; and producing a second energy source from biomass at the second site with- the reactor or a converter.

In some embodiments, the first and second energy sources are the same.

For example, the energy source can be an alcohol, such as ethanol or n-butanol, gasoline, hydrocarbons, hydrogen, natural gas, biodiesel electricity or mixftues of any of these. In specific embodiments, the energy source is or inctudes an alcohol, such as ethanol.

In another aspect, the invention features methods of producing products from biomass that include producing a first product from biomass at a first site with a reactor or a converter; transporting the system to a second site; and producing a second product from biomass at the second site with the reactor or a converter. 9 2017228592 13 Sep 2017

In some embodiments, product of products can be made in a mobile facility, and then finished in a fixed facility, e.g.r fixed production facility. For example, the on-finished product or products can be. transported by a vehicle, e.g,, a train and/or a ship, or another conveyance method, such as pipes. Combinations of these conveyance methods can he utilized. 5 In some embodiments, the first and Second, products are the same.

In some embodiments, the first or second products include ethanol and/or a-butanol.

For example, product can be ethanol, n-hutanol, hydrocarbons, gasoline, natural gas, methane, biodiesel, hydrogen, electricity, polymers, nutrients, proteins, biomoleeules, pharmaceuticals, pharmaceutical products, fertilizer or mixtures of any of these, ip In some embodiments, the first or second products include one or more biomolecules.

For example, the biomoieeule can be a nucleic acid, a protein, a lipid, a steroid, .a natural product, a metabolic product, a nucleotide, a fat, an amino acid, a pqrtide or mixtures of any of these.

In another aspect, the invention features methods of producing products from biomass, j5 e.g., eeliulosic or jignpeeliulosie materials, the include producing a first product from biomass at a first-site with a reactor, the first site being located on a body of water, transporting the reactor to a second site also on the body of water; and producing a second product from biomass at the second site with the reactor. In such aspects, the biomass can obtained from the body of water, 20 For example, the biomass can be plankton, aquatic plants, algae, seaweed or ouxfufes of these. hi another aspect, the invention features methods of producing products from biomass that include producing a first product from'biomass at a first site with a reactor or converter; transporting the reactor or converter by a first mode to a second site; producing a second 25 product from biomass at the second site with the reactor or converter; and transporting tire reactor or converter by a second mode different than the first mode to a. third site.

Definitions “Bioethaabl”: The term “biocthanol” refers to ethanol produced partially or entirely from biomass. In certain embodiments, bioethanol is producedhy fermentation of sugars 30 derived from biomass. The term bioethanol is used interchangeably herein; with the term 10 ethanol “Biomass": The term “biomass” refers to any material or combination of materials that «an be used in the production system to produce energy (e g. , ethanol, hydrocarbons, gasoline, natural gas,.-methane, biodiesel* and hydrogen gas), electricity, "plastics, polymers, nutrients (human and animal), proteins, biomoieoules, pharmaceuticals(human and veterinary; e.g,, drugs and medicines), fertilizer, or other products, hi certain embodiments, sugars or other organic compounds from the biomass are converted into ethanol (e.g.f by fermentation). Exemplary biomass indudes crops (e.g., com, sugar cane, sugar beets), trees, shrubs, grasses, plankton (eg,, phytoplankton, zooplankton, bacteriopiankton), algae, raacroalgae (e.g., species from the genus Sdrgassum), seaweed, agricultural waste (e.g., branches, com husks, bushes, and weeds),-synthetic materials,.synthetic plasties, industrial waste, recycled waster, municipal solid waste,--synthetic waste, human waste, animal waste, commercial organics (eg., beverage industry waste, cheese, whey, dairy waste, food processing waste, lumber and industrial wood waste, pulp and paper facility waste, restaurant waste, fabrics, cotton, wool, and linen), construction and demolition debris, waste paper (e.g,, old newspapers, old corrugated explainers,· mixed paper, pulp substitutes, computer printouts, white office paper, and printing plant scraps), yard waste (eg., leaves, twigs, grass, plant cuttings, branches, trees, and vines). Biomass includes both virgin biomass and non-virgin, biomass. “Biompleeule”; The term “biomoleeule” refers to any chemical compound that can he produced, by a cell or organism:. In certain embodiments,: the cell is wild type and has not been genetically engineered by the band of man, in other embodiments, the cell lias been altered by the hand of man. Exemplary biomolecules .includenucleic acids, proteins, lipids, steroids, natural products, metabolic products, nucleotides, nucleosides, fats, amino acids, and peptides. 'wC0mpon«®ts-’:' The term “component** refersto any part of a biomass conversion facility. The component may be of any size or shape. It may include one or multiple pieces of equipment used in the energy production or biomass conversion process. In certain embodiments, the component includes several pieces of equipment, It may optionally include piping or wiring and may optionally include hookups so that it can he connected with other components or infrastructure at. the site, in certain embodiments, the component is transportable by air, water, or land. Exemplary components comprise one or more of the following: pre-processing means ter the biomass, mills, mixers, pumps, wiring, cookers, 11 2017228592 13 Sep 2017 heating means, cooling means, aeration means, cooling containers, holding containers,: fermenters, distillation apparatuses, columns, piping, transfer containers' and mixing containers. In-certain embodiments, the components are for the modular assembly of m. ethanol production facility. 5 “Dehydration5’; The term “dehydration” refers to removing water from a material. In. certain embodiments, dehydration refers to removing water front the ethanol produced by the system. The resu Iting ethanol may be free of ethanol, or 1,2, 3,4, or 5% water may remai n in the ethanol In certain embodiments, the ethanol alter dehydration includes less than 1% water. The .ethanol may he dehydrated using any means known in tfee'-art including distillation, 10 axeoiroping, or using molecular sieves, “Denatured ethanol··’: The term “denatured alcohol” refers to ethanol that has been mixed with another material to make it unfit for human consumption. In most jurisdictions, the sale of ethanol as-a pure substance of in tire form of alcoholic beverages, is heavily taxed. In order to relieve non-beverage industries of this tax burden, governments specify formulations 15 for denatured alcohol which consists of ethanol blended wife various adds fives to render it unfit for human consumption, .These additives, also known as denaturants, are either toxic and/or have an unpleasant taste or odor, Denatured ethanol formulations intended for a particular use {e.g, use as a fuel additive) contain denaturants chosen so as not to interfere with that use, 20 “Distillation”: The term “distillation” refers to a process of purifying the ethanol from the fermented mash. The distillation process typically involves a change of state from a liquid to a gas and subsequent condensation as a means of purification, “Energy”: The term: “energy” includes any energy source that can be produced from biomass. The energy produced from biomass is typically organic compounds. The energy can 25 be burned to produce heat which can be used to produce electricity or power a vehicle for example. In certain embodiments, the energy is ethanol. In other embodiments, the energy is alcohol, hi other embodiments, the energy is hydrocarbons- In certain embodiments, the energy Is fete. In certain embodiments, the energy is fatty acids. In other embodiments, the energy is acetic acid. In other embodiments, the energy js. gasoline. In certain embodiments, 30 the energy is a mixture of organic compounds. In certain embodiments, the energy is natural gas, In certain embodiments, the energy is hydrogen, gas, In certain embodiments, the energy 12 2017228592 13 Sep 2017 is methane gas. In certain embodiments, the energy is biodiesel in certain embodiments, the energy is electricity. ^Ethanol”: The term “ethanof' refers to the chemical compound, CB3CH7OH. Ethanol is also .referred to as grain alcohol Ethanol is a flammable, tasteless,·colorless,.mildly toxic h chemical compounds with a -distinctive odor. The terra ethanol may refer to any depee of purity of ethanol. In certain embodiments, the ethanol is at least 50%, 60%, 70%, 80%, 90%, 95%, 98%, or 99% pure. In some eases, tire ethanol is 100% pure. In other cases, the ethanol is denatured with 1-10% or 2-5% other solvents (&amp;g.. methanol, isopropanol, gasoline, hexanes, pentane) to make it unfit for human consumption. In certain .embodiments, the' 10 ethanol is mixed with water. In other embodiments, the ethanol is anhydrous (e.g., after a dehydration step). “Fermentatioivh The term ife^eatattm’’refers to the process of converting sugars to ethanol Or any other desired products including energy (e.gc, hydrocarbons, gasoline, natural gas, methane, biodiesel, and hydrogen gas),.'electricity, plastics, polymers, nutrients (human 15 and animal), proteins, hiomoleeules, pharmaceuticals (human and veterinary; e.g,, drugs and medicines}, and lertilmer. In certain embodiments, the term fermentation refers to the process of making organic molecules useful as an energy source from biomass. Fermentation is typically performed by vnicroorganisms such as bacteria or yeast. The fermentation process for ethanol is typically performed in an oxygen-deficient atmosphere to prevent the further 20 oxidation of the desired ethanol to acetic acid,

As defined herein, a “fermentor, reactor or a converter” is a device that is capable of holding at least about 1,000 gallons of material, such as a ecllulosie and/or lignoceilulosic material, a microorganism and a solvent, sueli as water. Is some embodiments, the fermenter, reactor of converter is capable of holding: greater than about 2,000 gallons of material, greater 25 than about 2,500 gallons, greater than about 5,000.gallons, greater than about 10,000 gallons, greater than about 25,000 gallons, greater than about 50,000 gallons, or:even greater that about 100,000 gallons.

All publications, patent applications, patents, and otlter reierences mehtioned herein, are incorporated by reference in their entirety for all that they contain. 30 Other features and advantages of the invention will be apparent from the following detailed description, and from the claims. 13 2017228592 13 Sep 2017

DESCRIPTION OF DRAWINGS

Fig. I is a block -diagram· that schematically illustrates methods of producing various products, such as ethanol or mbutanoh

Fig. 2 is a emss-sectiomd view of a rotary knife cutter.

DETAILED DESCRIPTION

Described .herein are mobile-and/of small-scale (e.g,, less than i-5.mill.io» gallons per 10 year) systems for producing energy (eg:, ethanol, hydrocarbons, gasoline, natural gas, methane, biodiesel, and hydrogen gas), electricity, plastics, polymers, nutrients (human and animal), proteins, biomolecules, pharmaceuticals (human and veterinary; e,g., drugs and medkines), fertiliser, or other products including processes, feeilities, and components of the facility for producing the desired product, from biomass. The. systems eliminate or at least 15 reduce the seed for transporting the starting material biomass, which can fee, e.g., of a low bulk density, to a stationary large-scale production facility, it also may reduce the need to transport the desired product produced by the mobile facility a long distance to its end user or a distribution facility. The system for producing the desired product allows for the processing of biomass that ordinarily would not be economically suitable for:conversion to energy1 (erg., 20 ethanol, hydrocarbons, gasoline, natural gas, methane, biodiesel, mid hydrogen gas), electricity, plastics, polymers, nutrients (human and animal), proteins,, biomolecules, pharmaceuticals (human and veterinary; &amp;.g., drugs and medicines), fertilizer, or otherproducts due to transportation, processing, or other costs. The system makes the production of energy (eg., ethanol hydrocarbons, gasoline, natural gas, methane, biodiesel, and hydrogen gas), electricity, 25 plastics, polymers, nutrients (human and .animal), proteins, hiomolecuies, pharmaceuticals: (human and veterinary; &amp;,g., drugs:and medicines), fertilizer, or other products more economical by reducing the costs, particularly the transportation costs, of producing the desired product.

Production facilities that are configured: in such a way that it or its various components 30 can fee easily transported by land, sea, air, or a combination thereof, in certain embodiments, the materials and equipment need to produce desired product from, biomass are compactly 14· 2017228592 13 Sep 2017 organized so that it or its components can be transported by a car, frock, tractor trailer,'railroad, boat barge, airplane, helicopter, or combination thereof. In certain embodiments, the taeMty or its components may be limited in size depending on: how the facility or its components are transported. For example, a facility or component being transported, by tractor trailer will need 5: to fit on the bed of a truck, or trailer for transport.

Referring to Fig, I , methods of producing products, such as ethanol or c-butanol, from biomass, e.g„ ceilulosicer lignoeeilulosic material, include producing a first product at .a first site with a system that includes a reactor or converter, e.g., a fermenter. The system is transported to a second site, and then a second product is produced from biomass at the second 10 site with the system.

Any number of sites may be utilized. For example, the number of sites can be 2,3,4, 5, 6, or more, e,g., 10, 20,30, 50,100 or more, e,g,, 1000.

For example, a she may fonnpartof a complex or a campus, and portions of the complex or campus may be joined by various .manufacturing infrastructure, such as rail 15 Spacing between a first site and a second site can be relatively small or relatively large.

For example, the sites can be physically beside each other, For example, the system can be carried by a moving train:and producing: ethanol while moving.

In other embodiments,, the first site and second site are spaced apart by a distance of about 10 miles or more, e.g., about 23 miles or more, about 35 or more, about 65 miles or more, 20 about 85 miles: or more, about 100 or more, about 200 miles or more, about 300 or more, or even about 500 miles or more*

In some embodiments, the fermentor, reactor or converter can hold between about 1.,000 gallons and about :100,000 gallons of material e.g., between about 2,500 gallons and about 100,000 gallons, or between about 5,000 gallons and about 75,000 gallons, 25 In certain ei.nbfxlime.nts, the mobile systems or one or more of its components for producing the desired product is transported by land. When the mobile facility or Its components is transported by roads, it preferably·complies with all applicable laws governing the roads of that country, state, province, county, or city. In the U.S., facilities transported, by land using highways and roads may comply with all federal, state, and local laws and 30 regulations, in certain embodiments, the mobile facility being transported by a tractor frailer is no larger than 8 feet 6 inches wide and no longer than 57 feet in length. In certain 15 embedments, the facility is no wider than 8 feet 6 inches and no longer than 53 feet, in certain embodiments, the facility is no wider than 8 feet 6 inches and no longer than 48 feet. In certain embodiments, the facility is no wider than 8 feel 6 inches and no longer than 20-24 feet in length. The height of the vehicle may vary depending on the obstacles on the road the facil ity is being transported via. However, typically the facility is less than 15 feet in height. In certain embodiments, it is less than 14 feet in height In certain embodiments, the facility is transported by a double tractor trailer in which case the total .length for the combination is no greater than 75 feet. In certain embodiments, the total length of the doable is no greater than 65 fee t. In certain embodiments*.· the gross combination weight of the vehicle with die mobile facility or one or more of its componentfs) is no greater than 80,000 pounds. In certain embodiments, the faeilify or a component ihereof fits into a standard container used for shipping by tractor trailer. As would be appreciated by one of skill in this art, the components of the facility may be transported by more than: one land vehicle or may be transported by a land vehicle arui aernnhinatipnof lartd, water, and air vehicles. In eertain embodiments, components that are not sni tnhk. for trmisport by water or air are transported by land. In certain embodiments, components for which water and/or air transportation are not economical are transported by land. However, it is appreciated that in-.certain embodiments land transportation of the fac ility or its componen ts i s not feasible or is not possible (e,g,, due to lack of passable roads).

In certain embodiments, the mobile production facility or some of its eamponenis am small enough: to be transported by a car, sport utility vehicle (SUV), or pickup truck. In certain embodiments, the facility or its components are transported on a trailer pulled by a car, SUV, of pickup truck.

The mobile facility or its various components can also transportable by railroad. In certain embodiments, the facility to be transported by rail is no wider that 14 feet. In other embodiments, the facility is no wider than 13 feet 6 inches. In still other embodiments, the facility is no wider than 13 feet, In certain embodiments, foe facility h no wider than 12 feet 6 inches. The width clearance of thefacility including its outer container will depend on the railways being used to transport the Iacility. In certain embodiments, the minimum width of 12 feet 6.'inches or 13 feet is used to accommodate all railways the iacility could possibly travel along. The length of the facility is no longer than <50 feet In embodiments, the length 16' of the facility is less than 60 feet In certain embodiments, the length is approximately 58 feet in other embodiments, the length is approximately 59 feet, approximately 57 feet, or approximately 56 feel. The height of the facility is typically Jess than 23 feet. In certain embodiments, the height is less than 22 feet, hi other embodiments, the height is less than 21 feet In certain embodiments, the height is less than 20 feet In certain embodiments, the facility or a component thereof fits into a standard container used for shipping by railroad. In yet other embodiments, the height is less than 19 feet The weight of the facility typically does not exceed 200.000 pounds. In certain embodiments, when a l arger mobi le prod uc tion facility is needed, die facility is transported using more than one railroad car where each railroad ear includes a component. These components are then assembled, into an operational facility at the desired, site. In certain embodiments, the facility is assembled on a mi! road track, set of tracks, or spur. In certain embodiments, the. facility comprises 1-ID railroad car's, la certain embodiments, the facility comprises 1 -5 railroad cars. In certain embodiments, each step or a combination of steps of the process of producing ethanol is performed in a separate car. In certain embodiments, the equipment for performing one or more steps is combined into one car. Various components of the faci lity may also be brought to the site for assembly by other land transportation, air transportation, or water transportation.

Any combination of transporting modes can be u ti lized . For example, the systems can be transported by land,and then by water, or by air and then by land.

For exmnpie. the products such as ethanol can be produced during transportation or after transportation.

When the facility or its components are transported by water, the foeility is optionally within the allowed limits of the vessel transporting the facility or coinponent(s}. These limits include length, width, height, and weight limits of the vessel transporting the facility. As will be appreciated by one of skill In this art, the size of the facility will greatly depend on the ske of the vessel transporting the facility or its eomponent(s). 'Larger ships and barges can transport a much larger ethanol production facilities than smaller boats. When the facility or its eomponentfs} are transported by water, the facility may be assembled on a barge, dock, wharf, platform, derek, rig, sand bar, and island. In certain embodiments, the. facility or a component thereof fits into a standard container used for shipping by water. In certain embodiments, the facility is assembled on a flotation device. Various components of the 17 2017228592 13 Sep 2017 facility may be brought to the site for the facility by land or air as well as by water. Facilities on the water or close to the water facilitate the use of aquatic biomass such :a$-plankton, algae, and aquatic plants In the production of the desired product.

Similarly, when the facility is transported by air, the facility or its oomponetxt(s) arc 5 optionally within the allowed limits of the aircraft transporting the facility. These limits include length, width, height, and weight limits of the aircraft; tensportiag the facility. In certain embodiments, the aircraft is an airplane. The airplane may be a: propeller driven plane, a jet, a cargo plane, a military plane, and a commercial airliner. In certain embodiments., the aircraft is a helicopter. In certain embodiments, the aircraft will transport 10' the 'facility or the eompbnent(s) hanging from the aircraft. In certain embodiments, the facility or a component thereof fits into a standard container used far shipping by air. The facility or component may land with the aircraft and he unloaded from the aircraft for use or the facility or component may be used while on board the aircraft. In certain embextimenis, the facility or component .is dropped from the air to the site where it is to he used. In certain IS embodiments, the facility or component includes parachutes or other landing device for a sale landing of the facility . The facility may also include a floatation device for a water landing.

In certain embodiments, the facility or a component thereof includes a. means for absorbing the impact of the landing. In certain embodiments, the facility or components is later moved by land, any or water to a new site. In other embodiments, the facility or components are not 20 -moved and may be abandoned temporarily or permanently. Various other components of an facility may be transported by land or water as well as air. The components may be assembled into aft operational facility at an airport, landing strip, drop site, or any other land or water site. la certain embodiments, the facilities or any of its components are. capable of being 25 transported by any combination of air, land, and/or water transport. In certain embodiments, the facility or its components are transported by all three. In other embodiments, the facility orris components are iransported by land and water, In certain embodiment, the facility or its components are transported by land and air. In other embodiments, the facility or its components arc transported by air and water. In these cases, the vehicle transporting the 30 facility or any of Its-components preferably meets the requirements (e.g., length, width, height, and weight) of the mode of transportation being used. Given that the ethanol, 18 2017228592 13 Sep 2017 hydrocarbons, natural gas, or gasoline being produced acre flammable, any applicable safety laws, rales, or regulations are preferably followed regarding the transport and production, of a flammable liquids or gases. In certain embodiments, equipment for handling spills, fires, and explosions is incorporated into the facility, 5: In certain, embodiments, the facilities include at least one portable component used: in the: production of energy (<·?.$,, ethanol, hydrocarbons, gasoline, natural gas, methane, biodiesel, and hydrogen gas), electricity, plastics, polymers, nutrients (human and animal), proteins, biomolecules, pharmaceuticals (human and veterinary: ag., drugs and medicines), fertiliser, or other products from biomass. The assembled facility as well as any components 10 of the facility are considered to be within the scope of the: disclosure.· A. Component-based facility allows for easy assembly of the facility, raterchangeability, sesiabilityyand pre-lubrication of the components. Breaking the facility into various components also facilitates the mobility aspect of the facility. In certain embodiments, the facility is divided Into two, three, four, fi ve, six, seven, eight, nine, ten, or more-components. Each components may 15 include one or more pieces of equipment with the necessary wiring, piping, drains, control systems, beating and cooling means, stands, coupling devices, and pullets,.. In certain embodiments, the component include walls, roof, flooring, or other iniresiraeture for the component itself, other components, or the entire facility , to certain embodiments, the component. Includes a contained for easy transport of the compdnoat The container may fee 20 used In the production process (e,g\, as a mixing, container or other vat). The sides, bottom, or top of t he container may be used as tire walls, floor, or roof of the shelt er housing the facility or components thereof

In certain embodiments, each Step of the production process is performed in a separate component That Is, all the equipment for a step in the process is included In the component. 25 The various steps and equipment useful in the production of bioefhanoi from biomass are described herein. In other embodiments, a step may require equipment from one or more components. In other embodiments, more than one step of the production process Is included in a component. One or more components of tire facility are assembled to produce an operable facility. The components are typically assembled at a site; prepared for the 30 installation. However, in certain embodiments, there, is afe preparation or infrastructure at the site, instead, the facility or components are sellksupporting. In certain embodiments, the 19 2017228592 13 Sep 2017 components are assembled using a crane, fork lift, truck, or other moving device, which is optioBaliy included in foe system. In other embodiments, the components are assembled using only human labor. Tools may be used in foe assembly of foe .facility. The site may include all the necessary infrastructure to make foe facility operational, Inirastracfore may 5 include walls, roof, foundation, floor, electricity, wiring, piping, sewer, water, and natural gas. lo certain embodiments^ foe infrastructure is not mobile and is stationary. When the facility or any of Us components arc moved, the infrastructure may left behind to potentially be used again foe future. In certain embodiments, the infrastruciure is used to assemble an production facility every month, every season, every year, or any time sufficient biomass is 10 available at the site to supply the facility.

Efoanol production facilities that are smaller in scale than traditional ethanol production facilities. Typically, efoanol production facilities produce greater than 10-20 million gallons of efoanol per year with some facilities exceeding 50 million gallons of ethanol peryear.. The facilities produce less than 5 million gallons of et hanol or other energy source per year. In 15 certain embodiments, foe-facility produces less than I million gallons of ethanol or other energy source per year. In certain embodiments, the facility produces less than 0,5 million gallons of ethanol or other energy source per year. In certain embodiments, the facility produces less than 0.1 million gallons of efoanol or other energy source per year. In certain embodiments, the facility produces: less them 0.01 million gallons of ethanol or other energy 2D source per year. In certain embodiments, the facility produces less than 0.001 million gallons of ethanol or other energy source per year. These facilities may he mobile or include mobile components as described herein. In certain embodiments, the facility is stationary. The amount of energy produced by a facility'is sufficient fo meet the demands of a factory, military base, small town, rural village, county, form, and island. The small size of the 25 facility' allows for numerous facilities to be placed in a geo^apMcregiom For example, a facility may be placed in any areas where there is sufficient biomass (e g., crops, waste) to supply the facility with. Snialler-seale facilities closer to the biomass being processed by the system reduce transportation costs, aid in certain cases, may alknv ethanol to he produced economically where it could not he produced economically by large-scale facilities, 30 The hioethanoi production facilities can have all or some of the equipment necessary for producing the desired product from biomass. The biomass used by the systems include any 20 2017228592 13 Sep 2017 'type of biomass. In certain embodiments, more conventional sources of biomass such as com, sugar beets, grains, sugar cane, or whey is used as the starting material* In. other embodiments, conventional sources of biomass are used including agricultural waste, algae, waste, and human waste. In certain embodiments, the systems do no t use com, sugar 5 beets, or sugarcane. Iii certain embodiments;, the systems: do use com. In other embodiments, the. system uses sugar beets or sugarcane. In certain embodiments, the system is designed to use a variety of different types of biomass as starting material. In other embodiments, the system I s designed to use one type of biomass. In certain embodiments, various components may be switched interchanged to allow' for different' types of biomass as starting materials, 10 .In certain embodiments, the systems includes processes and apparatuses for pre processing the biomass. In certain embodiments, the biomass is.sorted. In other embodiments, the biomass is cleaned. In other embodiments, the biomass is packaged. In certain embodiments, the biomass is compacted or compressed. In other embodiments, the biomass is liquefied. In other embodiments, the biomass is dehydrated. The pre-processing 15. of the biomass may take place at the site of harvesting tire biomass, before transportation of the biomass, during the transportation, during storage of the biomass, or at the she of the energy production. Any equipment and methods used to pre-process biomass, for energy production may be used. In certain embodiments, the pre-processing means is considered to be part of the system. 20 The process of producing energy (e.g., ethanol hydrocarbons, gasoline, natural gas,: methane, biodiesel, and hydrogen gas), electricity, plastics, polymers, nutrients (human and animal), proteins, biomolecules, pharmaceuticals (human and veterinary; e,g., drugs and medicines), fertilizer, or Other products from biomass can be broken down into several steps. The first involves grinding the biomass into a fine powder, chopping the biomass, shearing 2 S the biomass* or otherwise making the complex carbohydrates or other biomoiecules in the biomass available for further processing. In certain embodiments, the resulting biomass is then mixed with water and optionally microorganisms («?.#., bacteria), algae, enzymes, acid, base, or chemical reagent. The mixture is then optionally heated in a cooker or other apparatus to facilitate the break-down of complex sugars (mg,, cellulose, starch) into 30 fermentable, simpler sugars (e.g,, glucose). This step may also facilitate the breakdown of other biomoiecules or cellular structures such as lipids, protein, nucleic acids, steroids, 21 2017228592 13 Sep 2017 natural, products, cell wail, cell .membrane, and intracellular membranes. The resulting mixture, commonly Known as the mash, is then fermented with the addition of a microorganism such as yeast in certain embodiments, other genetically engineered mierbbrg&amp;nisms are used in the fermentation: process. The microorganisms may be 5 particularly suitable for fermenting or converting the biomass used in the process into the desired product The iementatioTyconyersion process is continued until most of the sugars or other starting materials in the fermentation have been converted to ethanol or other desired product. In certain embodiments, co-products· such as carbon dioxide, proteins, polymers, nutrients, fertilisers, or biomoiecuies arc produced during the: process. These may be 10 collected, purified, packaged, and/or sold. The ethanol or other desired product is then optionally separated from the liquid, solid waste, and side products. This is typically done.by distillation; however, other means of separating: or purifying can also be used (eg, column chromatography, extraction, chromatography, and crystallization). The distilled ethanol or other liquid energy source may still contain water so the desired product is optionally 15 dehydrated. In certain embodiments, the desired product («Kg., ethanol) Is dehydrated by running it over a substance that absorbs the remaining water such as molecular sieves. Once the desired product (e.g., ethanol) is purified to the desired degree of purity and water is removed, the desired produet, particularly ethanol, is optionally denatured making it unfit for human consumption. The denaturation process is performed by missing the purified ethanol 20 with 1-5% of gasoline or other organic solvent (e,g·..,. methanol, acetone, isopropanol, and hexanes). Any waste can be discarded. In certain embodiments, the resulting distillers gram is used as livestock feed or as a fertilizer. Carbon dioxide also is produced as a by-product in the fermentation process. The carbon dioxide may be collected and sold. Ollier products such as polymers, protein, lipids^ or other biomolecules are side products may he collected, 25 packaged, and/or sold. in certain embodiments, for example, when bioethanol is being produced from biomass, the facility or a component thereof includes a fermenter and distillation apparatus, hi other embodiments, ihe. prodnction facility or component thereof also includes a. cooker. The facility may also include a mill for grinding the biomass into smaller particles. The facility 30 may also contain equipment such as columns for further purifying and dehydrating the ethanol after distillation. In certain embodiments, the facility also includes containers and 22 2017228592 13 Sep 2017 mix ing equipment for denaturing the produced ethanol In certain embodiments^ the various equipment is interconnected using piping to easily rtansfer foe pmduct froin one step into equipmentfor performing the next step. As needed, the various equipment used in the process is fitted with heating and cooling means, 5 The process begins with biomass. The biomass used by the system may he any biomass suitable for producing ethanol or any other desired product. In certain embodiments, the biomass is high ..starch-or high sugar agricultural crops such as com, sugar cane, sugar ami-beets, The facilities are particularly useful and economical in converting crops to bioethanol because they can arrive or be assembled at the site when the crops (or other biomass) are 10 ready for processing and then leave or he disassembled when the crops (or other biomass) have beep processed, hr certain embodiments, the biomass includes materials that contain cellulose, hemieeMose, lignin, protein, starch, and/or sugar, in certain embodiments, the biomass include plant Matter such as trees, shrubs, grasses, weeds, agricultural crops, and agricultural waste. In certain embodiments, the biomass includes aquatic biomass, for 15 example plankton, aquatic plants, and algae. Aquatic biomass is particularly suitable for being processed by the production facilities that are transported on water. In certain embodiments, the biomass is municipal waste, waste paper, and yard waste. A production facility may routinely travel to a particular area to convert its waste to ethanol or another desired product, or the facility may be assembled at a particular site, brother embodiments, 20 the biomass is human waste.

The initial phases of suing, milling, chopping, cutting, shearing, washing, iiqueficatioa, 'and/or saccharification of the biomass are performed by the facility qr-components-thereofm some embodiments In other embodiments, these steps or some of these steps axe not performed by the facility or components thereof. 25 In .certain embodiments, the biomass is mechanically broken down. For example, in catain embodiments, the soring, milling, chopping, cutting, shearing, washing, or other preprocessing of the biomass for fermentation or -conversion is not performed by the facility or components- thereof* and the resulting processed biomass (also known as the xneal) is the starting material used by the facility or a component thereof In certain embodiment, the 30 facility or a component thereof processes the bi omass to allow for nrxcroogamsxns or chemical to act on the carbohydrates in the biomass. This may Include breaking down cell 23 2017228592 13 Sep 2017 membranes, breaking down cells walls, increasing the surface area, breaking clown macmstrucfaresin the biomass.

In certain embodiments, the biomass or cellulose in the biomass Is texturized or opened up as described in U,S, Patents 5,952,105; 5,973,035; 6,207,729;; 6,258,876; 6,448307; 5 7,074,918; each ofwhich is .incorporated herein by reference; and published U.S. patent applications: 2()050984671; 20050090577; 20050200050; each of which is incorporated herein by reference. This process opens up the fibers in the biomass for further processing by chemicals and mi croogani sms added to the processed biomass in subsequent steps. The process increases the surface area where microorganisms or chemicals can work, 10 Referring to Fig> 2, a rotary knife cutter 20 includes a hopper 22 that can be loaded with a shredded liber source 10" prepared by shredding fiber source 10. Shredded fiber source 10' is sheared between stationary biases 24 and rotating blades 26 to provide a first-fibrous material 12. First fibrous material 12 passes through screen 16, and the resulting second fibrous material 4 is captured in bin 30. To aid in the collection of the second fibrous 15 material 4, bin 30 can have a pressure below nominal atmospheric pressure, e.g., at least 10 percent below nominal atmospheric pressure, e.g„ at least 25 -percent below nominal atmospheric pressure, at least 50 percent below nominal atmospheric pressure, or id least 75 percent below nominal ionospheric pressure. In some embodiments, a vacuum source 50 is utilized to maintain the bin below nominal atmospheric pressure, 20 In certain embodiments, tire biomass is mixed with water and optionally enzymes, microorganisms (e.g., bacteria, fungi, yeast), algae, other organisms, chemical reagents, or a combination thereof. This step breaks down the cellular structures, sugars, and hlomolepufes of the biomass before. Ms .-conversion, into fee desired product, in certain embodiments,fee biomass is mixed with a microorganism that aids in the breakdown of the biomass. The 25 microorganism may be genetically engineered. In certain embodiments, the biomass is mixed with an. algae that aids in the breakdown of fee biomass. The respiting mixture may he heated, cooled, and mixed to effect the desired changes to the biomass. In certain embodiments, the biomass is substantially liquefied resulting nr s mash -before- It is transferred to theiaeility or a component thereof In still other embodiments, the .complex- sugars in the 30 mash am broken down Into simpler, fermentable sugars, and the resulting mash is hansibrred to the facility or a component thereof for processing. 24 2017228592 13 Sep 2017

Once the biomass or a processed ibnn. of the biomass (e.g. , the meal, the mash, opened apd hber) enters Ore facility or component thereof) it is further processed to form ethanol or any other desired-product .In certain embodiments, the facility or a component pre-processes, bquefies, and converts the: complex sugars in. thernash to simpler sugars. In" other 5 embodiments the facility or a component thereof liquefies and converts the complex sugars to simpler sugars for distillation. In still oilier embodiments. the:-c»inplex·. sugar in the mash are. converted to simpler sugars in the facility or a component thereof. This conversion process is effected by enzymes such as amylase or cellulase, acid (e.g., sulfuric acid), microorganisms, aod/ατ heat. The conversion process breaks down complex sugars such as cellulose and i 0 starch to simpler 5- or 6- carbon sugars such as glucose.

Once the mash with the broken down sugars is obtained either through processing inside or outside the facility, the ferrnentation/conversion process is begun, in certain embodiments, the mash is fermented to produce ethanol. The fermentation .process is typically begun by bringing the mash to a particular temperature, for example, between 30 15 and 45 i5C. in certain embodiments, the fermentation takes place at approximately 30 %1 In certain embodiments, the pH of the mash is adjusted to approximately pH 6-8, preferably appnxximately pH 7-7.5. in certain embodiments, tire fcrmentahon is carried out hum oxygen-depleted atmosphere. A.fomenting nhcrOorganism is then added to the mash. In certain embodiments, the fepi^ti%anciO0i^amsm':is' yfeast. in other embodiments, the 20 fermenting microorganism is Sacchammyms cerevmae. la.certain embodiments, the fermenting organism is Schtzosacekaramyces pomhe. in oilier embodiments, the microorganism is Zymammas mobilis. In other emlmdimenis, the microorganism is Escherichia colt In certain embodiments, the microorganism is a geneticaliy engineered organism. Examples of genetically engineered fermenting organisms useful in the production 25 of bioeihano! are described in U.S. Patents; 6,697,696; 6,306,639; 5,162,516; 5,028,539; 5,000,000; -4,400,470; each of which is incorporated herein by : reference, in certain embodiments, the fermentation mixture is kept at a constant temperature and pH during the fermentation process. The fermentation typically last from 24 hours to 500 hours. In certain embodiments, the fermentationlasts from 50-200 hours. In certain other embodiments, die 3(} fermentation last from 100-200 hours. As would be appreciated by one of skill in tins art, the 25 2017228592 13 Sep 2017 biomass vmicToargaiusm5 temperature, and other -conditions used in the fennentatioh will determine the leo|th of time needed to convert the biomass to ethanol

In other 'embodiments, the processed biomass or mash is converted into another energy source besides ethanol {<?.£.. gasoline, hydrocarbons, hydrogen gas, natural gas, biodiesel, and 5 electricity) or another desired product or co-product This conversion is effected by microorganisms, in certain embodiments, the microorganisms are genetically engineered, in certain particular embodiments, the microorganisms are genetically engineered to produced the desired product. For example, in certain embodiments, the microorganisms are designed to produce natural gas or hydrogen gas from biomass. In other embodiments, fee 10 microorganisms are designed toproduce gasoline or hydrocarbons from biomass.

In other embodiments, the processed biomass or mash is converted into other desired products such as plastics, polymers, and nutrients.. This conversion is effected by microorganisms.. In certain .embodiments, the microorganisms are genetically engineered. In certain particular embodiments, fee microorganisms are genetically engineered, to produced 15 the desired polymer. In certain embodiments, the microorganisms are designed to produce nutrients.

In certain embodiments, fee desired product is removed as it is produced. In other embodiments, the desired product is purified from fee feromutatiomeemveraon alter fee iermentatiomcoriversion Is stopped. In the production of bioe&amp;anol, after fee fermentation 20 step is complete, fee fermented mash (also known as beer) contains anywhem from 5% to 20% ethanol in some embodiments, fee ethanol is removed as it is-produced. Tbs ethanol is purified from the water, and solids by distillation. The distillation process involves vaporizing fee ethanol and then recondensing it into liquid form again. The purity of fee ethanol obtained from fee distillation can he increased by repeatedly distilling fee: resulting 25 ethanol until the desired purity is achieved. The ethanol may be further purified by removing any remaining water using a dehydration step. In certain embodiments, fee ethanol is passed over a material which absorbs water such as molecular sieves. In certain embodiments, the ethanol is distilled or azeotroped to remove most of the water from the ethanol Similarly, if a .different desired product is produced than ethanol, it can similarly he purified from fee 30 converted biomass. Preferably, as much of the desired product is produced before fee 26 «.inversion process Is stopped -In certain embodiments, the desired product: is drawn off as it is produced.

Analogously, the facilities may produce 100% ethanol or ethanol of any desired state of purity. For example, the facility with its distillation apparatus may produce less than 1005¾ pure ethanol in certain embodiments, the ethanol is at least 80%, at least 90%, at least 95%, at least 985», or at least 9954 pure. The ethanol, if desired, can .'then be further purified and/or dehydrated outside the mobile facility. In certain embodiments, the facility produces pure ethanol that is subsequently denatured. An organic solvent such as methanol, isopropanol, hexanes, and gasoline, is added to the purified ethanol to produced denatured ethanol, which is unfit for human consumption. Exemplary denaforants Include methanol, camphor, aldehydes, amyl alcohol, gasoline, isopropanol, terpmeol, benzene, castor oil, acetone, nicotine, acids, kerosene, and diethyl phthalate, hi certain embodiments, 1-10% of organic sol vent is added to the ethanol. In other embodiments, 1-354 of organic solvent is added. In certain embodiments, 2-5% of gasoline is added to the ethanol to denture it.

Any of the knowledge in the art of producing of ethanol, from biomass may be used in the system for producing: ethanol. Various aspects of the process of producing ethanol from biomass are described in U.S. Patents 7,070,967; 7,037,704- 7,037,378; 7,033,781; 7.026,152; 7,022,894; 6,933,404; 6,927,048; 6,908,995; 6,861,248; 6,849,434; 6,846,657; 6,803,218; 6,755,975; 6,737,257; 6,716,631; 6,703,227; 6,699,696:6,663,780; 6,660,506; 6,648,930; 6 JO553?6;6,596,908; 6,592,921; 0,582,944; 6,555,350; 6,528,31I; 6,509,180; 6,468,567; 6,420,146; 6,387,554; 6,379,964; 6,372,269; 6,355,456; 6,352,859; 6,335,198; 6,335,177; 6,333,181; 6,326,204; 6,306,639; 6,287,862; 6280,986; 6,267,309; 6,251,674; 6,224,915; 6,136,577; 6,130,076; 6,107,093; 6,090,595; 6,054,611; 6,045,660; 6,001,568; 5,981,807; 5,975,439; 5,958,698; 5,932,456; 5,916,787; 5,916,780; 5,892,107; 5,882,905; 5,869,301; 5,840,971; 5,821,093; 5,789,210; 5,779,164; 5,756,862; 5,735,916; 5,705,369; 5,677,154; 5,616,478; 5,609,723; 5,578,472; 5,571,703; 5,559,031; 5,554,520; 5,545,543; 5,504,259; 5,503,996; 5,488,185; 5,487,989; 5,482,846; 5,474,924; 5,470,433; 5,424,417; 5,424,202; 5,407,817; 5,397,436; 5,372,93915,345,477: 5,258,293; 5,231,017; 5,223,567; 5,186,722; 5,182,199; 5,135,861; 5,134,944; 5,106,634; 5,100,791; 5,086,144; 5,081,285; 5,071,675; 5,063,150; 5,061,497; 5,047,332; 5,028,539; 5,013,436; 5,000,000; 4,985,355; 4,952,504; 4,952,503; 4,933,198; 4,886,751; 4,885,241; 4,859,758; 4,S40,903; 4,840,902; 27 K> 30 2 to to to to Us to to to to io to to to to to S"\ p, -/-N O' O' 05 o •C' Ό1 CD CD r~·, O' Ό o O CD Ο···" o GO p· 44 v« V V( V Vt V Vi V Os O'"- /“*·. o o Cr o sCv o CD o fo o s iv> .p. o iO o CD <«Λ y»/ to t-J ό go 45v •-O OO S'-J 0*3 Us Os 4^ 4a O'- u; Ui -Ϊ -Pa Us Vi u> Us C to to -ia Ca 04 Us OO o o Ui >~~«. OO s£3 -4 to o> 0¾ Us '-Ϊ u> 00 VO 4>. . p! O**' tO --5 VC 5.0 <Us O -o 4^ CD '£> o to Vi 4a oe Ό 00 DC O Vi O". sc / to to to to to to ia> to iO to iO to to to to to λ'-, o o ,*"·*·,· . y*«- o O: o o ό 3 o CD o P Λ- O' o o o o ό o o -ia 4a. 4a Us Vj Us Vi Us Vi Vs Os OD Ο O O /-'D o CT: o ό o o o to o .«***». to CD i—‘ V—- .,—* to to CD o tO 4- /Ds •/S V cd to c··- o OJ Ό OJ o. o to ¢--0 ---4 wy to 30 C 'C V- VI' Ui Os sO CD. o Us Ό (¾ <Os <;λ Vi --3 CD O V: -o to oc Us DC Ot ca Ο·· Ό to o ui U Vt -o o VD Us oc -4 Vi 4a V ··> '* v < ·/ + *» r si » ·' Si « i iS ' ' ’* ' * ' to fO to fO to KJ 30 to to KS to to 3-4 to to o O o O' o O' CD O,' o o o o*s O o o O o o· CD to 4a Ja, 4a Us Vi Us Vi Us V! Vi ds ό ό o r~‘) O o o O o o o o o to ~wi to o CD fHivi yw* r-—’4 to to CD o W,J to 0s DO to Ό O'. to ΐΤ3^. o vi oo to i—- δ -C; o --5 --3 >—* V -~3 o% y»iii o <3a Vi Ό to 00 GC '4a OS y~> ~~3 4^. Us Ο;· 'C 4is 4¾.. O·) o. w SC 4a 4D. oo to O' Vi Ό O to DO oo DC c\ V C V·· to o to oc o -y * Ό •i ' 'i * si » s* « » V S ’♦ ' V 1 •y « -* - to to to 30 NJ l-o to to to t-4 to to to to to to /«s o CO o O o Ό' gD> Ό' o δ o o o o C? o o O O CD 4¾ 4* 4* 4¾ '...') Vi Us Vt V V/'* Vi Vi O', /+*·> o /**S P o o Λ*^ o o o O N> p .v^ to o o to to to >**</· r>. Dr; :k~m4 C V !0 ¢7-- o to yww CD. oc MV. ivsM ό to δ . |!a UJ O^. Cs 4^- C·' 40 o ’Ό u< to c*·. Ό to O Ov CD Ό Us oa to oo u> Ό 4» Ui «Τ'. 03 Os Us yvw Ό >Wi Vi --1 O, US DC W 4a ;--3 G-* to ’••4 S"' V •CD ·> . Vi * ·« * si . ·' " ' i ·.» i ' Λ ^ •y « '*' to to to to to (O to ίΟ to to to to to to to o .'w·. Λ~·; o o o CD O CD Λ o s**\ P Os o o o o O CD O O' SO· to 4^ f-.. S Us Vi Vi Vi Us Vi Vi Vi CD. o 5"~> O O- o o o o CD O Ό to o !·**·. ywi SO o o S-" y-*'·· ?— ND to to o Vs 00 P CO (i/i C''; --.,3 >*’>- Vi --) 4* o 00 00 C O- Vi 4lk to u> /!**') vO ¢7 c 'vO Ό •o 4j* VO 3"" "" cc- KJ V< 4a oo --3 O'. to y,»y, O‘‘ CD 00' y»,y. •C' V -?:« 0o w 00 O'! Us to os O* to o^t to ψλ i"" •Λ / -> si r ·' si / v ' -i i ^ ' ‘* ' ' ' -y ' " ' ' to to to to to to to to to to to to :r-o O to to o o o o ¢^1 o o C£' Ό Ό Ο-. O 4- o y—-. o £S> CD CD CD? o CD Ό; w··- Ui 4a 4a 4a V Ui Vi Us Vi Ui Vs Ui C7. o o o 4**; /"*·, o O· o CD o CD: CD O' y-.-.y w 4‘: o ,---4 io ό ‘CD s-.-y. >· ^D to tO -«y VD \j-i Vt 00 rO OO to i-»> Us 4>^ Vt CD· Imv VD C7 V* „«v<. to v< UJ O'-· Us OC; 4y o. u> c*, o Us O-S 'O o- 0D DO 0^ sO oc Us to -o 4a 4a ΪΟ ό Ό C7, -O to >»y. 04 4i o>. O> ΓΓ o o ,;^·1 .ΓΓ .5? Vj •^-3 Ct·, .y-V. V) .7f Kft 2017228592 13 Sep 2017

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QIMSPIMMI 15 A member of embodiments1 of theftwention have been described. Nevertheless, ft will be imderstood that various modifications may be made wifemt departing from the spirit and scope of the invention. -Aecopdingly, other embodiments are within the scope of the following claims.

Claims (28)

1. CLAIMS: ί. A method of producing ethanol from bioma ss, comprising: ikrdthtoixi$/^teol/fr@m biomass at a first site with a fermenter^ mtnsporling the fermenter to a second site; and producing ethanol from biomass at the second site with the fermenter.
2. 2. The method of claim '1, wherein, the Kiomass is selected from the gnmp consisting of eeilulosie material, Hgnoceilulosic material, com, sugar cane, sugar beets, trees, shrubs, grasses,. ph>1opiankton, ziX>plmTkton, algae, maeroalgae, seaweed, com husks, bushes, lunibei;, wood waste, pulp, cotton, wool, linen, paper, newspapers, eomtgated containers, mixed paper, computer printouts, white office paper, printing plant scraps, leaves, twigs, grass, plant cuttings, branches, frees, vines, sewage agricrdtwal waste, and-.mixtures thereof.
3. 3. The method of claim 1 or 2, wherein transporting is performed with a nautical vessfcd.
4. 4. The method of claim 3, wherein the nautical vessel is aboat, a barge, a ship, a dock, a floating platform, a sea platform, or a sea rig.
5. 5. Themethod of claim 1 or 2, whercm .lrasrsportmg is performed with a land vehicle.
6. 6. The method of claim 5; wherein the land vehicle is a car, track, tractor frailer or train.
7. 7. The method of claim 1. or 2, wherem irmisporting is performed with an tdrlmme vehicle; 8; The method of claim 7, wherein the airborne vehicle is a plane, helicopter or blimp..
8. 9. The method of claim 1 or \vherein tmn^oriuig is perfomied by more than a single mode. 10; The method of claim 9, wherein the transporting is:performed by a land vehicle ami awater vehicle.
9. 11, The method of any one of the. above dams, wherein produc ing is performed while transporting.
10. 12, The method of any one of the above claims, wherein the fermenter -ferns part of a system, the system, comprising a component selected horn the group consisting of cutters, shearing devices, measuring devices, flow devices, mills, mixers, pumps, wiring, cookers:, heaters, coolers, aerators, containers, holding containers, distillation columns, piping, electrical components, energy sources, sewage sources, -water sources, and .mixtures thereof. 1.3, The method of any one of the above claims, wherein the -first site aid second site are spaced apart by a distance of about 25 miles or more.
11. 14. The method of any one of the above claims, wherein the first site and second site are spaced apart by a distance of about 100 miles or more,
12. 15. The method any one of the above claims, wherein producing ethanol from biomass at the first and/or second site comprises hydrolyzing the biomass, and then fermenting the biomass.
13. 16. The method of any one of the above claims, further comprising transporting the system to a third site, and then producing ethanol at the third site.
14. 17. The method of claim 16, further comprising transporting ike fermenter to a fourth site, and then producing ethanol at the fourth site,
15. 18. The method of any one of claims 1-15, wherein prior to producing ethanol from biomass at the first andfer second site with the fennenter, the fermenter is assembled as part of a system. If). The method any one of the above claims, wherein producing ethmmi from biomass comprises contacting the biomass with one or more microorganisms disposed in the fennenter.
16. 20. The method of claim 19, wherein the one or more microorganisms comprises one or more genetically-engineered bacteria.
17. 21. A method of producing energy fibm biomass, comprising; producing a first energy source from biomass at a first site with a fermenter, reactor or a converter: transporting fee fermenter, reactor or a converter to a second site; and producing a second energy source-from biomass at the second site with the fennenter, reactor or a converter,
18. 22. The method of claim 21, wherein the first and second energy sources are the same,
19. 23. The method of claim 21 or 22, wherein the energy source is selected from the group consisting of alcohols,.-ethanol, n-butanol, gasoline, hydrocarbons, hydrogen, natural gas, biodiesel, electricity, and mixtures thereof
20. 24. The method of claim 21, wherein the energy source comprises ethanol.
21. 25. A method of producing a product from biomass, comprising: producing a first product from biomass at a first site with a reacior or a converter; transpoiting the reactor or a con verter to a second site; and producing a second product from biomass at the second site with the reactor ora converter.
22. 26. The method of claim 25 , wherein the first and second prod acts are the same.
23. 27 . The method of claim 25, wherein the first or second prodacts comprise ethanol.
24. 28, The method of claim 25, wherein the first or second products arc selected from the group consisting of energy, ethanol, ndmtanpl* alcohols, hydrocarbons, gasoline, natural gas, methane, biodiesel, hydrogen, electricity, polymers, nutrients, proteins, biomolecules, pharmaceuticals,, pharmaceutical products, fertilizer, medial products, chemical products, and mixtures thereofi
25. 29. The method of claim 25, wherein the first or second products comprise one or more biomolecules selected from the group consisting of nucleic acids, proteins, lipids, steroids, natural products, metabolic products, nucleotides, nucleosides, fats, amino acids, peptides, and mixtures thereof.
26. 30. A method of producing a product from biomass, comprising: producing a first product from biomass at a first site with a reactor, the first site being located on a body of water; transporting the reactor to a second site also on the body of water; and producing a second product from biomass at the second site with the reactor, wherein the biomass is obtained from the body of water.
27. 31. The method of claim 30, wherein the biomass is selected from the group consisting of plankton, aquatic plants, algae, seaweed, and mixtures thereof.
28. 32. A method of producing a product from biomass, comprising: producing a first product from biomass at a first site with a reactor or converter; transporting the reactor or converter by a first mode to a second site; producing a second product from biomass at the second site with the reactor or converter; and transporting the reactor or converter by a second mode different than the first mode to a third site.