CONTINUOUS PILOT SCALE HYDROTHERMAL HORIZONTAL REACTOR DESIGN FOR MAKING INDUSTRIAL BY-PRODUCTS
The presently disclosed subject matter relates to a horizontal reactor system that can be used for processing various plant material biomass to produce fermentable carbohydrates, paper and pulp products, or both. Particularly, the disclosed system comprises a horizontal reactor vessel comprising a body with first and second ends. The reaction vessel is intended to encompass and retain a reaction medium (i.e., biomass slurry) that is to undergo a biological and/or biochemical reaction. The vessel comprises an internal agitator that functions to mix the contents of the reactor. The agitator is powered by a drive, which can be a motor, positioned outside the reaction vessel.
1 . A horizontal bioreactor apparatus comprising:
a horizontal reaction vessel comprising an interior and first and second ends;
a first hub positioned at the first end of the vessel;
a second hub positioned at the second end of the vessel; and
an agitator positioned within the interior of the vessel, the agitator comprising:
a central rotating bore operably connected to the first and second hubs; and
one or more arms connected to the central rotating bore and operably connected to the first and second hubs.
2 . The apparatus of claim 1 , wherein the horizontal reaction vessel is constructed from stainless steel or a polymeric material.
3 . The apparatus of claim 1 , wherein the central rotating bore is coupled to an external drive device via the first or second hub.
4 . The apparatus of claim 3 , wherein the external drive device is a motor.
5 . The apparatus of claim 1 , wherein the horizontal reaction vessel is capable of processing about 1-2 liters of biomass slurry per minute.
6 . The apparatus of claim 1 , wherein the horizontal reaction vessel can accommodate pressures of up to about 1,550 psi.
7 . The apparatus of claim 1 , wherein the horizontal reaction vessel can accommodate temperatures of up to about 450° F.
8 . The apparatus of claim 1 , wherein the horizontal reaction vessel r is pressurized through the use of a gas tank.
9 . The apparatus of claim 8 , wherein the gas is nitrogen.
10 . The apparatus of claim 1 , wherein the arms contact the interior surface of the reactor.
11 . The apparatus of claim 1 , further comprising a viewing glass for monitoring progress of the reactions in the vessel.
12 . The apparatus of claim 1 , further comprising a sample port.
13 . A horizontal bioreactor system comprising:
a mechanical pre-treatment module;
a bioreactor module comprising:
a horizontal reaction vessel comprising an interior and first and second ends;
a first hub positioned at the first end of the vessel;
a second hub positioned at the second end of the vessel;
an agitator positioned within the interior of the vessel, the agitator comprising:
a central rotating bore operably connected to the first and second hubs;
one or more arms connected to the central rotating bore and operably connected to the first and second hubs; and
a collection module.
14 . The system of claim 13 , wherein the mechanical pre-treatment module comprises a hammer mill.
15 . The system of claim 13 , further comprising a heating module comprising a heat exchanger.
16 . The heat exchanger of claim 15 , comprising metal tube elements housing heated or cooled liquid.
17 . A method of processing biomass to produce fermentable carbohydrates, paper and pulp products, or both, the method comprising:
preparing a biomass slurry comprising a biomass to be treated;
introducing the biomass slurry to a horizontal bioreactor apparatus, wherein the horizontal bioreactor apparatus comprises:
a horizontal reaction vessel comprising an interior and first and second ends;
a first hub positioned at the first end of the vessel;
a second hub positioned at the second end of the vessel;
an agitator positioned within the interior of the vessel, the agitator comprising:
a central rotating bore operably connected to the first and second hubs;
one or more arms connected to the central rotating bore and operably connected to the first and second hubs;
allowing the horizontal bioreactor apparatus to proceed for a desired amount of time; and
collecting end products of fermentable carbohydrates, paper and pulp products, or both.
18 . The method of claim 17 , wherein the biomass is selected from corn, wheat, soybean, cabbage, sugar beet, sugar cane, greens, tobacco, bamboo, lavender, algae, Artemisia , cotton linter, hemp, lumber, chipped wood, corn stover, potato sacks, coffee sacks, paper cups, and combinations thereof.
19 . The method of claim 17 , wherein the biomass slurry comprises biomass and a solvent selected from water, NaOH, buffer, and combinations thereof.
20 . The method of claim 17 , wherein the ratio of biomass to solvent is about 1:7 to 1:20.