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Title:
PROCESS FOR SYNTHESIS OF LIGNOCELLULOSIC BASED BIOPRODUCTS
Document Type and Number:
WIPO Patent Application WO/2023/204823
Kind Code:
A1
Abstract:
The present invention relates to a process for the synthesis of lignocellulosic-based bioproducts. The process involves the biochemical conversion of lignocellulosic biomass generated through agriculture, non-agriculture, and forest that produces streams of high-value goods including cosmetic ingredients, nutraceuticals, carbon fiber, activated carbon, graphene, low-calorie sugar, bioplastic, cellulose pulp, and nano-cellulose based aerogel. The process comprises; a process stage-1 for removing the phenolic compounds (lignin) from lignocellulosic biomass as well as decreasing the crystallinity of the cellulose using alkaline modified ethyl-hydro-oxides (m-EHOs) extraction, a process stage-2 for removal of the hemicellulose fraction of the holocellulose using mild sulfuric acid extraction, and a process stage-3 for chemically treating cellulose pulp with alkaline modified ethyl-hydro-oxides (m-EHOs) solvent for the production of nano-cellulose and micro-cellulose fractions. Along with the production of high-value goods, the process generates energy.

Inventors:
JAIN ARPAN (US)
Application Number:
PCT/US2022/026462
Publication Date:
October 26, 2023
Filing Date:
April 27, 2022
Export Citation:
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Assignee:
JAIN ARPAN (US)
International Classes:
C12P19/02; C12P7/14; C12P19/14; D21H17/00
Domestic Patent References:
WO2021041782A12021-03-04
Foreign References:
US20150087030A12015-03-26
Other References:
JAIN ET AL.: "Biochemical conversion of sugarcane bagasse into bioproducts", BIOMASS AND BIOENERGY, vol. 93, October 2016 (2016-10-01), pages 227 - 242, XP029698236, DOI: 10.1016/j.biombioe.2016.07.015
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Claims:
Claims:

What is claimed is:

1. A process for the synthesis of lignocellulosic based bioproducts, comprising: a process stage-1 for removing the phenolic compounds (lignin) from lignocellulosic biomass as well as decreasing the crystallinity of the cellulose using alkaline modified ethyl-hydro-oxides (m-EHOs) extraction; a process stage-2 for removal of the hemicellulose fraction of the holocellulose using mild sulfuric acid extraction; and a process stage-3 for chemically treating cellulose pulp with alkaline modified ethyl-hydro-oxides (m-EHOs) solvent for the production of nano-cellulose and micro-cellulose fractions; wherein the process stage-1 is further comprising steps of:

(a) milling and grinding of lignocellulosic biomass and feeding the milled and ground lignocellulosic biomass into a reactor-1 (1 ) using a feed inlet (2),

(b) adding a modified ethyl-hydro-oxides (m-EHOs) solvent consisting of ethanol in an amount of 10 - 90 % by volume, potassium hydroxide (KOH) in an amount of 1 - 20 % by weight, potassium carbonate (K2CO3) in an amount of 0 - 20 % by weight, hydrogen peroxide (H2O2) in an amount of 1 - 20 % by weight, nitrogen (N2) in an amount of 0 - 80 % by volume, hydrogen (H2) in an amount of 0 - 20 % by volume, and seawater/water (H2O) in an amount of 20 - 60 % by weight, to the 40 - 100 % of the total volume of the reactor-1 (1 ) and a ratio of biomass to the modified ethyl-hydro-oxides (m-EHOs) solvent is maintained between 1 :50 - 1 :1 by weight over volume,

(c) preparing a heterogeneous mixture of the lignocellulosic biomass and the modified ethyl-hydro-oxides (m-EHOs) solvent in the reactor-1 (1) by mixing the said mixture using an impeller (3),

(d) supplying hydrogen gas (H2) into the reactor-1 (1) using hydrogen (H2) gas inlet valve (5) provided at the bottom portion of the reactor-1 (1) through nitrogen (N2) gas sparging by maintaining the concentration of hydrogen gas in the nitrogen gas between 1 - 20 % by volume,

(e) supplying nitrogen (N2) gas into headspace (8) in the reactor-1 (1) using a Nitrogen (N2) gas inlet valve (6) for accelerating the chemical reaction between the lignocellulosic biomass and the modified ethyl-hydro-oxides (m-EHOs) solvent allowing a reaction time of 1 - 15 minutes to generate pressure up to 10 - 800 psi, more specifically at 400 psi,

(f) allowing chemical reaction in the reactor-1 (1) at a temperature of 65 - 75 °C with an incubation period of 1 - 8 hours wherein the temperature in the reactor-1 (1) is controlled using a temperature controlling jacket (4),

(g) allowing transfer of carbon dioxide (CO2) gas generated because of a reaction between the lignocellulosic biomass and the modified ethyl-hydro-oxides (m- EHOs) solvent and accumulated in the space (8) of the reactor-1 (1 ) to a power generation unit-1 (13) after removing the vapor content of ethanol and water carried by carbon dioxide (CO2) in a packed bed column-1 (12) in which pressure is maintained at 10 - 800 psi, more specifically at 400 psi using carbon dioxide,

(h) At the end of the incubation period, the reactor-1 (1) contents are cooling down to a temperature of -10 to 25 °C using an internal colling coil (14),

(i) neutralizing the pH of a biomass slurry of the reactor-1 (1 ) by adding hydrochloric acid (HCI) or citric acid from a storage tank (19) to the reactor-1 (1 ),

(j) separating a liquid and a solid fraction of biomass slurry of the reactor-1 (1 ) by discharging biomass slurry using a biomass discharge port (7) on a stack of vibrational screens (15) of 3.5 - 500 mesh (or higher) size,

(k) liquid fraction collected in a vessel containing solvent extract with precipitated salt (27) from the stack of vibration screens (15) is further processed through a centrifuge unit (32) (centrifugation at greater than 1 ,000 rpm) followed by a filtration unit (33) (filter pore size: less than 0.2 microns) equipped with a nitrogen/carbon dioxide compressor unit (37) to remove biomass residues with precipitated salt (30) and residual biomass (34) before phase separation in a phase separator and injection molding unit (23) equipped with a nitrogen compressor (39) to separate hydrophobic lignin (solids in the form of small disc flakes) and hydrophilic lignin (liquid) content after extraction of ethanol at 60 - 120 °C, more specifically at 78 °C,

(l) the solid fraction is transferred from the vibration screen (15), after subjecting to compressive force by a roller pressing (installed on the vibrational screen) to squeeze excessive solvent extract, to a water washing reactor (20) equipped with a water supply vessel (38),

(m) transferring biomass from the water washing reactor (20) to the stacks of vibration screens (21 ) of 3.5 - 500 mesh (or higher) size for separating the biomass slurry into solid and liquid fractions,

(n) the stacks of vibration screens (21) further separate the solid fraction into a holocellulose (31 ) and a cellulose-xylan-lignin,

(o) the liquid fraction collected from the stacks of vibration screens (21 ) into a vessel containing water-diluted solvent extract with dissolved salt (28) is further processed through a centrifuge unit (32) (greater than 1 ,000 rpm) followed by a filtration unit (33) (filter pore size: less than or equal to 0.2 microns) equipped with a compressor (37) to remove biomass residual (30 and 34) before phase separation using a phase separator and an injection molding unit (23) to separate hydrophobic lignin with dissolved salt (solids in the form of small disc flakes) and hydrophilic lignin (liquid) content after extraction of ethanol at 60 - 120 °C, more specifically at 78 °C,

(p) the distilled ethanol produced through the processing of solvent extracts (containing precipitated salt and dissolved salt) is recycled to ethanol storage (35) after condensation (36) for the application in the reactor-1 (1 ),

(q) the generated holocellulose is subjected to compressive force by a roller pressing to squeeze the excessive aqueous solvent on the vibrational screen (21), and water washing before transferring to stage-2 processing,

(r) the final content of organic solvent (i.e. , ethanol) in the holocellulose ranges between 2 - 40 % (by volume), more specifically 8 %. wherein the process stage-2 is further comprising steps of:

(s) producing concentrated hemicellulosic sugars (between 50 - 200 g/L) by employing a sulfuric acid having a concentration in a range of 0.1 - 5 % of the total weight of holocellulose in a reactor-2 (201 ) to remove the hemicellulose fraction of holocellulose wherein the total biomass inlet in stage-2 ranges between 50 - 90 % of the initial biomass (on the dry basis) from stage-1 , a ratio of biomass to solvent ranges between 1 :1 - 1 :10, operating conditions involve an operating temperature of 70 - 100 °C for 1 - 2 hours with the introduction of pressurized carbon dioxide (CO2) in a range of 0 - 600 psi, more specifically 250 psi, from the stage-1 ,

(t) adding calcium hydroxide (216) to the reactor-2 (201 ) content to bring the pH of the biomass slurry between 5 - 6.5 before discharge on a vibrational screen (203) followed by moisture squeezing, a series of water washing, and roller pressing to generate cellulose pulp (211 ),

(u) the vibrational screen (203) resulted in two different liquid fractions, namely a vessel containing concentrated hemicellulosic sugars (204) and a vessel containing diluted hemicellulosic sugars (205),

(v) the vessel containing the concentrated hemicellulosic sugars (204) is further processed through a centrifugation unit (208) to remove biomass residues with precipitated salt (209), followed by a distillation column (206) to generate the organic solvent-free concentrated hemicellulosic sugar,

(w)the generated ethanol through the distillation column (206) is stored in a vessel (212) after condensation (213) for use in the reactor-1 (1 ) processing,

(x) the vessel containing diluted hemicellulosic sugar (205) utilized in an anaerobic digestor (202) to produce hydrogen gas and/or methane gas (214) wherein an operating temperature of anaerobic digestion varies between 37 - 80 °C, and

(y) water sparging of the produced gas through the anaerobic digestor (202) in a water sparging unit (207) at a temperature in a range of 0 - 60 °C resulted in the production of carbonated water (215), wherein the process stage-3 is further comprising steps of:

(z) chemically treating cellulose pulp received from stage-2 of the process in a reactor-3 (301 ) with modified ethyl-hydro-oxides (m-EHOs) solvent having the composition similar to the modified ethyl-hydro-oxides (m-EHOs) solvent of the process stage-1 with maintaining the similar operating conditions of biomass to the solvent ratio of 1 : 1 - 1 :50 weight per volume (w/v), and the processing temperature of 65 - 75 °C, wherein the transferred biomass content from the process stage-2 to the process stage-3 range between 25 - 75 % of the total biomass at process stage-1 , (aa) the processing time of the process stage-3 varies between 1 - 24 hours,

(bb) allowing transfer of carbon dioxide (CO2) gas generated because of a reaction between the cellulosic pulp and the modified ethyl-hydro-oxides (m-EHOs) solvent and accumulated in the headspace of the reactor-3 (301 ) to a power generation unit-2 (303) after removing vapor content of ethanol and water carried by carbon dioxide (CO2) in a packed bed column in which pressure is maintained at 10 - 800 psi, more specifically at 400 psi, using carbon dioxide similar to process stage-1 ,

(cc) At the end of the incubation period, the reactor-3 (301 ) contents are cooling down to a temperature in a range of -10 to 25 °C using an internal colling coil similar to the stage-1 processing,

(dd) neutralizing pH of a biomass slurry of the reactor-3 (301 ) by adding hydrochloric acid (HCI) or citric acid from a storage tank (305) similar to the stage-1 processing,

(ee) the biomass content from the reactor-3 (301) is discharged on a vibration screen (306) resulting in the separation of solid and liquid fractions similar to the stage-1 processing,

(ff) performing solvent squeezing of the solid fraction (of biomass) using the rollers on the vibrational screen (306), transferred to ethanol or organic solvent washing reactor (307) connected with ethanol and/or organic solvent supply (320),

(gg) discharging biomass from the ethanol or organic solvent washing reactor (307) to the stacks of vibration screens (308) similar to the stage-1 processing, separates slurry into solid and liquid fractions wherein the solid fraction is further separated into coarse fibers (316) and micro cellulose fibers (315),

(hh) the vessels containing solvent with fibers and precipitated salt (311 and 312) resulted through the vibrational screens (306 and 308) are further processed through a centrifuge unit (317) (to remove residual biomass with salt (313), followed by a filtration unit (318) (filter pore size: less than 0.2 microns) equipped with a compressor (319) to capture nano-cellulose fibers (314) from the solvent stream,

(ii) the generated solvent stream is recycled to an ethanol recycling vessel (310) in the process without distillation for the next batch of processing.

2. The process for the synthesis of lignocellulosic-based bioproducts as claimed in claim 1 , wherein the reactor-1 (1) and the reactor-3 (301) design separates the liquid phase from the gas phase at the processing stages of 1 and 3.

3. The process for the synthesis of the lignocellulosic-based bioproducts as claimed in claim 1 , the modified ethyl-hydro-oxides (m-EHOs) solvent in the stages of 1 and 3 can be replaced with the solvent consisting of organic solvent (wherein the organic solvent is an aliphatic alcohol, a carboxylic acid, a polyhydric alcohol, or mixtures thereof, for instance, ethanol, butanol, methanol, ethylene glycol, glycerol, 1 ,2- propane diol, 2,3-butanediol, acetone, formic acid, or acetic acid., or mixtures thereof, and the organic solvent has an average molecular weight of between about 32 grams per mole and to about 200 grams per mole), alkaline reagent (wherein the alkaline reagent is metal hydroxide or metal carbonate or their combination, for instance, sodium hydroxide, potassium hydroxide, calcium hydroxide, magnesium hydroxide, lithium hydroxide, ammonium hydroxide, potassium carbonate, sodium carbonate, calcium carbonate, magnesium carbonate, lithium carbonate, ammonium carbonate or mixtures thereof), oxidizing agent (wherein the oxidizing agent is anthraquinone derivatives, polysulfides, ozone, or hydrogen peroxide), and aqueous agent (wherein the aqueous agent is water, processed water, sea water or mixtures thereof) with and without incorporation of nitrogen and hydrogen in the process.

4. The process for the synthesis of lignocellulosic-based bioproducts as claimed in claim 1 , wherein the combination of the piston assembly and the packed bed column at stages 1 and 3 are maintained at 65 °C to 75 °C and pressure at 10 - 800 psi, more specifically at 400 psi.

5. The process for the synthesis of lignocellulosic-based bioproducts as claimed in claim 1 , wherein the operating temperature and operating pressure of power generation unit-1 (13) and power generation unit-2 (303) vary between the temperature of 30 °C to 200 °C or more and the pressure of 10 psi to 1000 psi or more.

6. The process for the synthesis of lignocellulosic-based bioproducts as claimed in claim 1 , wherein the said process at stage 1 and stage 3 is performed without the use of the packed bed column.

7. The process for the synthesis of lignocellulosic-based bioproducts as claimed in claim 1 , wherein the power generation units (1 and 2) are driven by pressurized carbon dioxide would be utilized in developing high-efficiency automobiles and spacecraft.

8. The process for the synthesis of lignocellulosic-based bioproducts as claimed in claim 1 , wherein the collected cellulose-xylan-lignin fraction is either directly utilized for activated carbon formation or further processed for bioplastic production.

9. The process for the synthesis of lignocellulosic-based bioproducts as claimed in claim 1 , wherein the hydrophobic lignin content would be utilized in graphene, carbon fiber, and activated carbon processing.

10. The process for the synthesis of lignocellulosic-based bioproducts as claimed in claim 1 , wherein the addition of organic solvent (for example - diethyl ether, toluene, benzene) and inorganic solvent (for example - borazine) to modify the physical properties of hydrophobic lignin toward the production of graphene and carbon fiber

11. The process for the synthesis of lignocellulosic-based bioproducts as claimed in claim 1 , wherein the hydrophilic content of biomass (in the form of diluted or concentrated antioxidant) is utilized in consumer cosmetic formulations such as skincare, and nutraceutical products.

12. The process for the synthesis of lignocellulosic-based bioproducts as claimed in claim 1 , wherein pressurized carbon dioxide (CO2) gas is introduced in stage- 2 from the power generation unit-1 (13) of the process stage-1 , and/or the power generation unit-2 (303) of the process stage-3, or the combinations of process stages 1 and 3.

13. The process for the synthesis of lignocellulosic based bioproducts as claimed in claim 1 , wherein gas (hydrogen or methane) generated by the anaerobic digestor (202) is utilized in heat energy generation for the operation of several different units including thermal desalinated water (at 100 - 160 °C), carbon fiber (at 1 ,000 - 1 ,500 °C), graphene (at 2,000 - 3,000 °C) and activated carbon (at 800 - 1 ,100 °C).

14. The process for the synthesis of lignocellulosic-based bioproducts as claimed in claim 1 , wherein the heat energy in process stage-2 can be significantly enhanced using a complete fraction of hemicellulosic sugars or introducing a separate stream from agriculture products such as sugarcane juice and or sweet sorghum juice or similar.

15. The process for the synthesis of lignocellulosic-based bioproducts as claimed in claim 1 , wherein the generated carbon dioxide coming from power generation unit-1 (13, at stage 1 ), anaerobic digestor (202, at stage 2), and power generation unit-2 (303, at stage 3) are decarbonized through water and/or catalytic reagents such as NaOH or KOH.

16. The process for the synthesis of lignocellulosic-based bioproducts as claimed in claim 1 , wherein the carbonated water from the process stage-1 , process stage-2, and process stage-3 are utilized in irrigation and/or cold beverages formation.

17. The process for the synthesis of lignocellulosic-based bioproducts as claimed in claim 1 , wherein the energy for the process is harvested through the power generation unit-1 (13), the anaerobic digestor (202), and the power generation unit-2 (303).

18. The process for the synthesis of lignocellulosic-based bioproducts as claimed in claim 1 , wherein the concentrated hemicellulosic sugars are utilized for low- calorie beverages and as an alternative to traditional glucose sugar production.

19. The process for the synthesis of lignocellulosic-based bioproducts as claimed in claim 1 , wherein the concentrated hemicellulosic sugars are utilized to produce xylose through a chemical-specific process, thereby, to produce consumer goods, jet biofuel (in the form of furfural) and other bioproducts.

20. The process for the synthesis of lignocellulosic based bioproducts as claimed in claim 1 , wherein generated cellulose pulp at the end of the process stage-2 is utilized in the production of biofuels (such as ethanol, biodiesel, butanol, hydrogen, methane), paper, desert/draught soil remediation, and/or other bioproducts

21. The process for the synthesis of lignocellulosic-based bioproducts as claimed in claim 1 , wherein the process stage-3 generates nano-cellulose and microcellulose along with coarse fibers.

22. The process for the synthesis of lignocellulosic-based bioproducts as claimed in claim 1 , wherein generating nano-cellulose and micro-cellulose fibers involves further processing using organic solvents using diethyl ether, acetone, water, and their combinations.

23. The process for the synthesis of lignocellulosic based bioproducts as claimed in claim 1 , wherein the nano cellulose and micro cellulose fibers have application in the formation of aerogel, membrane, medical-grade bandage, 3-D printing material, pharmaceutical ingredient, an alternative to steel body manufacturing, paper and paperboard manufacturing, reinforcing material in polymer composite, food and hygiene products, emulsion and dispersion, oil recovery and other bioproducts.

Description:
Process for Synthesis of Lignocellulosic Based Bioproducts Cross-Reference to Related Applications

[001] This application is a continuation of and claims priority to U.S. Provisional Application Ser. No. 63182035, filed on April 30, 2021. The content of which is hereby expressly incorporated by reference in its entirety.

Statement Regarding Federally Sponsored Research

[002] This invention was made without Federal government support.

Background of the Invention

[003] Lignocellulosic biomass consists of plants and trees and is the most abundant and renewable resource on Earth. Lignocellulosic biomass mainly consists of 25 - 55 % of cellulose, 24 - 50 % of hemicellulose, and 10- 35 % of lignin with a minor amount of pectin, protein, ash, and extractives. These polymers form a complex matrix to different degrees and vary relative to composition depending on the type, species, and source of the biomass. Different structural chemical properties of cellulose, hemicellulose, and lignin are summarized in Table 1 [Jain A et. al. Chapter 11 . In: H Luo, Y Wu, C Kole, (Editors). Compendium of Bioenergy plants: Switchgrass. Science Publishers, p. 315-355, 2013],

Table 1. Structural and physical properties of lignocellulosic biomass.

Cellulose

- Monomer unit: Glucan (6-carbon).

- Degree of polymerization: 300 to 1,700 units.

- Linkage: p (1^4)-glycosidic linkage.

- Bonding: Hydrogen bond (through inter and intra-hydroxyl groups),

Ether bond (in cellulose, and between cellulose and lignin).

- Occurrence: Crystalline and amorphous forms.

- Nature: Hygroscopic.

- Solubility: Water-insoluble.

Hemicellulose

- Monomer units: Xylan (5-carbon), arabinan (5-carbon), galactan (6-carbon), and mannan

(6-carbon).

- Degree of polymerization: 150-200 units.

- Linkages: (1^4) or p (1^3) glycosidic linkages.

- Bonding: Hydrogen bond (through inter hydroxyl groups),

Ether bond (in hemicellulose, and between hemicellulose and lignin), Ester bond (in hemicellulose, and between hemicellulose and lignin).

- Occurrence: Highly branched and contains acetyl groups, crystallinity lower than cellulose. - Nature: Hygroscopic.

- Solubility: Acid and/or Alkaline-water solution.

Lignin

- Monomer units: p-courmaryl alcohol, coniferyl alcohol, and sinapyl alcohol units (9- carbon).

- Degree of polymerization: Not listed (due to fragmentation and heterogeneity in lignin structure).

- Linkages: Connected through ether bonds (2/3) and carbon-carbon bonds.

- Bonding: Hydrogen bond (through inter hydroxyl groups),

Ether bond (in lignin, and between lignin and (hemi)cellulose), Ester bond (between lignin and hemicellulose), Carbon to carbon bond (in lignin).

- Occurrence: Amorphous three-dimensional polymer, solidify with aging.

- Nature: Hydrophobic.

- Solubility: water-insoluble; low molecular weight organic solvent-soluble.

[004] Cellulose is the main constituent of plant cell walls. The repeating unit of the cellulose chain is the disaccharide cellobiose. The cellulose chains (20-300) are grouped together to form microfibrils, which are bundled together to form cellulose fibers. The long-chain cellulose polymers are linked together by hydrogen bonding (through inter and intra-hydroxyl groups) and van der Waals forces, which cause the cellulose to be packed into m icrofibrils. Hemicellulose and lignin are intermixed with the microfibrils to provide a rigid structure. Cellulose exists in two forms - crystalline cellulose (in major quantity) and amorphous cellulose (in minor quantity). Cellulose in its amorphous form is easy to hydrolyze compared to crystalline form. The existence of intra-hydrogen bonding within a cellulose microfibril results in the sturdiness of the cellulose (in crystalline form) whereas inter-hydrogen bonds may perhaps introduce disorder (in amorphous form) into the structure of the cellulose.

[005] Hemicellulose is the second most abundant polymer containing about 20- 50 % of lignocellulose biomass. It is chemically heterogeneous, unlike cellulose. Hemicellulose has branches with short lateral chains consisting of different types of sugars. Hemicellulose has a lower molecular weight compared to cellulose and branches with short lateral chains that are easily hydrolyzed. Hemicellulose is found to differ in composition. In agricultural biomass like sugarcane bagasse, hemicellulose is composed mainly of xylan. Whereas in forestry biomass like softwood, hemicellulose contains mainly glucomannan. Xylan can be extracted easily in acid or alkaline conditions while extraction of glucomannan requires a stronger alkaline. Among the key components of lignocellulosic biomass, hemicellulose exists as the most thermo- chemically sensitive fraction [Turk J Agric For 23:667-671 ; Fengel, Dietrich, and Gerd Wegener, eds. Wood: chemistry, ultrastructure, reactions. Walter de Gruyter, 2011], To have access to the significant portion of cellulose content of lignocellulosic biomass, at least 50 % of hemicellulose must be removed by means of chemical extraction and/or biological degradation. However, chemical extraction parameters should be carefully optimized to avoid the formation of hemicellulose degradation products such as furfurals and hydroxymethyl furfurals that has an inhibitory effect during the fermentation process. The formation of inhibitory products in sulfuric acid-based extraction generally occurs at the temperature of 130 °C. For the same reason, the chemical extraction seventy conditions are usually compromised to maximize sugar recovery. Hemicellulose could be obtained either as a solid fraction (generally in alkaline pH conditions), a liquid fraction (generally in acidic pH conditions), or a combination of both solid and liquid fractions.

[006] Lignin is the third most abundant polymer in nature. It is a complex, large molecular structure containing cross-linked polymers of phenolic monomers. Lignin provides a natural barrier for the plant cell to thrive through its rigid structure and provides impermeable resistance to microbial attack and oxidative stress. The presence of phenolic compounds in lignocellulosic biomass reduces its application toward unfertile soil remediation. The physical and chemical properties of lignin in different lignocellulosic biomass play a critical role in the selection of optimum chemical extraction formulation.

[007] Lignocellulosic biomass is a renewable source of different bioproducts including biofuels, paper pulp, textile, biochemicals, agriculture fertilizer, food preservatives, cosmetics, and consumer goods. To develop lignocellulosic biomassbased bioproducts, there is a need to fractionate lignocellulosic material into reactive intermediates such as cellulose, hemicellulose, and lignin.

[008] To access the recalcitrant nature of lignocellulosic biomass, both physical and thermochemical treatments are required. A physical treatment, such as milling, is required to increase the surface area of the sized particle per unit of volume. Whereas thermochemical treatments are required to convert polysaccharide content from crystalline to amorphous with lignin removal. Several different thermochemical treatments employing steam, ethyl-hydro-oxides (EHOs), sulfuric acid-based reagent, soda-ethanol, alkaline hydroxide (including sodium hydroxide, soaking in aqueous ammonia (SAA)), and alkaline hydrogen peroxide have been reported for lignocellulosic biomass conversion [Biomass & Bioenergy. 93; 227-242, 2016; Biomass & Bioenergy. 94; 130-145, 2016], However, the methods of lignocellulosic biomass conversion often favor one of these intermediates to the detriment of the others. This leads to the insufficient overall yield of these treatments from the economic and ecological point of view. As cellulose is the most common by-product of lignocellulosic biomass, the known methods of treatment of the lignocellulosic material produce a poor yield and/or a poor quality of lignin or hemicellulose.

[009] The selection of reactants in a solvent formulation is the most critical challenge toward the complete utilization of lignocellulosic biomass. Based on the pH of the solution, the chemical treatment is either acidic or basic in nature. The breakage of bonds in lignocellulosic biomass occurs due to the formation of hydronium ions (in acidic pH) and hydroxyl ions (in basic pH). To understand different chemical treatments, it is important to have knowledge of the physio-chemical properties of reactants with reference to different fractions of lignocellulosic biomass [Biomass & Bioenergy. 93; 227-242, 2016; Biomass & Bioenergy. 94; 130-145, 2016],

[0010] The prior art of alkaline-organic solvent treatment using ethyl-hydro-oxides (EHOs) [US Patent Application # 20150087030; Biomass & Bioenergy. 93; 227-242, 2016; Biomass & Bioenergy. 94; 130-145, 2016] has demonstrated the importance of pressurized conditions in the biochemical conversion of various lignocellulosic biomass including sugarcane bagasse and pinewood chips. However, despite the shorter processing time, and ability to recycle the organic solvent in the process, the EHOs process has been missing the critical system engineering details including the content of pressurized gas, the method to extract pressurized gas from the reactor, the constituent of the solvent formation for the commercial operation, development of different bioproducts and their application. All these factors are equally important in the successful commercialization of the technology. [0011] In view of the known prior art, the objective of the present invention is to provide a process for the synthesis of lignocellulosic based bioproducts that generates streams of high-value goods including cosmetic ingredients, nutraceuticals, graphene, carbon fiber, activated carbon, low-calorie sugar, bioplastic, cellulose pulp, and nanocellulose based aerogel using alkaline-organic solvent treatment using modified EHOs composition leading to better mass transfer, thereby, the safety of the process (compared to previously filed ethyl-hydro-oxides (EHOs) composition) at a commercialscale operation. Another objective of the present invention is to make the process robust and safe compared to the previously filed EHOs process. The other objective of the present invention is to provide a process with enough alkaline concentration in the aqueous organic solvent for both delignification of biomass and decreasing the crystallinity of biomass. The further objective of the present invention is to provide a process that replaces water with seawater reducing the dependability on the freshwater resources. Another object of the present invention is to provide a process that generates hydrogen or methane gas that can be utilized for heat energy generation for the operation of several different units including thermal/ membrane-based desalinated water, carbon fiber, graphene, and activated carbon. Another object of the present invention is to provide a process that generates energy along with the production of high-value goods. Another objective of the present invention is to provide a process to decarbonize atmospheric carbon dioxide.

Summary of the Invention

[0012] Along with the production of high-value goods, the process as per the present invention generates energy. The generated energy in the process would be utilized in the desalination of seawater and empowering the electricity gridlines. Similarly, the generated cellulose pulp can be applied for biofuel production as well as in soil remediation.

[0013] A subject of the present invention is therefore a process for the synthesis of lignocellulosic based bioproducts, comprising: a process stage-1 for removing the phenolic compounds (lignin) from lignocellulosic biomass as well as decreasing the crystallinity of the cellulose using alkaline modified ethyl-hydro-oxides (m-EHOs) extraction; a process stage-2 for removal of the hemicellulose fraction of the holocellulose using mild sulfuric acid extraction; and a process stage-3 for chemically treating cellulose pulp with alkaline modified ethyl-hydro-oxides (m-EHOs) solvent for the production of nano-cellulose and micro-cellulose fractions.

[0014] The process stage-1 is comprising the steps of:

(a) milling and grinding of lignocellulosic biomass and feeding the milled and ground lignocellulosic biomass into a reactor-1 (1 ) using a feed inlet (2),

(b) adding a modified ethyl-hydro-oxides (m-EHOs) solvent consisting of ethanol in an amount of 10 - 90 % by volume, potassium hydroxide (KOH) in an amount of 1 - 20 % by weight, potassium carbonate (K2CO3) in an amount of 0 - 20 % by weight, hydrogen peroxide (H2O2) in an amount of 1 - 20 % by weight, nitrogen (N2) in an amount of 0 - 80 % by volume, hydrogen (H2) in an amount of 0 - 20 % by volume, and seawater/water (H2O) in an amount of 20 - 60 % by weight, to the 40 - 100 % of the total volume of the reactor-1 (1 ) and a ratio of biomass to the modified ethyl-hydro-oxides (m-EHOs) solvent is maintained between 1 :50 - 1 :1 by weight over volume,

(c) preparing a heterogeneous mixture of the lignocellulosic biomass and the modified ethyl-hydro-oxides (m-EHOs) solvent in the reactor-1 (1) by mixing the said mixture using an impeller (3),

(d) supplying hydrogen gas (H2) into the reactor-1 (1) using hydrogen (H2) gas inlet valve (5) provided at the bottom portion of the reactor-1 (1) through nitrogen (N2) gas sparging by maintaining the concentration of hydrogen gas in the nitrogen gas between 1 - 20 % by volume,

(e) supplying nitrogen (N2) gas into headspace (8) in the reactor-1 (1) using a Nitrogen (N2) gas inlet valve (6) for accelerating the chemical reaction between the lignocellulosic biomass and the modified ethyl-hydro-oxides (m-EHOs) solvent allowing a reaction time of 1 - 15 minutes to generate pressure up to 10 - 800 psi, more specifically at 400 psi,

(f) allowing chemical reaction in the reactor-1 (1) at a temperature of 65 - 75 °C with an incubation period of 1 - 8 hours wherein the temperature in the reactor-1 (1) is controlled using a temperature controlling jacket (4), (g) allowing transfer of carbon dioxide (CO2) gas generated because of a reaction between the lignocellulosic biomass and the modified ethyl-hydro-oxides (m- EHOs) solvent and accumulated in the space (8) of the reactor-1 (1 ) to a power generation unit-1 (13) after removing the vapor content of ethanol and water carried by carbon dioxide (CO2) in a packed bed column-1 (12) in which pressure is maintained at 10 - 800 psi, more specifically at 400 psi using carbon dioxide,

(h) At the end of the incubation period, the reactor-1 (1) contents are cooling down to a temperature of -10 to 25 °C using an internal colling coil (14),

(i) neutralizing the pH of a biomass slurry of the reactor-1 (1 ) by adding hydrochloric acid (HCI) or citric acid from a storage tank (19) to the reactor-1 (1 ),

(j) separating a liquid and a solid fraction of biomass slurry of the reactor-1 (1 ) by discharging biomass slurry using a biomass discharge port (7) on a stack of vibrational screens (15) of 3.5 - 500 mesh (or higher) size,

(k) liquid fraction collected in a vessel containing solvent extract with precipitated salt (27) from the stack of vibration screens (15) is further processed through a centrifuge unit (32) (centrifugation at greater than 1 ,000 rpm) followed by a filtration unit (33) (filter pore size: less than 0.2 microns) equipped with a nitrogen/carbon dioxide compressor unit (37) to remove biomass residues with precipitated salt (30) and residual biomass (34) before phase separation in a phase separator and injection molding unit (23) equipped with a nitrogen compressor (39) to separate hydrophobic lignin (solids in the form of small disc flakes) and hydrophilic lignin (liquid) content after extraction of ethanol at 60 - 120 °C, more specifically at 78 °C,

(l) the solid fraction is transferred from the vibration screen (15), after subjecting to compressive force by a roller pressing (installed on the vibrational screen) to squeeze excessive solvent extract, to a water washing reactor (20) equipped with a water supply vessel (38),

(m) transferring biomass from the water washing reactor (20) to the stacks of vibration screens (21 ) of 3.5 - 500 mesh (or higher) size for separating the biomass slurry into solid and liquid fractions, (n) the stacks of vibration screens (21) further separate the solid fraction into a holocellulose (31 ) and a cellulose-xylan-lignin,

(o) the liquid fraction collected from the stacks of vibration screens (21 ) into a vessel containing water-diluted solvent extract with dissolved salt (28) is further processed through a centrifuge unit (32) (greater than 1 ,000 rpm) followed by a filtration unit (33) (filter pore size: less than or equal to 0.2 microns) equipped with a compressor (37) to remove biomass residual (30 and 34) before phase separation using a phase separator and an injection molding unit (23) to separate hydrophobic lignin with dissolved salt (solids in the form of small disc flakes) and hydrophilic lignin (liquid) content after extraction of ethanol at 60 - 120 °C, more specifically at 78 °C,

(p) the distilled ethanol produced through the processing of solvent extracts (containing precipitated salt and dissolved salt) is recycled to ethanol storage (35) after condensation (36) for the application in the reactor-1 (1 ),

(q) the generated holocellulose is subjected to compressive force by a roller pressing to squeeze the excessive aqueous solvent on the vibrational screen (21), and water washing before transferring to stage-2 processing,

(r) the final content of organic solvent (i.e. , ethanol) in the holocellulose ranges between 2 - 40 % (by volume), more specifically at 8 %.

[0015] The process stage-2 is further comprising steps of:

(a) producing concentrated hemicellulosic sugars (between 50 - 200 g/L) by employing a sulfuric acid having a concentration in a range of 0.1 - 5 % of the total weight of holocellulose in a reactor-2 (201 ) to remove the hemicellulose fraction of holocellulose wherein the total biomass inlet in stage-2 ranges between 50 - 90 % of the initial biomass (on the dry basis) from stage-1 , a ratio of biomass to solvent ranges between 1 :1 - 1 :10, operating conditions involve an operating temperature of 70 - 100 °C for 1 - 2 hours with the introduction of pressurized carbon dioxide (CO2) in a range of 0 - 600 psi, more specifically 250 psi, from the stage-1 ,

(b) adding calcium hydroxide (216) to the reactor-2 (201 ) content to bring the pH of the biomass slurry between 5 - 6.5 before discharge on a vibrational screen (203) followed by moisture squeezing, a series of water washing, and roller pressing to generate cellulose pulp (211),

(c) the vibrational screen (203) resulted in two different liquid fractions, namely a vessel containing concentrated hemicellulosic sugars (204) and a vessel containing diluted hemicellulosic sugars (205),

(d) the vessel containing the concentrated hemicellulosic sugars (204) is further processed through a centrifugation unit (208) to remove biomass residues with precipitated salt (209), followed by a distillation column (206) to generate the organic solvent-free concentrated hemicellulosic sugar,

(e) the generated ethanol through the distillation column (206) is stored in a vessel (212) after condensation (213) for use in the reactor-1 (1 ) processing,

(f) the vessel containing diluted hemicellulosic sugar (205) utilized in an anaerobic digestor (202) to produce hydrogen gas and/or methane gas (214) wherein an operating temperature of anaerobic digestion varies between 37 - 80 °C, and

(g) water sparging of the produced gas through the anaerobic digestor (202) in a water sparging unit (207) at a temperature in a range of 0 - 60 °C resulted in the production of carbonated water (215),

[0016] The process stage-3 is comprising steps of:

(a) chemically treating cellulose pulp received from stage-2 of the process in a reactor-3 (301 ) with modified ethyl-hydro-oxides (m-EHOs) solvent having the composition similar to the modified Ethyl-hydro-oxides (m-EHOs) solvent of the process stage-1 with maintaining the similar operating conditions of biomass to the solvent ratio of 1 : 1 - 1 :50 weight per volume (w/v), and the processing temperature of 65 - 75 °C, wherein the transferred biomass content from the process stage-2 to the process stage-3 range between 25 - 75 % of the total biomass at process stage-1 ,

(b) the processing time of the process stage-3 varies between 1 - 24 hours,

(c) allowing transfer of carbon dioxide (CO2) gas generated because of a reaction between the cellulosic pulp and the modified ethyl-hydro-oxides (m-EHOs) solvent and accumulated in the headspace of the reactor-3 (301 ) to a power generation unit-2 (303) after removing vapor content of ethanol and water carried by carbon dioxide (CO2) in a packed bed column in which pressure is maintained at 10 - 800 psi, more specifically at 400 psi, using carbon dioxide similar to process stage-1 ,

(d) At the end of the incubation period, the reactor-3 (301 ) contents are cooling down to a temperature in a range of -10 to 25 °C using an internal colling coil similar to the stage-1 processing,

(e) neutralizing pH of a biomass slurry of the reactor-3 (301 ) by adding hydrochloric acid (HCI) or citric acid from a storage tank (305) similar to the stage-1 processing,

(f) the biomass content from the reactor-3 (301 ) is discharged on a vibration screen (306) resulting in the separation of solid and liquid fractions similar to the stage-1 processing,

(g) performing solvent squeezing of the solid fraction (of biomass) using the rollers on the vibrational screen (306), transferred to ethanol or organic solvent washing reactor (307) connected with ethanol and/or organic solvent supply (320),

(h) discharging biomass from the ethanol or organic solvent washing reactor (307) to the stacks of vibration screens (308) similar to the stage-1 processing, separates slurry into solid and liquid fractions wherein the solid fraction is further separated into coarse fibers (316) and micro cellulose fibers (315),

(i) the vessels containing solvent with fibers and precipitated salt (311 and 312) resulted through the vibrational screens (306 and 308) are further processed through a centrifuge unit (317) (to remove residual biomass with salt (313), followed by a filtration unit (318) (filter pore size: less than 0.2 microns) equipped with a compressor (319) to capture nano-cellulose fibers (314) from the solvent stream,

(j) the generated solvent stream is recycled to an ethanol recycling vessel (310) in the process without distillation for the next batch of processing.

Brief Description of the Figures

[0017] A complete and enabling disclosure of the present subject matter, including the best mode thereof to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying figures in which:

[0018] FIG. 1 is a block diagram for different stages of lignocellulosic biomass processing in the production of bioproducts.

[0019] FIG. 2A is a schematic diagram showing electricity generation at a lower temperature.

[0020] FIG. 2B is a schematic diagram showing electricity generation at a higher temperature.

[0021] FIG. 2C is a schematic diagram showing a stage 1 processing for the synthesis of bioproducts.

[0022] FIG. 3 is a schematic diagram showing the electricity generation process.

[0023] FIG. 4 is a schematic diagram showing stage 2 processing for the synthesis of lignocellulosic biomass-based bioproducts.

[0024] FIG. 5 is a schematic diagram showing stage 3 processing for the synthesis of lignocellulosic biomass-based bioproducts.

[0025] FIG. 6 is a schematic diagram showing a commercial set-up of the process; and

[0026] FIG. 7 is a block diagram showing various bioproducts obtained by the conversion of lignocellulosic biomass and its application in desert soil remediation.

[0027] Other objects, features, and aspects of the subject matter are disclosed in or are apparent from the following detailed description.

Detailed Description of Preferred Embodiments

[0028] Reference will now be made in detail to various embodiments of the disclosed subject matter, one or more examples set forth below. Each embodiment is provided by way of explaining the subject matter, not the limitation of the subject matter. It will be apparent to those skilled in the art that various modifications and variations may be made in the present disclosure without departing from the scope or spirit of the subject matter. For instance, features illustrated or described as part of one embodiment may be used in another embodiment to yield a still further embodiment. Thus, it is intended that the present disclosure cover such modifications and variations as come within the scope of the appended claims and their equivalents. [0029] In general, the present disclosure is directed to a process design for the synthesis of lignocellulosic-based bioproducts. The process utilizes lignocellulosic biomass generated through agriculture, non-agriculture, and forest. The process involves the biochemical conversion of lignocellulosic biomass that generates streams of high-value goods including cosmetic ingredients, nutraceuticals, carbon fiber, activated carbon, graphene, low-calorie sugar, bioplastic, cellulose pulp, and nanocellulose based aerogel. Along with the production of high-value goods, the process generates energy. Furthermore, the application of generated products is not limited to a single application. For example, the generated energy in the process would be utilized in the desalination of seawater and empowering the electricity gridlines. Similarly, the generated cellulose pulp can be applied for biofuel production as well as in soil remediation.

[0030] On the technical side, the disclosed technology work as a biofuel cell that comprises three different stages in the biochemical conversion of lignocellulosic biomass. In the stage-1 process, the phenolic compounds (lignin) are removed from lignocellulosic biomass while decreasing the crystallinity of cellulose and generating electricity. In the stage-2 process, the hemicellulose fraction of the holocellulose (from stage-1 processing) is removed while generating heat energy. In the stage-3 process, cellulose pulp (generating from the stage-2 process) converting to nano-cellulose and micro-cellulose fractions along with coarse cellulose production while electricity generation takes place. The simplified block diagram is shown in FIG. 1.

[0031] In the stage-1 process, modified ethyl-hydro-oxides (m-EHOs) solvent consisting of potassium hydroxide along with potassium carbonate, hydrogen peroxide, ethanol, water/seawater, nitrogen gas, and hydrogen gas. The overall composition leads to better mass transfer, thereby, the safety of the process (compared to previously filed ethyl-hydro-oxides (EHOs) composition) at a commercial-scale operation. The addition of seawater, nitrogen gas, hydrogen gas, and potassium carbonate in m-EHOs make the process robust and safe compared to the previously filed EHOs process. Potassium carbonate is a stable salt (and retains heat energy) compared to the hygroscopic nature of potassium hydroxide. The replacement of 5 - 90 % part of potassium hydroxide (KOH) with potassium carbonate (K2CO3) in the solvent formation reduces the formation of hydrogen gas (while reacting with ethanol and/or water) and hence, increases the safety of the process. The pH of the solvent between 11 - 14 of modified EHOs leads to the dissociation of hydrogen peroxide (pKa value =11 .5) into water and oxygen gas. The exothermic reaction in the process occurs while hydrogen gas (controlled parameter with nitrogen gas) is reacting with oxygen. The above said modification of the process provides enough alkaline concentration in the aqueous organic solvent for both delignification of biomass and decreasing the crystallinity of biomass. On the other side, replacing water with seawater reduces the dependability on the freshwater resources and is utilized in the production of consumer care goods such as skincare products such as soap, and lotion.

[0032] FIG. 2A, 2B, and 2C show a schematic diagram showing stage-1 processing for the synthesis of bioproducts. The design of a reactor-1 (1 ) includes a Teflon coating (9) on an interior surface of stainless steel to nullify the effect of high pH of solvent, an internal cooling coil (14) to control exothermic temperature, thereby, generating pressure, an impeller (3) to provide mixing, a feed inlet (2) for lignocellulosic biomass, a biomass discharge port (7) to remove contents of the reactor, a temperature controlling jacket (4) to maintain the temperature at 65 - 75 °C, a hydrogen gas inlet valve (5) and a nitrogen gas inlet valve (6).

[0033] During the stage-1 processing, after mixing lignocellulosic biomass with modified ethyl-hydro-oxides (m-EHOs) solvent, an increase in temperature and pressure is observed (similar to the EHOs process). The pressure starts building up at the temperature of 65 - 75 °C to 10 - 800 psi, more specifically 400 psi, after 1 -15 minutes of incubation. The generated pressure is mainly due to the production of carbon dioxide in reactor-1 (1 ). The other gaseous components include ethanol and water. The exact mechanism for the formation of carbon dioxide in the reaction is not known yet. However, it is believed the production of radical or anionic species of oxygen (through hydrogen peroxide, pKa 11 .5) reacts with phenolic compounds of lignocellulosic biomass and/or ethanol (organic solvent) leads to the formation of carbon dioxide.

[0034] In the process stage-1 , lignocellulosic biomass is milled and ground, and feed into a reactor-1 (1 ) using a feed inlet (2). The lignocellulosic biomass includes but is not limited to big chunks of forestry biomass such as pine wood chips of an average size of 10 mm x 10 mm x 10 mm and crushed agricultural biomass such as crushed sugarcane bagasse without size reduction. The advantage of using agricultural biomass (for example, crushed sugarcane bagasse) without further size reduction help to generate a long length of fibers and their processing with minimal biomass loss. A modified ethyl-hydro-oxides (m-EHOs) solvent consisting of ethanol in an amount of 10 - 90 % by volume, potassium hydroxide (KOH) in an amount of 1 - 20 % by weight, potassium carbonate (K2CO3) in an amount of 0 - 20 % by weight, hydrogen peroxide (H2O2) in an amount of 0 - 20 % by weight, nitrogen (N2) in an amount of 0 - 80 % by volume, hydrogen (H2) in an amount of 0 - 20 % by volume, and seawater/water (H2O) in an amount of 20 - 60 % by weight is added to the reactor-1 (1 ) to the 40 - 100 % of the total volume of the reactor-1 (1). A ratio of biomass to modified ethyl-hydro-oxides (m-EHOs) solvent is maintained between 1 :50 - 1 :1 by weight over volume. A heterogeneous mixture of the lignocellulosic biomass and the modified ethyl-hydro- oxides (m-EHOs) solvent is prepared in reactor-1 (1 ) by mixing the said mixture using the impeller (3). Hydrogen gas (H2) is supplied into the reactor-1 (1 ) using the hydrogen (H2) gas inlet valve (5) provided at the bottom portion of the reactor-1 (1) through nitrogen (N2) gas sparging. The concentration of hydrogen gas in the nitrogen gas is maintained between 1 - 20 % by volume. Nitrogen (N2) gas is supplied into headspace (8) in the reactor-1 (1 ) using the Nitrogen (N2) gas inlet valve (6) for accelerating the chemical reaction between the lignocellulosic biomass and the modified ethyl-hydro- oxides (m-EHOs) solvent. A reaction time of 1 - 15 minutes is allowed to generate pressure up to 10 - 800 psi, more specifically 400 psi. The exothermic chemical reaction is allowed in reactor-1 (1 ) at a temperature range of 65 - 75 °C with an incubation period of 1 - 8 hours. The temperature in reactor-1 (1 ) is controlled using a temperature controlling jacket (4).

[0035] Hydrogen and K2CO3 are used in the process stage-1 to replace the quantity of KOH in the process. The exothermic reaction of KOH with ethanol results in the production of hydrogen gas. The replacement of K2CO3 and H2 (through N2 carrier gas, at the bottom of the reactor-1 (1 )) helps to control exothermic reactions compared to the use of KOH alone. In comparison to KOH, K2CO3 salting-out ethanol in an aqueous ethanol mixture at 25 °C. [0036] Carbon dioxide (CO2) gas generated because of a reaction between the lignocellulosic biomass and the modified ethyl-hydro-oxides (m-EHOs) solvent and accumulated in the space (8) of the reactor-1 (1 ) is transferred to a power generation unit-1 (13) after removing the vapor content of ethanol and water carried by carbon dioxide (CO2) in a packed bed column (12). The pressure is maintained at 10 - 800 psi, more specifically at 400 psi, using carbon dioxide in the packed bed column-1 (12).

[0037] Furthermore, the packed bed column-1 (12) expressed a design to remove the liquid content itself. To enhance the separation of the liquid phase in the reactor-1 (1) and the vapor phase in the power generation unit-1 (13), the packed bed column-1 (12) is equipped with a hydrophobic membrane to remove water content at the range of 65 - 75 °C and to selectively pass the vapors of ethanol. Furthermore, the ethanol vapors can be restricted through a hydrophilic membrane and/or catalyst such as zeolites. Therefore, the combinations of hydrophobic and hydrophilic membrane stacks are utilized in the process. Therefore, the packed-bed column-1 (12) can be operated with and without packing material. Furthermore, based on the lower reactor loading of 40 - 85 %, the need for the packed-bed column also diminishes. The packed bed column-1 (12) is connected to the spent CO2 line from the power generation unit-1 (13) to remove the accumulated liquid content from the reactor-1 (1 ) and to pressurize the packed-bed column-1 (12). The suggested process is to increase the efficiency of the power generation unit-1 (13) by increasing the retention of carbon dioxide in the packed-bed column-1 (12).

[0038] The pressure generated because of the generated carbon dioxide in the reactor-1 (1) vessel is captured through a connected piston assembly-1 (16) of the power generation unit-1 (13) via a packed bed column-1 (12). Both the packed bed column-1 (12) and the piston assembly-1 (16) are at the same temperatures controlled in the range of 65 - 75 °C, more specifically at 65 °C. During the pressure generation, valves (17, 18, 24) are kept in “on position” as shown in FIG. 2A and the piston of the piston assembly-1 (16) start moving in the downward direction (as shown in FIG. 3). Once the optimum pressure of 10 - 800 psi, more specifically 400 psi, is reached in the system (comprised of the reactor-1 (1 ), the packed bed column-1 (12), and the piston assembly-1 (16), the “on position” valve changes to the “off position”. The density of carbon dioxide varies between 60 kg/m 3 (at 65 °C, 400 psi) to 113 kg/m 3 (at 65 °C, 725 psi). Whereas the density of water steam at 230 °C and 435 psi is 15 kg/m 3 . As seen from the presented data above, the production of carbon dioxide through the biochemical conversion process (at 65 °C, >400 psi) has almost four times energy efficiency compared to water steam production.

[0039] During the “off position” of the valves (17, 18, 24), the movement of the piston assembly-1 (16) is either controlled through the reacting torque of the piston itself or controlled through the temperature of the piston assembly-1 (16). The change in the temperature of the piston assembly-1 (16) from 65 °C to 30 °C increases the density of carbon dioxide in the piston assembly-1 (16) from 60 kg/m 3 to 73 kg/m 3 , respectively. For example, using 1 ,000 L reactor with the piston assembly volume of 176.5 L, the force of 435 kN would be exerted by generated carbon dioxide, thereby, work done of 487 kN m (Conditions: temperature: 65 °C, inlet pressure = 400 psi; bore volume = 0.1765 m 3 , diameter: height = 0.4, diameter = 0.448 m, height = 1.12 m, area = 0.158 m 2 ). The total power generation of 1 .46 MWh would be achieved using carbon dioxide in a 1 ,000 L reactor operation. For the commercial electricity production of 4.38 GWh requires 3,000 reactors (volume of each reactor = 1 ,000 L). FIG.6 shows the possible set-up of such an arrangement at the commercial scale. A similar carbon dioxide-based power generation unit can be utilized to empower automobiles and to develop spacecraft.

[0040] In the process of electricity generation, an outlet valve (25) will be opened at > 1 ,000 psi and at the temperature range of 30 - 100 °C. The process would create thrust force for the movement of a piston of the piston assembly-2 (26). The volume of the carbon dioxide displacement in the piston would be based on the physicochemical properties of carbon dioxide. The piston assembly-1 (16) and the piston assembly-2 (26) can be coupled through the wheel movements. The second stage of the piston movement would be performed either in series or parallel arrangements of the piston assembly-1 (16). The temperature of consecutive piston assemblies (40) can be regulated between 30 - 200 °C as shown in FIG. 2a and FIG. 2b for the recycling of carbon dioxide. The energy source for controlling the piston movement would be generated through the processing itself or using solar energy panels. Furthermore, the energy of carbon dioxide (at > 1 ,000 psi, at 30°C) would be utilized either in oil extraction (using oleaginous microorganisms such as yeast or algae), pressurizing a reactor-2 (201 ) of the processing stage-2, and generation of carbonated water (through water sparging for algae cultivation and desert/drought soil remediation). The process converts carbonated water into oxygen through photosynthetic converters. During the water carbonation process, nitrogen gas can be recovered due to its insolubility in water and feedback to the nitrogen compressor.

[0041] The stage-1 process removes the phenolic compounds (lignin) from a plant/tree cell matrix as well as decreases the crystallinity of the cellulose similar to the EHOs process while empowering the commercial electricity generation process.

[0042] At the end of the stage-1 process, the contents of the reactor-1 (1 ) are cooled down to a temperature range of -10 °C to 25 °C using an internal colling coil (14). After cooling, the pH of a biomass slurry of reactor-1 (1 ) is neutralized by adding hydrochloric HCI or citric acid from a storage tank (19) to reactor-1 (1 ). The salt formation of potassium-based and or sodium-based citrate and/or chloride are resulted due to pH neutralization. The densities of both salts are around 1 ,980 kg/m 3 and are in the precipitated form in the organic solvent. The liquid and solid fraction of biomass slurry of the reactor-1 (1 ) is separated by discharging biomass slurry using a biomass discharge port (7) on a stack of vibrational screens (15) of 3.5 - 500 mesh (or higher) size.

[0043] A liquid fraction collected in the vessel containing solvent extract with precipitated salt (27) from the stack of vibration screens (15) is further processed through a centrifuge unit (32) (centrifugation at greater than 1 ,000 rpm). Due to the existing densities differences between the precipitated salt (1 ,980 kg/m 3 ) and the solvent extract (1 ,000-1 ,100 kg/m 3 ), both precipitated salt with biomass residues (30) and the salt-free solvent extract would be generated. Following the centrifugation, a filtration unit (33) (filter pore size: less than 0.2 microns) equipped with a nitrogen/carbon dioxide compressor unit (37) removes residual biomass (34) to produce solvent extract without particulate matter. The construction of the filtration unit can include a membrane and layers of quartz (a combination of macro, micro, and nano quartz) for the removal of particulate matters, before phase separation in a phase separator and injection molding unit (23) equipped with nitrogen compressor (39) to separate hydrophobic lignin (solids in the form of small disc flakes) and hydrophilic lignin (liquid) content after extraction of ethanol at 60 - 120 °C, more specifically at 78 °C. The ethanol distillation process can be coupled with a vacuum to lower the heat energy requirement. Furthermore, different organic and inorganic solvents (such as diethyl ether, toluene, acetone, and borazine) can be utilized to remove precipitated salt content during and after the removal of ethanol content in the phase separator and injection molding unit (23). The minimal chemical reactivities of these solvents with the generated salt and the ability to do a phase separation are the most important parameters of consideration for their application in the process.

[0044] A solid fraction from the vibration screen (15) is transferred to a water washing reactor (20) equipped with a water supply vessel (38) after subjecting to compressive force by roller pressing to squeeze excessive solvent extract. Biomass from the water washing reactor (20) is transferred to a vibration screen (21 ) for separating the biomass slurry into solid and liquid fractions. Furthermore, the vibration screen (21 ) also separates the solid fraction into holocellulose (31 ) and cellulose-xylan- lignin (29) fractions. The liquid fraction collected from the vibration screens (21 ) into the vessel containing water-diluted solvent extract with dissolved salt (28) is further processed through a centrifuge unit (32) (greater than 1 ,000 rpm) followed by a filtration unit (33) (filter pore size: less than or equal to 0.2 microns) equipped with compressor (37) to remove biomass residual (30 and 34) before phase separation using a phase separator and injection molding unit (23) to separate hydrophobic lignin with dissolved salt (solids in the form of small disc flakes) and hydrophilic lignin (liquid) content after extraction of ethanol at 60 - 120 °C, more specifically at 78 °C. The final content of alcohol in the holocellulose varies between 2 - 8 %. The alcohol content in holocellulose can vary up to 40 % to reduce the water content in stage-2 processing. The generated holocellulose (31 ) after the process stage-1 is subjected to compressive force by roller pressing to squeeze the excessive solvent extract on a vibrational screen, moisture squeezing, and water washing before transferring to stage-2 for further processing. [0045] The collected cellulose-xylan-lignin fraction (29) is either directly utilized for activated carbon formation or further processed for bioplastic formation. After salt precipitation, cellulose-xylan-lignin is processed under a nitrogen atmosphere at 150 - 250 °C for melting and casting into films or powder. The hydrophilic lignin (in liquid form) would be utilized in the formation of nutraceutical and cosmetic products such as skincare lotion and medical cosmetic products including soap. Whereas the hydrophobic lignin (in an amorphous solid form) can be processed to produce graphene, activated carbon, and/or carbon fibers.

[0046] In the processing stage-2, a mild sulfuric acid is employed to remove the hemicellulose fraction of the holocellulose. The total biomass inlet to the processing stage-2 ranges between 50 % to 90 % of the initial biomass at stage-1. FIG. 4 shows a schematic diagram of stage-2 processing for the synthesis of lignocellulosic biomassbased bioproducts.

[0047] In the processing of stage-2, a sulfuric acid having a concentration in a range of 0.1 - 5 % of the total weight of holocellulose (dry basis from stage 1 ) is employed to remove the hemicellulose fraction of holocellulose. The ratio of biomass to solvent ranges between 1 :1 to 1 :10 by weight over volume. The operating conditions involve an operating temperature of 70 °C - 100 °C for a period of 1-2 hours and the introduction of pressurized carbon dioxide (CO2) gas with pressure in the range of 0 - 600 psi, more specifically 250 psi, from the processing stage-1 (the power generation unit-1 (13)). The selection of the temperature for the process is to avoid the formation of inhibitory products (such as furfural and hydroxy furfural), limit the dissolution of carbon dioxide, increase the contact surface of biomass, and produce concentrated hemicellulosic sugars (between 50 - 200 g/L). Due to the crystallinity difference between hemicellulose and cellulose content of lignocellulosic biomass, the hemicellulosic sugars are easy to extract compared to cellulosic sugar. Following the hemicellulose extraction, calcium hydroxide (216) is added to the reactor-2 (201 ) content to bring the pH of biomass slurry between 5 - 6.5 before discharge followed by squeezing, a series of water washing, and roller pressing to generate cellulose pulp (211 ). The addition of calcium hydroxide changes the sulfuric acid to calcium sulfate (insoluble in water). Following the pH adjustment, the slurry is discharged on the vibrational screen (203) similar to the processing stage-1 . The vibrational screen (203) is equipped with a roller press and/or hydraulic press to squeeze the excess moisture resulting in concentrated hemicellulosic sugars production. Following the moisture squeezing, a series of water washing, and a roller press applies to generate cellulose pulp (211).

[0048] The vibrational screen (203) resulted in two different liquid fractions, namely a vessel containing concentrated hemicellulosic sugars (204) and a vessel containing diluted hemicellulosic sugars (205). The vessel containing the concentrated hemicellulosic sugars (204) is further processed through a centrifugation unit (208) to remove biomass residues with precipitated salt (209), followed by a distillation column (206) to generate the organic solvent-free concentrated hemicellulosic sugar. The centrifugation process (208) may be combined with the filtration process. The generated ethanol through the distillation column at 60 - 120 °C, more specifically at 78 °C (206) is stored in the vessel (212) following the condensation (213) for use either in reactor -1 (1) or reactor-3 (301 ) processing. The lower temperature in the ethanol distillation column is preferred to minimize the carbonization of extracted hemicellulosic sugar. The vessel containing diluted hemicellulosic sugar (205) is utilized in an anaerobic digestor (202) to produce hydrogen gas and/or methane gas (214) wherein the operating temperature of anaerobic digestion varies between 37 °C - 80 °C. The produced gas (through the anaerobic digestor (202)) is water sparged (207) at the temperature range of 0 °C to 60 °C to produce carbonated water (215). The solubility of carbon dioxide ranges between 3.25 g of CO2 per kg of water (at 0 °C) to 0.6 g of CO2 per kg of water (at 60 °C). Furthermore, the carbon dioxide sequestration can be achieved through the catalytic activity of KOH and NaOH in the production of potassium carbonate and sodium carbonate, respectively. The generated potassium carbonate or sodium carbonate would utilize in the process at stages 1 and 3.

[0049] The generated concentrated hemicellulosic sugar (210) is further processed according to the traditional sugar-making process (using heating) to make crystalline sugar. However, the same concentrated hemicellulosic sugar (210) can be utilized in beverages formation (such as cold, alcoholic, and energy drinks). Moreover, the concentrated hemicellulosic sugar (210) and/or the concentrated hemicellulosic sugar with organic solvent (204) followed by centrifugation (208) provides the platform to extract xylose and arabinose sugars (using the chemical extraction process). The application of xylose has been reported in the formation of furfural (for jet fuel production) and consumer consumption goods (with a glycaemic index of 70). The generated hydrogen or methane gas by the anaerobic digestion is utilized for heat energy generation for the operation of several different units including thermal desalinated water (at 100 °C to 160 °C), carbon fiber (at 1 ,000 °C to 1 ,500 °C), graphene (at 2,000 °C to 3,000 °C) and activated carbon (at 800 °C to 1 ,100 °C). The heat energy through hydrogen or methane gas (214) can be significantly enhanced using a complete fraction of hemicellulosic sugars or by introducing a separate stream from agriculture products such as sugarcane juice and or sweet sorghum juice or similar. Thereby, the generated carbonated water (215) is utilized in the production of cold beverages and for soil irrigation purposes. Whereas the generated cellulose pulp (211 ) at the end of the process in the processing stage-2 is utilized in the production of biofuels (such as ethanol, biodiesel, butanol, hydrogen, methane, jet fuel), membranes, paper, and/or desert/draught soil remediation.

[0050] Furthermore, the generated cellulose pulp in the processing stage-2 is processed to produce nano-cellulose and micro-cellulose fibers using the processing stage-3. The transferred biomass content from the processing stage-2 to the processing stage-3 range between 25 - 75 % of the initial biomass at stage-1 . FIG. 5 is a schematic diagram showing stage 3 processing for the synthesis of lignocellulosic biomass-based bioproducts.

[0051] In the processing of stage-3, chemically treated cellulose pulp received from stage-2 of the process in a reactor-3 (301 ) with modified ethyl-hydro-oxides (m- EHOs) solvent having a composition similar to the modified ethyl-hydro-oxides (m- EHOs) solvent of process stage-1 with maintaining the similar operating conditions of biomass to the solvent ratio of 1 : 1 - 1 :50 weight per volume (w/v), and the processing temperature of 65 - 75 °C, and the processing time of 1 - 24 hours.

[0052] Similar to the processing stage-1 , carbon dioxide gas was generated in the reactor-3 (301 ) because of a reaction between the cellulosic pulp and the modified ethyl-hydro-oxides (m-EHOs) solvent and accumulated in the headspace of the reactor- 3 (301 ) to a power generation unit-2 (303) after removing the vapor content of ethanol and water carried by carbon dioxide (CO2) in a packed bed column in which pressure is maintained at 10 - 800 psi, more specifically 400 psi. The decarbonization of generated carbon dioxide would be achieved through water and/or catalytic reagents such as NaOH/KOH. At the end of the reaction in reactor-3 (301), the reactor contents cooled down to -10 °C to 25 °C using an internal coil similar to stage-1 processing, followed by pH neutralization using hydrochloric acid (HCI) or citric acid from a storage tank (305) similar to stage 1 processing. The biomass content from reactor-3 (301) is discharged on the vibration screen (306) resulting in the separation of solid and liquid fractions similar to processing stage-1. The solid and liquid fractions of discharged slurry from reactor-3 (301 ) would be achieved following the vibrational screen (306). Ethanol or organic solvent washing is performed on the solid fraction received from the vibration screen (306) in ethanol or organic solvent washing reactor (307). Biomass from the ethanol or organic solvent washing reactor (307) is discharged to the vibration screen (308) that separates slurry into solid and liquid fractions. The solid fraction from the vibrational screen (308) is further separated into coarse fibers (316) and micro cellulose fibers (315). The nano-cellulose or aerogel fractions (314) are captured from the liquid solvents (311 and 312) separated by the vibration screen (306) and (308) through the centrifuge unit (317) and filtration system (318) equipped with nitrogen/carbon dioxide compressor (319). This process would recycle the organic solvent with and without distillation for the next batch of processing. The distillation of organic solvent arises due to the application of different organic and inorganic solvents in the process. These solvents help to remove accumulated salt in nanocellulose fibers (314). Examples of organic solvents other than ethanol include toluene, diethyl ether, and acetone. The processing stage-3 generates nanocellulose fibers (314), micro-cellulose fibers (315) along with coarse fibers (316). The nanocellulose fibers have application in the formation of aerogel, membrane, high strength bioplastic, medical-grade bandages, 3-D printing, pharmaceutical ingredient, an alternative to steel body manufacturing, paperbased manufacturing, reinforcing material in a polymer composite, food products, hygiene products, emulsion and dispersion, and oil recovery.

[0053] In another embodiment of the present invention, all three different process stages can be performed using a single reactor. [0054] The present disclosure may be better understood concerning the examples provided below.

EXAMPLE-1

[0055] In the presented example, a sugarcane crop quantity of 6,667 kg is utilized. The manual extrusion of sugarcane resulted in the production of 2,000 kg of biomass (with 50 % moisture) and 4,667 kg of juice (with a sucrose content of 467 kg). After juice extraction, the generated biomass is washed in warm water (at 40°C) to remove the residual sugars. The biomass to warm water is utilized in the ratio of 1 :10 (w/v). Both extracted juice and warm water extracted residual sugars utilized in the production of methane and carbon dioxide at the stage-2 processing using an anaerobic digestor at 37 °C.

[0056] The generated biomass of 2,000 kg (contains 50 % moisture) is utilized in the Stage-1 processing. The reactor volume of 10,000 L is utilized for biomass processing at stage-1. The crushed sugarcane bagasse reacted with modified ethyl- hydro-oxides (m-EHOs) solvent in the ratio of 1 :10. The composition of m-EHOs solvent (for 10,000 L) consists of 7,000 L of ethanol + 250 kg of KOH + 250 kg of K2CO3 + 500 kg of H2O2 + 2,000 kg of water. During the solvent formulation, the volume of water is compensated with the moisture content of crushed sugarcane bagasse. After adding the contents (biomass and chemical reagents) to the reactor vessel, nitrogen is sparged through the vessel port to pressurize the reactor to 10 psi. Doing the process, the pressure starts rising after 2 minutes. The process was carried out for 1 hr at a temperature of 65 °C and at a pressure of 400 psi. Both temperature and pressure are generated due to exothermic reactions of the contents. At the end of the process, the pH neutralization is performed using citric acid at the temperature of 10 °C. The pH neutralization leads to the formation of potassium citrate. Following the pH neutralization, the biomass slurry was passed through stacks of sieves that separate liquid and solid fractions. The processing of the solvent extract (including biomass residual and precipitated salt removal followed by ethanol distillation) resulted in the formation of hydrophobic lignin (in the form of disk flakes) and hydrophilic lignin (in the form of liquid). Whereas the solid fraction results in the production of holocellulose and cellulose-xylan-lignin fractions. [0057] At stage-2, the removal of hemicellulosic sugars from holocellulose was performed using 0.5 wt% of sulfuric acid in the ratio of 1 :5 (w/v). The process was carried out under pressurized conditions using carbon dioxide at a pressure of 250 psi and at a temperature of 90 °C for 1 hour. At the end of the process, pH neutralization is performed using calcium hydroxide at the temperature of 25 °C to 30 °C. Initially, the slurry was discharged on the sets of sieves to separate concentrated hemicellulosic sugar from the cellulose pulp. The washing of cellulose pulp resulted in the formation of diluted hemicellulosic sugars. The diluted hemicellulosic sugars, warm water extracted residual sugars (before using at stage 1 ), and extracted sugarcane juice (from the preprocessing of sugarcane) are utilized in the anaerobic digester for the production of methane and carbon dioxide. The generated carbon dioxide dissolved in water is controlled at 50 °C. The solubility of carbon dioxide in water is 0.7 kg/m 3 at 50 °C.

[0058] At stage-3, the cellulose pulp is further treated with m-EHOs solvent using the ratio of 1 :10 (w/v). The composition of m-EHOs was similar to stage-1 using nitrogen in the process. The process was carried out for 1 hour. Similar to the stage-1 process, the stage-3 generated a temperature of 65 °C and a pressure of 400 psi due to the exothermic reaction of the contents. After cooling down the reactor contents at 10 °C, the pH neutralization is performed using citric acid. Following the similar steps in stage-1 , the generated biomass slurry was passed through the stack of sieves followed by filtration to capture the different fractions of nano-cellulose, micro-cellulose, and coarse-fibers. The results are summarized in tables 2, 3, and 4.

Table 2 - For 1000 kg of sugarcane bagasse (dwb) processing.

Sugarcane Crop (kg) 6,665

Sugarcane Juice (kg) 4,666

Sucrose content (kg) 467

Sugarcane Bagasse (with moisture) 2,000

Sugarcane Bagasse (dry weight) 1 ,000

Moisture content 1 ,000

Table 3 - Chemical composition of sugarcane bagasse at different stages of processing.

. . Warm . . .

„ . Juice ... . Stage Stage Stage

Comp ronents . .. Water Extraction . .. 1 2 3 a

Extraction

Polysaccharides 562 562 489 368 360

- Cellulose 413 413 378 359 350 - Xylan 132 132 98 10 10

- Arabinan 16 16 13 0 0

Lignin 207 207 30 15 5

- Acid Insoluble Lignin 196 196 24 15 5

- Acid Soluble Lignin 11 11 5 0 0

Others 179 78 39 0 0

- Ash 68 68 39 0 0

- Extractive 111 10 0 0 0

Solid Content (dwb, kg) 947 846 557 383 365

Table 4 - Different bioproduct syntheses at different stages of sugarcane processing.

. . Warm . . .

„ . Juice ... . Stage Stage Stage

Comp ronents . .. Water Extraction . .. 1 2 3

Extraction

Methane Production (kg) 131 28 47

CO2 Generation (kg) 360 78 130

Net CO 2 Generation (kg) 720 156 310 259 310

Wa'e Requirement for

CO 2 Dissolution (t)

Lignocellulosic Biomass

Product

- Cellulose 383

Nano-cellulose 221

Micro-cellulose 84

Coarse cellulose 60

- Hemicellulosic Sugars 187

- Lignin 154

- Antioxidants 15

- Cellulose-Xylose- 73

Lignin Residues

Note: The net CO2 generation includes the carbon dioxide production due to the combustion of methane and during methane production. EXAMPLE-2

[0059] The present example is the continuation of example-1 wherein the commercial setup of the technology has been evaluated in the production of bioproducts while empowering the desalination process and transforming the desert into farmland. FIG. 7 represents the simplified block diagram of the overall process. Sugarcane crop (without juice extraction) is utilized in the process. The process would require

36,435,311 t of sugarcane on year basis. The processing of sugarcane would generate

10 GWh of electricity (through carbon dioxide application) and 39,660,372 MJ of heat energy (equivalent to 11 GWh, using the diluted hemicellulosic sugars and extracted juice). The produced energy utilized for various unit operations including seawater desalination, ethanol distillation, production of graphene, carbon fiber, and activated carbon, milling and grinding of lignocellulosic biomass, high-pressure filtration, centrifugation, and electricity gridlines are a few examples. Around 10 kWh of energy is required to desalinate 1 liter of seawater using reverse osmosis filtration.

[0060] In the process, the generated carbon dioxide is decarbonized using desalinated water. Around 6.5 Gt of resulting carbon dioxide (through biochemical conversion of the sugarcane) can be decarbonized using desalinated water. Carbonated water along with cellulose pulp would be utilized in the desert transformation. The generated biomass (through desert transformation into agricultural land) would utilize in the process.

[0061] It will be appreciated that the foregoing examples, given for the purpose of illustration, are not to be construed as limiting the scope of this disclosure. Although only a few exemplary embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this disclosure. Accordingly, all such modifications are intended to be included within the scope of this disclosure which is defined in any following claims and all equivalents thereto. Further, it is recognized that many embodiments may be conceived that do not achieve all the advantages of some embodiments, yet the absence of a particular advantage shall not be construed to necessarily mean that such an embodiment is outside the scope of the present disclosure.