The invention to which this application relates is to apparatus and a method which allows improvements to be achieved in the extraction of one or more components of materials or liquids from biomass materials.

In particular, the invention is related to the efficient extraction and/ or for the extraction of additional components, from the material.

It is known that certain biomass materials possess structural and chemical properties which can be exploited for use for other purposes once separated from the bio mass material such as for foodstuffs, medicines, fuels and the like. It is also known that the remaining bio mass material can be subsequently processed and utilised.

Conventional technologies which are designed to extract these components are typically used as“standalone” apparatus. Furthermore, the extraction of the liquid suspended“extracts” which include lipids, hemicellulose, lignin, sugars, nitrates, and the like from within the biomass material is conventionally performed on the biomass material when it is in the same condition as it is initially supplied to the extraction apparatus.

Known forms of extraction apparatus include twin-screw apparatus in which the biomass material is passed along and between the said screws of the apparatus such that the biomass material is effectively squeezed by the twin screws and the one or more components are extracted from the biomass material as part of the liquid which is squeezed out of the biomass material. The liquid is then collected and further processed to allow the components carried thereby to be, if required, separated out of the liquid. While this process does allow for the separation of the components to a certain extent it is acknowledged that even once the extraction process has been completed, there may still be quantities of the same components retained in the biomass material which cannot be accessed and/ or there may be further components in the biomass material which are not separated at all and remain in the biomass material.

An aim of the present invention is therefore to provide a means of allowing a greater degree of extraction of components and/or to allow access to and extraction of further components from the biomass material.

In a first aspect of the invention, there is provided apparatus for the extraction of one or more components from biomass material, said apparatus including means to allow the biomass material to be pre-processed and then moved to apparatus to allow the extraction of components from the said biomass material and wherein the pre-processing means at least partially defibrillate the said biomass material prior to the same being passed to the extraction apparatus.

In one embodiment, the extent of defibrillation of the biomass material is such as to at least partially open out the fibres of the biomass material and thereby allow greater access to the fibres and hence said one or more components during the subsequent extraction step.

In one embodiment, the apparatus which is used to defibrillate the biomass material, can be of any form which is suitable for the particular biomass material which is to be used.

In one embodiment the apparatus includes an elongate screw with the aim being to provide sufficient defibering and/or micro and/or nanofiber opening of the biomass material in order that it is sufficientiy open to allow the liquid extract apparatus which is subsequentiy used to extract a greater extent or number of the one or more components from the biomass material.

In one embodiment the said at least one component is removed as, or as part of a liquid which is extracted from the biomass material. In one embodiment, the defibrillation process includes the injection of fluids such as water into the apparatus at appropriate locations as the process of the defibrillation is performed to further encourage opening of the fibres and to encourage the flow of the mainly non-fibrous extracts which constitute part of the biomass.

In one embodiment, the apparatus includes filtration sections to allow extracts to be flushed out of the biomass material.

In one embodiment, at least one part of the apparatus includes means to allow the application of pressure to force the fluids introduced through the apparatus into the biomass material and so carry with the liquid, the extracted components which can then be collected and moved for further processing as required.

In one embodiment, the liquids can be further processed to remove particular components which can then be used for specific purposes and the fibrous biomass itself can then be used as cellulose fibre for further purposes, and thus it will be appreciated that both the extracted components and also the pulp can be used for different purposes.

In one embodiment the defibrillation apparatus and the extraction apparatus are provided as part of a common item of apparatus, with the extraction apparatus located downstream of the defibrillation apparatus with respect to the direction of feed of the biomass material through the apparatus.

In one embodiment the biomass passes through a two stage extraction and cutting apparatus prior to being passed to a fibre processor.

Typically in the pre - extraction stage of the apparatus the biomass / fibre is manipulated using purpose designed fibre manipulation elements which are provided as part of the apparatus and which contact the fibres. In one embodiment the first set of elements which contact the biomass with respect to the direction of passage of the biomass perform a tearing action on the fibres sop as to produce relatively large and long 5 - 50mm length fibred.

Subsequent sets of elements are provided and designed to achieve an optimum opened fibre structure of the biomass with the length of the fibres sequentially reduced and defibrillated using elements which include multi planar fibre refining/ contact surfaces and the relative movement and contact between the fibres which for example can be linear, and the contact surfaces which can be for example rotational, cause the change in condition of the fibres to be achieved .

Typically the elements orientation and the provision of the contact surface designs can be selected and provided in a specific sequence with reference to the required fibre reduction which is to be achieved.

In one embodiment the sets of elements can be selected and provided in a sequence with respect to the direction of the movement of the biomass through the apparatus such that there is provided an initial relatively aggressive fibre defibrillation zone or zones with precise / extreme machine element contact; and/or one or more fibre to fibre defibrillation zones and /or one or more high and low pressure fibre structure state changing zones and/ or one or more material holding zones and/ or one or more technology hardware element alignment zones - machine life extending.

In a further aspect of the invention there is provided a method of treating biomass material to allow the extraction of one or more components therefrom for further use, wherein said method includes the step of pre-processing the said biomass material prior to the movement of the material through extraction apparatus.

In one embodiment the pre-processing step includes defibrillating the biomass material. In on embodiment the defibrillating includes and/ or any combination of, cutting, shredding and/or granulating said biomass material so as to achieve a predetermined degree of de fibrillation.

Typically, once the pre-processing step has been completed, the defibrillated material is moved to extraction apparatus to allow liquid and one or more of said components and/ or liquid to be separated and leaving a biomass pulp.

In one embodiment the one or more components include any or any combination of; Ethanol / related extracts; Polysaccharides; Lignocellulosic & Extract Sugars / Oligomeric Sugars / Total Sugars such as Arabinose, Arabinitol, Cellobiose; Cellobiosan, Fructose, Fucose; Galactose, Galactosan, Glucose, Glycerol, Levoglucosan; Mannitol, Mannose, Mannosan, Sucrose, Rhamnose, Raffinose, Sorbitol, Trehalose, Xylitol, Xylose; Lignin incl. Lignin (Klason), Lignin (Acid Soluble), Related solids including Acid Insoluble Residue, Ash (Acid Insoluble); Starch; Proteins; Flavonoids; Fats; Pectin such as Water soluble pectin (WSP), calcium chelator soluble pectins (CSP), diluted alkali soluble pectins (DASP); Uronic Acids such as Glucuronic Acid, Galacturonic Acid, Mannuronic Acid, Guluronic Acid, 4-O-Methyl-D-Glucuronic Acid; Acetyl; Biomass Amino Acids, Alanine, Arginine, Aspartic Acid, Cystine, Glutamic Acid, Glycine, Histidine, Isoleucine, Leucine, Lysine, Methionine, Phenylalanine, Proline, Serine, Threonine, Tyrosine, Valine; Organic Acids and Furans such as Levulinic Acid, Formic Acid, Hydroxymethylfurfural, Furfural, Acetic Acid, gamma-Valerolactone; Uronic Acids such as Glucuronic Acid, Galacturonic Acid, Mannuronic Acid, Guluronic Acid, 4- O-Methyl-D-Glucuronic Acid; Combustion related / Volatile Matter / Fixed Carbon such as Ash, Carbon, Hydrogen, Nitrogen, Sulphur, Oxygen, Chlorine; Components relating to Biomethane Production (BMP) i.e.: -Methane, Carbon Dioxide, Oxygen, Hydrogen Sulphide, Ammonia; Related Solids incl. Volatile Solids; Special Seaweed Carbohydrates i.e. Glucuronic Acid, Galacturonic Acid, Mannuronic Acid, Guluronic Acid; Amino Acids such as Alanine, Arginine, Aspartic Acid, Cystine, Glutamic Acid, Glycine, Histidine, Isoleucine, Leucine, Lysine, Methionine, Phenylalanine, Proline, Serine, Threonine, Tyrosine, Valine; Additional Bio-Oil components such as Phenol, Furfural, Syringol, Vanillin; Major Elements such as Aluminium, Calcium, Iron, Magnesium, Phosphorus, Potassium, Silicon, Sodium, Titanium; Minor Elements such as Antimony, Arsenic, Cadmium, Chromium, Cobalt, Copper, Lead, Manganese, Mercury, Molybdenum, Nickel, Vanadium, Zinc and / or other Miscellaneous components such as D-limonene, Methanol, Pentoses, Galacturonic acid, Xyloglucan, fibrous fines’ or very short fibre that in the paper and pulp forming business blocks the sieves / wires and/or further extracts, the type or form of which is dependent upon the type of biomass material which is being processed.

Specific embodiments of the invention are now described with reference to the accompanying drawings wherein;

Figure 1 illustrates in a schematic manner the steps performed in accordance with one embodiment of a method in accordance with the invention;

Figure 2 illustrates apparatus in accordance with one embodiment of the invention in a schematic manner;

Figure 3 illustrates apparatus for performing an extraction operation in accordance with one embodiment of the invention.

Referring firstiy to Figure 1, there is illustrated in a schematic manner, the steps which can be performed in accordance with one embodiment of the method of the invention in order to increase the ability to extract larger quantities of one or more components from a biomass material and/ or to allow the ability to extract components from the biomass material which were not previously extractable using conventional methods.

In accordance with the invention, the biomass material is provided from one or more sources in a raw condition. Step 1, is an optional step to wash the biomass material thereby removing from the same, any extraneous material, debris and dirt. Step 2 of the method in accordance with the invention is to then pass the biomass material to a defibrillation apparatus which receives the biomass material in a raw form, if step 1 is not performed, or in a washed form if step 1 is performed.

The defibrillation step is performed in order to allow the fibres of the biomass material to be opened and hence allow a greater proportion of the biomass material to be exposed. Step 3 of the invention is to pass the defibrillated material through extraction apparatus in order to allow components of the biomass material, to be separated and extracted from the biomass material therefrom. Step 4 is for the extracted components to be collected and then further processed in order to further separate the components from each other and/ or the liquid in which the same may be carried from Step 3.

Step 5 is to further utilise the same components from Step 4 for one or more different purposes. Step 6 is to remove the remaining fibrous mass of the biomass material from the apparatus of step 3 and to pass this for further processing and further uses.

Figure 2 illustrates an example of apparatus which can be used in the method in accordance with the invention. The biomass material is typically supplied into a chamber 10 via an inlet 14 connected to biomass dosing and feeding apparatus 2. The inlet 14 is located at an end 4 of the chamber 10. The housing includes adjacent the inlet 14 defibrillating apparatus 6 which includes a single, twin or multiple screws, 8, which has or have a series of elements or members, or sets of elements or members located therealong and/or other apparatus may be provided in the chamber 10 with the aim of the said elements or members and/or other apparatus being to chop, cut, and generally separate the biomass material into a defibred/ defibrillated condition. The rotation of the screw or screws 8 causes the biomass material to move along the chamber as indicated by arrow 12 towards the end 16 of the housing 10. The selection of the elements which are used are discussed in more detail below and it will be appreciated that the contact faces of the elements with the fibres may change in shape and configuration along the length of the apparatus so as to provide a stepwise and sequential effect on the fibres of the biomass material in an advantageous manner.

In order to further encourage the defibrillation and/ or the extraction of components, one or more liquids may be provided to the chamber at selected positions along the chamber 10 in the defibering section 8 and/or pressure the pressure within the chamber 10 may be increased at at least one section of the chamber 10. The aim of these steps is to further encourage the defibrillation of the biomass material.

The action of the defibrillation therefore exposes and opens up, the fibres in the biomass material in comparison to the raw condition in which it is initially supplied. By opening up the fibres there is therefore exposed a greater surface area of the biomass material and, in turn, a greater exposure of the various components of the biomass material.

The biomass material passes in its defibrillated condition, to the extraction apparatus 18 which in this embodiment is in the same chamber 10 and which may comprise one or a number of screws provided to rotate along their respective axes which are parallel with the longitudinal axis 20. As the biomass material moves through the extraction apparatus 18 towards the end 16, the movement of the screws effectively acts to squeeze liquid from the biomass material and the liquid carries therein the components which are being extracted from the biomass material. The liquid, with the components therein, then passes through filtration stations 22 which can be provided in a format as required for specific component collection and, in this embodiment, the extracted liquid and components pass as appropriate to a collection tank 24 or a second collection tank 27. The collected components can then be further processed as required. This then leaves the fibrous mass of the remaining biomass material and the pulp can then be collected from an outiet 26 at the end 16 of the chamber 10 and passed for further processing for further uses.

It is therefore believed that the provision of the defibrillation of the biomass material prior to the extraction of components therefrom, allows a significant increase in the percentage of components which are extracted and also can make further components accessible for extraction which previously were not possible to extract. Thus, as a result, the potential uses of the biomass material are increased as is the extraction capability of components.

With regard to pre- extraction stage of the process, the biomass fibre is manipulated using purpose designed fibre manipulation elements and, in one embodiment, the manipulation is achieved using two stages of different components. In an initial stage, the initial elements which are used are typically larger in order to achieve a 5- 50mm fibre length reduction and this is achieved using specifically designed elements which cause a tearing action on the fibres. Subsequent to that, the fibres which have been processed at the initial stage, are passed to a second stage at which further elements, typically different in design to the first stage elements, are used in order to achieve the optimum open fibre structure. Typically, this involves a process of reducing the length of the fibres and sequentially reducing them and then defibrillating them using multi planer fibre refining contact surfaces.

In one embodiment, the fibre type is assessed, and specific elements can be selected to be used and/ or orientated in a particular way in order to achieve the sequencing of the fibre reduction and manipulation of the fibres.

In one embodiment, these elements can comprise of either separately and/or in combination: 1. Aggressive fibre defibrillations zones with precise and typically maximised mashing element contact thereby achieving a step-for-step biomass size processing.

2. Fibre to fibre defibrillation zones can be provided, high- and low-pressure fibre structures changing zones can be provided, material holding zones can be provided and/ or technology hardware element alignment zones can be provided to thereby allow the selective processing of the fibres. In one embodiment, the subsequent processing can also include a washing system for the recycled or residual lignocellulosic fibres.

3. Apparatus of one embodiment of the type which can be used, as illustrated in Figure 3.

4. Currentiy, many fibre sources from either recycled or residual sources require component extraction and size reduction before they can be fed into a fibre processor for shape and for modification.

Typically, fibres which undergo such modification which can be used in a variety of 2 and 3 dimensional products as a filler such as a reinforcement of the fibres or as complete composite singularly or with other similarly modified fibres.

The modification is typically carried out using a variety of machines typically with a screw extruder but also with various nails and/ or other fibre refiners. The component extraction and cutting of the fibres prior to the processing has the following advantages in that it prolongs the life of the fibre modification technology as damaging foreign body such as sand, metal, stones etc., are washed out. The fibre is cut without any physical cutting shredding systems being used thus avoiding any replacement parts as required with standard equipment and/or the fibres are more accurately cut to length to optimise the fibre modification process.

With reference to Figure 3, an alternative form of apparatus for extraction and cutting the fibres is shown. The fibre biomass material is taken from the store 30 and fed to dosing station number one 32 . This can typically be done by loading the fibre into the dosing station in batches, by use of a screw conveyor or it may be placed on a transport belt 34 or similar device to bring the fibres to the dosing station. The dosing station 32 then feeds the fibre into the washing section 36 at a desired rate.

The fibre is then floated in a tank at section 36 and is transported mechanically or with an appropriate waterflow rate towards a cutting section 38 and along this section, the fibre will shed most, if not all, foreign bodies. A suitable perforated or screen type transport band 40 picks up the fibre at the end of the washing section and transports the fibre through the cutting section and onwards, having been cut to a desirable size towards dosing station number two 42. A suitably strong water conveying system can replace the band, if desired.

The cutting section 38 typically uses high-pressure water jets which are set apart at an appropriate width as is required to achieve a desired cut fibre size.

The cutting section 38 is typically adequately dimensioned to allow the dewatering of the fibre before it reaches dosing section 42. Assistance for this with suction, blown air, infrared heat and/ or other heat source may be employed to dry the fibre and the conveyancing system with adequate drainage if required.

At the next stage, then having left the cutting section, the fibre is collected in dosing section 42 which functions as an accurate dosing system specifically for the fibre processor itself. The fibre may be dosed directly into the fibre processor feeder 44 or, if required, a transport band 46 with appropriate carrying capacity conveys the fibre to the fibre processor feeder 44. The fibre processor feeder receives the fibre and is calibrated to convey the material into the fibre modification technology as required for further processing .