CN116710211A

CN116710211A - Pressure valve assembly

Info

Publication number: CN116710211A
Application number: CN202180081115.6A
Authority: CN
Inventors: 莎伦·桑米辛格
Original assignee: Alpata Patent Co ltd
Current assignee: Alpata Patent Co ltd
Priority date: 2020-10-02
Filing date: 2021-10-01
Publication date: 2023-09-05
Also published as: CN116723776A; CN116710375A

Abstract

A valve assembly having a conical valve needle axially movable in a bore of a valve body, wherein a portion of the larger diameter of the valve needle seats at a downstream annular ring when the valve is closed. Even when closed, there is an open area between one end of the valve body to the annular ring and the nozzle for feeding liquid. The inner wall of the valve body comprises at least one opening for the ingress of liquid under pressure after the slurry or liquid is output from the pipe or conduit. The valve assembly is particularly useful for maintaining a semi-continuous or continuous pressurized flow of biomass from an extruder.

Description

Pressure valve assembly

Cross reference

The present application claims the benefit of U.S. provisional patent application No. 63/087,077 filed on month 2 of 2020, U.S. provisional patent application No. 63/146,608 filed on month 2 of 2021, and U.S. provisional patent application No. 63/153,740 filed on month 25 of 2021, each of which is incorporated herein by reference in its entirety.

Background

In many industrial processes, valves are used to control the flow of material. The interior of the pressure relief valve contains a plug that blocks or reduces the output of the material source when the valve is pressurized. When the pressure behind the plug is released, the plug is pushed back by the force from the output pressure. This allows the valve to open until the pressure behind the plug is equal to or greater than the output force. If the valve is coupled to an actuator that operates in response to an output, precise continuous movement is possible, not just a manually operated or spring operated valve.

When moving material under pressure, it is difficult to control the pressure in the container transporting the material. This is difficult for continuous or semi-continuous flow of a slurry of material moving in one direction under critical operating conditions caused by media processing. In order to maintain a constant pressure and speed of the moving material, a valve must be designed to keep the pressure in the pipe or bowl constant while allowing a certain speed. This is especially true for particulate matter (e.g., biomass) moving in a liquid under high pressure, where the valve involves further processing and the flow of material is rapid and gushing. Such harsh operating conditions can cause premature failure and leakage of the valve assembly, resulting in bursting and extreme wear. In addition, slurry particles may become trapped during the valve sealing cycle, resulting in degradation of the valve assembly. Typically, relief valves are not designed to handle such operations.

Disclosure of Invention

In one aspect, provided herein is a valve assembly comprising a valve body having an input end attachable to a pipe having a fluid or slurry input flowing through the valve assembly, a discharge end, and a chamber formed in the valve body connected to the input end and the discharge end; a conical valve needle having a cone with a wide end opposite its conical tip and axially movable in a chamber within the valve body; and a housing attached to the discharge end of the valve body and closing the valve needle when the valve needle is disengaged from the valve body; wherein the diameter of the valve needle at the wide end is at least 4% greater than the inner diameter of the valve body at its discharge end.

In some embodiments, the valve body has an annular ring that is positioned in a recess on an inner surface of the valve body at the discharge end. In some embodiments, the annular ring is replaceable. In some embodiments, the inner surface of the annular ring is aligned with the inner surface of the valve body. In some embodiments, the valve needle is located at the annular ring when the valve needle is closed in the valve body. In some embodiments, the housing includes a removable drain collar therein, the drain collar being located near the drain end of the valve body. In some embodiments, the drain ring has a tapered shape. In some embodiments, the valve body includes a nozzle for inputting the liquid. In some embodiments, the chamber of the valve body forms with the tube a part of the reaction zone for the biomass pretreatment process. In some embodiments, the tube is an extruder. In some embodiments, the extruder is a twin screw extruder (twin screw extruder). In some embodiments, the valve needle is operably linked to the actuator via a shaft. In some embodiments, the actuator maintains pressure on the valve needle. In some embodiments, the actuator maintains a pressure on the valve needle in excess of 1,800 lbf. In some embodiments, the actuator maintains a pressure on the valve needle of between 50,000 and 500,000 lbf. In some embodiments, the valve body has a circular portion at the discharge end, a circular collar having an inner diameter at the input end that is smaller than the circular portion at the discharge end, and an intermediate conical portion therebetween. In some embodiments, an annular space is formed in the chamber between the valve needle and the valve body when the valve needle closes on the valve body. In some embodiments, the housing includes a discharge conduit. In some embodiments, the inner diameter of the housing at the end of the housing adjacent the valve body is at least 7% greater than the inner diameter of the valve body at its discharge end. In some embodiments, the inner diameter of the housing at the end of the housing adjacent the valve body is about 7% greater than the inner diameter of the valve body at its discharge end. In some embodiments, the cone angle of the cone of the conical valve needle is in the range of about 45 degrees to about 75 degrees. In some embodiments, the taper of the conical valve needle is at a taper angle of about 45 degrees.

In another aspect, provided herein is a valve assembly comprising: a valve body comprising a large circular portion, an intermediate conical portion, and a small circular collar containing one or more nozzles for liquid input, the valve body having a chamber formed therein connecting an input end and a discharge end of the valve body, wherein the small circular collar has an inner diameter smaller than the inner diameter of the large circular portion; a valve needle axially movable within the chamber of the valve body; and a housing attached to the discharge end of the valve body and closing the valve needle when the valve needle is disengaged from the valve body.

In one aspect, provided herein is a system for processing biomass through an extruder, comprising: an extruder comprising one or more screws, wherein an internal plug of biomass is formed as a result of the action of the screws, thereby forming one end of a pressurized reaction zone; an apparatus for supplying steam and chemicals to a reaction zone; and a valve assembly at the output end of the extruder, the valve assembly forming the downstream end of the reaction zone and adding liquid to the reaction zone; wherein the valve assembly is capable of rapidly discharging pressurized treated biomass into a non-pressurized discharge zone.

In one aspect, there is provided a valve assembly comprising a housing, a valve body, and a valve needle attached to a tube with an output flowing through the valve assembly, wherein the valve comprises: a conical valve needle axially movable in the annular space of the valve body and having a conical valve needle tip at one end; and wherein the downstream inner diameter of the valve body is at least 4% greater than the inner wall of the housing. In one embodiment, the valve assembly has an annular ring that is part of the valve body and is replaceable.

In another embodiment, the valve assembly housing contains a removable drain collar. In another aspect, the valve body includes a nozzle for inputting a liquid. In a further embodiment, the valve needle is seated at the drain ring when closed in the valve body. In one aspect, the valve assembly forms a portion of the reaction zone with the tube. In another aspect, the valve needle is attached to the actuator. In one embodiment, the actuator maintains a pressure on the valve needle that is maintained above 1,800lbf on the valve needle. In another embodiment, the actuator maintains a pressure on the valve needle of between 50,000 and 500,000 lbf.

In one aspect, the tube attached to the valve assembly is an extruder. In a further aspect, the extruder is a twin screw extruder.

In some embodiments, a conical valve needle for engagement with a valve body is provided, the conical valve needle comprising a valve needle that extends beyond the valve body into a discharge region when the valve is closed. In one aspect, the annular ring is part of the valve body. In another aspect, the valve needle is positioned downstream of the annular ring. In a further aspect, the annular ring is replaceable. In one embodiment, the housing is attached downstream to a valve body containing the valve needle and the housing contains a removable drain ring. In another embodiment, the valve body comprises a nozzle for feeding liquid. In another embodiment, the valve needle is seated at the drain ring when closed in the valve body. In a further aspect, the valve body and the valve needle form together with the tube a part of the reaction zone. In another aspect, the valve needle is attached to the actuator. In a further aspect, the actuator maintains pressure on the valve needle. In a further aspect, the actuator maintains a pressure on the valve needle in excess of 1,800 lbf. In one embodiment, the actuator maintains a pressure on the valve needle of between 50,000 and 500,000 lbf.

In one embodiment, the valve needle is in a valve body attached to the extruder. In a further embodiment, the extruder is a twin screw extruder.

In one embodiment, a valve assembly is provided that becomes part of the reaction zone when attached to a tube or pipe. In another embodiment, the pipe or tube is an extruder. In a further embodiment, the extruder is a twin screw extruder. In another embodiment, at least a portion of the contents of the extruder are under pressure.

In one embodiment, a valve assembly is provided wherein a pressurized zone of tubing or piping or an extruder extends into the valve assembly. In another embodiment, the valve assembly has an increased inner diameter between the end of the discharge material of the valve body and the diameter of the discharge housing.

In one aspect, a valve assembly for pressurized passage of a fluid, slurry or other material is provided, the valve assembly comprising a housing and a valve body, the valve body comprising: a large circular portion, a middle conical portion, a smaller circular collar portion containing one or more nozzles for liquid input; and a valve needle. In another aspect, the housing includes a removable drain collar. In a further aspect, the drain collar is tapered. In another aspect, the valve body includes an annular ring. In another aspect, the annular ring is removable. In another embodiment, there is a space between the valve body and the valve needle when the valve needle is in place. In a further embodiment, a nozzle for liquid input delivers water into the space between the valve body and the valve needle. In a further embodiment, a nozzle for liquid input delivers liquid other than water into the space between the valve body and the valve needle. In a further embodiment, the liquid is selected from: an acid, a base, an alcohol, a ketone, an aldehyde, a solvent, or a combination thereof.

In another embodiment, a system for processing biomass through an extruder is provided, the system comprising: an extruder comprising one or more screws, wherein an internal plug of biomass is formed as a result of the action of the screws, thereby forming one end of a pressurized reaction zone; a method of supplying steam and chemicals to a reaction zone; a valve assembly located at the output end of the extruder, the valve assembly forming the downstream end of the reaction zone and adding liquid to the reaction zone and being capable of rapidly discharging pressurized treated biomass to a non-pressurized discharge zone. In another aspect, the biomass is selected from: silage, agricultural residues, corn stover, bagasse, sorghum, nuts, nut hulls, coconut shells, distillers dried grains solubles (Distillers Dried Solubles), distillers dried grains (Distillers Dried Grains), concentrated distillers solubles (Condensed Distillers Solubles), distillers wet grains (Distillers Wet Grains), distillers dried grains with their solubles (Distillers Dried Grains with Solubles), wood material, sawdust, wood chips, wood waste, factory waste, municipal waste, waste paper, recycled toilet paper, yard clippings and energy crops such as poplar, willow, switchgrass, alfalfa and grassy blue-stem grass (prairie blue-stem), nonwoody plant matter, cellulosic material, lignocellulosic material, hemicellulose material, carbohydrates, corn, sugarcane, grasses, switchgrass, high biomass sorghum, bamboo, corn cobs, pericarps and fruit pits. In a further aspect, the biomass is treated in the reaction zone for less than 60, 55, 50, 45, 40, 35, 30, 25, 20, 19, 18, 17, 16, 15, 14, 13, 12, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 second. In one embodiment, the temperature in the reaction zone is raised to 50-500 ℃, 75-400 ℃, 100-350 ℃, 150-300 ℃, 200-250 ℃, 150-300 ℃, 50-1000PSI, 100-750PSI, 200-600PSI, 300-500PSI, or 350-450PSI. In another embodiment, the chemical is an acid. In a further embodiment, the acid is sulfuric acid.

In one aspect, there is provided a system wherein the valve assembly comprises: a housing and a valve body, the valve body comprising: a large circular portion; a middle conical portion; a small circular collar containing one or more nozzles for liquid input; and a valve needle. In another aspect, the system has a valve assembly wherein the housing contains a removable drain collar. In a further aspect, the discharge ring of the valve assembly is tapered. In another embodiment, the valve body of the valve assembly comprises an annular ring. In a further embodiment, the annular ring is removable. In another aspect, the valve body comprises a space between the valve body and the valve needle when the valve needle is in place. In another embodiment, the valve assembly includes a nozzle for liquid input and delivery of water into the space between the valve body and the valve needle. In a further embodiment, a nozzle for liquid input delivers liquid other than water into the space between the valve body and the valve needle. In further embodiments, the liquid comprises an acid, a base, an alcohol, a ketone, an aldehyde, a solvent, or a combination thereof.

In one embodiment, there is provided a method for treating slurry or liquid in a pipe or bowl, comprising: a pipe or bowl with a plug forms one end of the reaction zone, moves liquid or slurry through the pipe or bowl, uses a valve assembly attached to the output end of the pipe or bowl to form the downstream end of the reaction zone while maintaining the pressure in the reaction zone, adds liquid to the upstream end of the valve assembly as it enters the valve assembly, and discharges the treated liquid or slurry to a non-pressurized zone using the valve assembly.

In one embodiment, a valve assembly is provided that is attached to a conduit or bowl that inputs liquid into a valve body after the liquid or slurry is output from the conduit or bowl but before the liquid or slurry reaches a valve needle.

In one embodiment, a valve assembly is provided wherein the valve body has a removable annular ring adjacent to the removable drain ring in the drain housing. In another embodiment, the discharge ring of the valve assembly is tapered.

Incorporation by reference

All publications, patents, and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference.

Brief description of the drawings

The novel features of the disclosure are set forth with particularity in the appended claims. A better understanding of the features and advantages of the present disclosure will be obtained by reference to the following detailed description that sets forth illustrative embodiments, in which the principles of the disclosure are utilized, and the accompanying drawings of which:

FIG. 1 is a schematic diagram depicting a modified pressure valve assembly.

Fig. 2 is a schematic diagram showing a longitudinal view of the valve and its housing.

Fig. 3A and 3B are schematic diagrams depicting longitudinal views of the valve assembly from the top (fig. 3A) and side (fig. 3B).

Fig. 4 is a longitudinal view of the valve assembly from the top plan view.

Fig. 5 is a larger view of portion a seen in fig. 4.

Fig. 6 is a cross-sectional view of the valve body without the valve needle.

Fig. 7A-7D depict cross sections of the valve at the annulus: a closed position (fig. 7A); 0.5mm stroke (fig. 7B); 1.0mm stroke (fig. 7C); and a 1.5mm stroke (fig. 7D).

Detailed Description

As used in the specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a purified monomer" includes a mixture of two or more purified monomers. The term "comprising" as used herein is synonymous with "containing," "comprising," or "characterized by," and is inclusive or open-ended and does not exclude additional, unrecited elements or method steps.

"about" means that the reference number indicates plus or minus the I0% indicated by the reference number. For example, the term "about 4" will include a range of 3.6 to 4.4. All numbers expressing quantities of ingredients, reaction conditions, and so forth used in the specification are to be understood as being modified in all instances by the term "about". Accordingly, unless indicated to the contrary, the numerical parameters set forth herein are approximations that may vary depending upon the desired properties sought to be obtained. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of any claim in any application claiming priority to the present application, each numerical parameter should be construed in light of the number of significant digits and ordinary rounding approaches.

The phrase "for example," "such as," "including," and the like, as used herein, is to be understood as "but not limited to" immediately following, unless expressly stated otherwise. Thus, "for example, ethanol production" refers to "for example, but not limited to, ethanol production.

In this specification and the claims that follow, reference will be made to a number of terms, which shall be defined to have the following meanings.

Definition of the definition

"optional" or "optionally" means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not. For example, the phrase "the medium may optionally contain glucose" means that the medium may or may not contain glucose as an ingredient, and the description includes both a medium containing glucose and a medium not containing glucose.

Unless otherwise defined, technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art.

The term "biomass" as used herein has a common meaning known to those skilled in the art and may include one or more carbonaceous biological materials that can be converted into biofuels, chemicals or other products. Biomass as used herein is synonymous with the term "feedstock" and includes silage, agricultural residues (cornstalks, grasses, straw, grain hulls, bagasse, etc.), nuts, nut hulls, coconut hulls, animal waste (cow, poultry, and pig manure), distillers dried solubles, distillers dried grains, distillers dried solubles, wet distillers dried grains, distillers dried grains and solubles thereof, wood materials (wood or bark, sawdust, wood chips, wood waste, and plant waste), municipal waste (waste paper, recycled toilet paper, yard clippings, etc.), and energy crops (poplar, willow, switchgrass, alfalfa, grassland bluegrass, algae including macroalgae such as members of the phylum green, algin, rhodophyta, etc.). One exemplary source of biomass is plant matter. The plant matter may be, for example, woody plant matter, nonwoody plant matter, cellulosic material, lignocellulosic material, hemicellulose material, sugarcane, grasses, switchgrass, sorghum, bamboo, algae, and materials derived therefrom. The plant may be in its natural state or genetically modified, for example to increase the cellulosic or hemicellulose portion of the cell wall, or to produce additional exogenous or endogenous enzymes to increase the separation of cell wall components. Plant matter may be further described by reference to the presence of chemicals such as proteins, polysaccharides and oils. Polysaccharides include polymers of various monosaccharides and derivatives of monosaccharides including glucose, fructose, lactose, galacturonic acid, rhamnose, and the like. Plant matter also includes agricultural waste byproducts or side streams such as pomace, corn steep liquor, corn cobs, corn fiber, corn steep liquor solids, distillers grains, pericarps, kernels, fermentation waste, straw, wood, sewage, trash, and food residues. The peel may be citrus, including but not limited to orange peel, grapefruit peel, orange peel, tangerine peel, lime peel, and lemon peel. These materials may be from farms, forestry, industrial sources, households, and the like. Another non-limiting example of biomass is animal matter including, for example, milk, bone, meat, fat, animal processing waste, and animal manure. "feedstock" is often used to refer to biomass for processes such as those described herein.

As used herein, "pretreatment" or "pretreated" refers to any mechanical, chemical, thermal, biochemical process, or combination of these processes, whether in a combined step or sequentially, that effects destruction or expansion of biomass to render the biomass more susceptible to attack by enzymes and/or microorganisms, and may include enzymatic hydrolysis of the released carbohydrate polymer or oligomer to monomer. In one embodiment, the pretreatment includes removing or destroying lignin, such as by treatment with an acid or base, to make cellulose and hemicellulose polymers in the plant biomass more available to cellulolytic enzymes and/or microorganisms. In one embodiment, the pretreatment includes the disruption or swelling of the cellulosic and/or hemicellulose material. In another embodiment, it may refer to starch release and/or enzymatic hydrolysis to glucose. Steam explosion and ammonia fiber expansion (or explosion) (AFEX) are well known thermal/chemical techniques. Hydrolysis, including methods utilizing acids, bases, and/or enzymes, may be used. Other thermal, chemical, biochemical, enzymatic techniques may also be used.

As used herein, "steam explosion" is a physicochemical process that uses high pressure steam to break bonds between polymer components and reduced pressure to break lignocellulosic structures. In this process, the lignocellulosic pulp is treated with high pressure steam for a period of time and then rapidly depressurized to atmospheric pressure.

As described herein, a "liquid" composition may contain solids, and a "solid" composition may contain liquids. Liquid compositions refer to compositions in which the material is predominantly liquid, while solid compositions are compositions in which the material is predominantly solid. "slurry" refers to a solid that is dissolved or not dissolved in a liquid.

Description of the invention

The following description and examples detail some exemplary embodiments of the present disclosure. Those skilled in the art will recognize that there are numerous variations and modifications of this disclosure that are encompassed by the scope of the invention. Thus, the description of specific example embodiments should not be considered as limiting the scope of the disclosure.

In one aspect, the structure and design of the valve assembly described herein addresses the degradation stresses encountered in the high pressure flow of treated liquid or slurry material through a pipe or conduit. The valve assembly is designed to incorporate partial treatment of such liquids or slurries as the flow enters the valve assembly upstream from the attached pipe or tubing, passes through the valve assembly and flows downstream into the discharge area.

In one embodiment, a valve assembly for a fluid end is provided. In another aspect, the valve assemblies disclosed herein may be used to continuously or semi-continuously process a liquid, slurry, viscous liquid, or any liquefied substance under pressure. In terms of processing, it should be understood that the material may be modified by heat, pressure, and/or addition of chemicals alone, or mixed under pressure, heated, by addition of chemical components (such as acids, bases, bleach components, dyes, etc.), by combining two or more components (either simultaneously or by subsequent addition). Examples of such components include plastics, plant materials, foods, polymers, polyurethanes, and the like.

In one aspect, the slurry of material may include pretreated biomass or partially hydrolyzed biomass. This arrangement can be used to obtain a constant velocity and pressure as the material moves through a passageway such as a pipe or tube. Water or steam may be added through the plug and valve assembly at the output to increase and maintain a constant pressure in the passageway. The portion between the plug and the pass-through valve assembly is the reaction zone where the material is modified. This region includes material flash vaporization through the valve needle end.

In one embodiment, the material may be processed using an extruder and valve assembly. The extruder moves liquid, slurry, solid and viscous materials through the barrel by means of screw elements. Depending on the shape of the element, the material may be slowed, mixed or pushed through the bowl. The extruder may be a single screw extruder, a twin screw extruder or a triple screw extruder. For biomass materials, a twin screw extruder is preferably used. An extruder with a specially constructed screw designed to allow the addition of very large amounts of steam to increase pressure makes it possible to pretreat biomass at high speeds. Rapid extruder pretreatment systems, such as those described in US2016/0273009A1 or WO2018/151833 (A1), each incorporated herein by reference in its entirety, provide a unique pathway for decomposing biomass and releasing cellulose and lignin from other biomass components. The combination of mechanical fibrillation, dilute acid hydrolysis, and steam explosion was all completed within 20 seconds, yielding a slurry of very clean soluble sugars, microcrystalline cellulose, and lignin. Short and intense treatment durations produce unique cellulose, hemicellulose and lignin products that have been converted to a highly active state without overcooking or sulfonation occurring in most other processes.

Restriction and release devices for liquids and materials moved through pipes or buckets have been proposed in the past. Several of these devices involve an insert valve in the extruder barrel itself. One such device described in US2007/0237022A1 is a medium barrel adjustable valve assembly. Other are end valves, such as are found in US2009/0053800A1, WO2010/056940A2 or US10,344,757B1. None of these are part of the processing system and do not allow for high speed continuous processing.

Extrusion may be continuous or semi-continuous and processing may be accomplished with hot or cold materials. Common extrusion materials include metals, polymers, ceramics, concrete, molded clay, and food products; however, the biomass may also be processed in an extruder. The extruder may have one or more shafts. Twin screw extruders are machines with two identical screws that co-penetrate and self-clean, mounted on a shaft and rotate in the same direction in a fixed closed housing called a "barrel". Twin screw extruders can be operated continuously at high temperatures and pressures for very short residence times.

In one embodiment, the acid, heat and explosion pretreatment process for extracting biomass components is a rapid treatment process that includes steam explosion. When the reduced size particles of biomass are treated to pressurized acid hydrolysis and high temperature by steam, the treatment is performed and then steam explosion is performed. Since the entire process is uniform throughout, it takes only a few seconds, which requires an efficient and fast moving valve system to maintain continuous process pressure.

In processing biomass, steam is injected into the vat to increase temperature and pressure. In one embodiment, the screw element is also used to slow down the flow of material to form a plug that is used to seal the material in the bowl after input and further build up pressure within the bowl. See, for example, U.S. application Ser. No. 15/932,340, which is incorporated herein by reference.

The example of a valve assembly is not meant to be limiting to extruders but is provided as an illustration showing its functional value. In this system, one functional embodiment of the pressure valve assembly is to help initiate and maintain a constant pressure in the extruder and through the valve body. This is the reaction zone through which most of the processing of biomass occurs. By using a specific screw, the plug in the extruder helps to slow down and steam is used to build up pressure in the reaction zone. The actuator sets the pressure on the valve needle to maintain the desired pressure in the extruder and within the valve body. Accurate continuous movement can be achieved if the valve is coupled to an actuator that operates in response to internal pressure at the end of the pipe or bowl, rather than a manual or spring-operated valve.

Preferably, the actuator is a hydraulic or pneumatic actuator, such as an actuator manufactured by Kyntronics (Solon, OH 44139, U.S. A.). The actuator keeps the valve needle moving in and out endlessly and rapidly with very little movement along the longitudinal axis. The actual force the needle valve must hold for the biomass in the reaction zone of the body of the extruder barrel can range from 1,800lbf to 82,000lbf, even higher (over 500,000 lbf). A constant force is achieved by controlling the annular space through which the treated biomass material or liquid flows. The actuator system transmits the electrical signal directly to the actuation mechanism. Which is arranged to operate at a specific pressure and react to the forces exerted by the material flowing out of the pipe or extruder.

In one aspect, when the liquid or slurry flashes off the annular ring (interface between annular ring and drain ring—see below), a shorter reaction zone length is required in the tube or pipe as the reaction zone includes the area between the plug (through the valve body) and the steam explosion area. In the example of processing biomass in an extruder, this shortens the length of the extruder reaction zone and reduces the metallurgical costs required for extruder processing.

In one example of a pressure valve assembly, as shown in fig. 1, the valve has a valve body 10 with a conical valve needle 11 and a housing 12 with a discharge tube 13. The valve body and the valve needle may be made of any material that is capable of withstanding the abrasion and tearing of liquids or slurries of different chemicals from the upstream inlet 30 through the valve body and the housing to the discharge pipe 13, but which is made of an inert metal or a metal with an inert coating. The valve needle is attached to the shaft 14. As shown in the longitudinal section of fig. 2, the valve body 10 has a cylindrical portion 15, a central conical portion 16 and another generally cylindrical collar 17 of smaller diameter than the first portion 15. The valve body comprises an annular (wear) ring 19 at its widest part. Which is located in a recess in the body portion 15. The inner surface of the annular ring 19 is aligned with the rest of the valve body 10 and serves as a replaceable wear member. An annular ring 19 is located in the reaction zone of the valve and extends to a minimum annular space 21 (see fig. 7A) after which flashing to the atmosphere (steam explosion) takes place.

The conical discharge ring 20 is located outside the valve body 10 in the housing 12 and is not part of the reaction zone. Which is a device that ensures that liquid or slurry is directed to the discharge pipe 13 and into the flash tank (not shown). It is also a wear part and is therefore easy to replace. The taper on the drain collar 20 (see fig. 3A and 3B) avoids a right angle connection with the valve body that could result in material build up and interfere with the movement of material from the needle tip to the outlet.

Fig. 3A and 3B are longitudinal cross-sections of a top view and a side view, respectively, of a valve and its housing. Material flows under pressure upstream from a pipe, bowl or conduit (fluid force), through the valve body inlet portion 17, and discharges downstream into the housing 12. The force from the actuator is applied to the valve needle via the shaft 14.

Between the valve body 10 and the valve needle 11 there is an annular space 21, the diameter of the cavity 22 of the housing 12 also being 7% greater than the inner diameter of the valve body 10, wherein the cavity 22 of the housing 12 receives the discharged liquid or slurry (material) and the valve body 10 receives the flashed material.

In operation, a pressure differential acting on the valve needle 11 displaces the valve needle 11 along its longitudinal axis 75. The pressure behind the valve shaft 14 seats the valve in the valve body portion 15 just before the widest end of the needle 11.

The widest part of the needle valve 11 is slightly larger than the widest part of the valve body 10, so that when closed the needle valve 11 is seated at an annular ring 19 in the valve body part 15. In one embodiment, the diameter of the wide end of the needle is at least 4% greater than the diameter of the valve body at the discharge end. In one embodiment, the diameter of the wide end of the needle is about 4% greater than the diameter of the valve body at the discharge end. In one embodiment, the diameter of the wide end of the needle is 416mm and the diameter of the discharge end of the valve body is 400mm. It may be larger or smaller. In one embodiment, the taper is at a taper angle of 45 degrees from its widest diameter to the needle tip 18. In other embodiments, the cone angle may be in the range of 45 degrees to 75 degrees. The measurement will be based on the material, raw material, process requirements, space requirements and force required to move the needle valve.

Collar 17 is a device that connects the pressure relief valve to an extruder or other tube. When the valve is fully in place and the extruder is attached, the needle tip 18 extends just to the beginning of the collar at the end of the conical portion 16 and there is a space between the tip of the needle and the discharge end of the tube or extruder 35 and the end of any screw 38. During pretreatment of the biomass in the extruder, water is injected through injection nozzles 36 in collar 17 after the materials leave the extruder but before they reach valve needle tip 18 (see fig. 4 and 5). Water is used to dilute the material, improving rheology by steam explosion, thereby reducing the torque on the extruder pushed through the valve. During processing, materials, particularly slurries, generally do not flow, but are subject to some fluctuation during processing through pipes or barrels. The flow at the outlet is turbulent and when it mixes with water it smoothly enters a laminar flow travelling downstream in the space of the valve 21. Any liquid may be added prior to output from the pipe to facilitate material flow through the valve system and/or to further process the material. In one embodiment, liquids such as water, acids, bases, alcohols, solvents, aldehydes, ketones, and the like may be used for this purpose.

In the closed position of the valve, the needle tip 18 rests in the interior space of the valve body 10, approximately at the interface of the intermediate conical portion 16 and the smaller cylindrical collar 17. See fig. 5. The needle tip 18 is located about 3-6mm downstream of the liquid injection.

Fig. 6 is a cross-sectional view of the valve body 10 without the valve needle 18 toward the discharge end of the extruder with twin screw 38. After the material leaves the extruder, an input nozzle 36 injects a liquid into the collar 17.

Fig. 7A is a cross-sectional illustration of the seal between the conical needle 11 and the conical valve body 15 at the annular ring 19. At this point, the pressure behind the valve shaft 14 is equal to or greater than the pressure of the fluid and/or material exiting the conduit and acts to prevent flow. Fig. 7B depicts the movement of the valve needle 11 when the pressure in the conduit increases and the valve needle 11 moves about 0.5mm towards the housing. The valve needle 11 is separated from its seated position in the annular ring 19 so that fluid and/or material can flow around the valve needle 11 through the passageway 21 to the discharge region 22 (shown in fig. 3). The increase in pressure from the conduit causes the valve needle 11 to move further towards the discharge area widening the gap between the needle and the annular ring 19 and allowing greater fluid and/or material flow; namely, 1.0mm (FIG. 7C) and 1.5mm (FIG. 7D) were moved.

In operation, the valve needle 18 is moved in and out several times per second to maintain the desired set pressure to move between fully closed and allowing a maximum annular space of 2 mm. A hydraulic actuator attached to the valve needle keeps the valve needle moving in and out along the longitudinal axis endlessly, very quickly and with very little movement.

In some cases, continuous processing of the material, the liquid, or both at a constant pressure is required. For example, pretreatment of biomass is uneconomical in mass production. Which is time consuming and wasteful of material. The problem is how to maintain a constant accurate pressure during the process while moving the material through the pipe or bowl and while discharging the pressurized material to atmospheric pressure. Furthermore, this is difficult to do when working with slurries, as the nature of the heterogeneous mixture can cause pulsations.

The valves described herein may be used at high speeds. For example, continuous biomass processing measured at the annular ring 19 is 185-190m/s at 0.5mm travel. The potential range is about 90m/s to 250m/s. In other embodiments, speeds of 95m/s, 100m/s, 110m/s, 120m/s, 130m/s, 140m/s, 150m/s, 160m/s, 170m/s, 180m/s, 190m/s, 200m/s, 210m/s, 220m/s, 230m/s, 240m/s, and higher are possible.

In some embodiments, the liquid or slurry is treated in the reaction zone for less than 60, 55, 50, 45, 40, 35, 30, 25, 20, 19, 18, 17, 16, 15, 14, 13, 12, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 second. In some embodiments, the biomass is treated in the reaction zone for about 5 to 15 seconds; in larger systems, the biomass is treated for 30 seconds or less, or for 60 seconds or less.

In another embodiment, the liquid or slurry may be treated at an elevated pressure. In one embodiment, the biomass is pretreated at a pressure in the range of about 1psi to about 30 psi. In another embodiment, the biomass is pretreated at a pressure of about 50psi, 100psi, 150psi, 200psi, 250psi, 300psi, 350psi, 400psi, 450psi, 500psi, 550psi, 600psi, 650psi, 700psi, 750psi, 800psi, or more, up to 900 psi. In some embodiments, the biomass may be treated at an elevated pressure by injecting steam into a vessel containing the biomass. In one embodiment, the biomass may be treated under vacuum conditions prior to or after alkali or acid treatment or any other treatment method provided herein.

Exemplary embodiments

Embodiment 1. A valve assembly comprising a housing, a valve body, and a valve needle attached to a tube with an output flowing through the valve assembly, wherein the valve comprises:

(a) A conical valve needle axially movable in the annular space of the valve body and having a conical valve needle tip at one end; and

(b) Wherein the downstream inner diameter of the valve body is at least 4% larger than the inner wall of the housing.

Embodiment 2. The valve assembly of embodiment 1, wherein the annular ring is part of the valve body.

Embodiment 3. The valve assembly of embodiment 2, wherein the annular ring is replaceable. Embodiment 4. The valve assembly of embodiment 1, wherein the housing comprises a removable drain collar.

Embodiment 5. The valve assembly of embodiment 1, wherein the valve body comprises a nozzle for inputting a liquid.

Embodiment 6. The valve assembly of embodiment 2, wherein the valve needle is seated at the drain ring when closed in the valve body.

Embodiment 7. The valve assembly of embodiment 1, together with a tube, forms part of a reaction zone.

Embodiment 8. The valve assembly of embodiment 1, wherein the valve needle is attached to an actuator.

Embodiment 9. The valve assembly of embodiment 8, wherein the actuator maintains pressure on the valve needle.

Embodiment 10. The valve assembly of embodiment 8, wherein the actuator maintains a pressure on the valve needle in excess of 1,800 lbf.

Embodiment 11. The valve assembly of embodiment 9, wherein the actuator maintains a pressure on the valve needle of between 50,000 and 500,000 lbf.

Embodiment 12. The valve assembly of embodiment 8, wherein the tube is an extruder.

Embodiment 13. The valve assembly of embodiment 13, wherein the extruder is a twin screw extruder.

Embodiment 14. A conical valve needle for engagement with a valve body, the conical valve needle comprising a valve needle extending beyond the valve body into a discharge area when the valve is closed.

Embodiment 15. The valve needle of embodiment 14, wherein the annular ring is part of the valve body.

Embodiment 16. The valve needle of embodiment 15, wherein the valve needle is located downstream of the annular ring.

Embodiment 17. The valve needle of embodiment 15, wherein the annular ring is replaceable. Embodiment 18. The valve needle of embodiment 14, wherein the housing is attached downstream to the valve body and contains a removable drain ring.

Embodiment 19. The valve needle of embodiment 14, wherein the valve body comprises a nozzle for inputting a liquid.

Embodiment 20. The valve needle of embodiment 14, wherein the valve needle seats at the drain ring when closed in the valve body.

Embodiment 21. The valve needle of embodiment 14, which together with the tube forms part of the reaction zone.

Embodiment 22. The valve needle of embodiment 14, wherein the valve needle is attached to an actuator. Embodiment 23. The valve needle of embodiment 22, wherein the actuator maintains pressure on the valve needle.

Embodiment 24. The valve needle of embodiment 23, wherein the actuator maintains a pressure on the valve needle in excess of 1,800 lbf.

Embodiment 25. The valve needle of embodiment 24, wherein the pressure on the valve needle is between 50,000 and 500,000 lbf.

Embodiment 26. The valve needle of embodiment 14, wherein the valve body is attached to an extruder. Embodiment 27. The valve pin of embodiment 1, wherein the extruder is a twin screw extruder.

Embodiment 28. A valve assembly that together with a tube or pipe becomes part of the reaction zone.

Embodiment 29. The valve assembly of embodiment 28, wherein the conduit or tube is an extruder.

Embodiment 30. The valve assembly of embodiment 29, wherein the extruder is a twin screw extruder.

Embodiment 31. The valve assembly of embodiment 30, wherein at least a portion of the contents of the extruder are under pressure.

Embodiment 32. The valve assembly of embodiment 30, wherein the pressurized region extends into the valve assembly.

Embodiment 33. A valve assembly having an increased inner diameter between an end of a discharge material of a valve body and a diameter of a discharge housing.

Embodiment 34. A valve assembly for use in pressurized passage of a fluid, slurry or other material, comprising:

(a) A housing;

(b) A valve body, the valve body comprising:

i. a large circular portion;

an intermediate conical portion;

a small circular collar containing one or more nozzles for liquid input; and

(c) A valve needle.

Embodiment 35. The valve assembly of embodiment 34, wherein the housing comprises a removable drain collar.

Embodiment 36. The valve assembly of embodiment 35, wherein the drain ring is tapered.

Embodiment 37. The valve assembly of embodiment 34, wherein the valve body comprises an annular ring. Embodiment 38. The valve assembly of embodiment 37, wherein the annular ring is removable.

Embodiment 39 the valve assembly of embodiment 34 wherein there is a space between the valve body and the valve needle when the valve needle is in place.

Embodiment 40. The valve assembly of embodiment 34, wherein the nozzle for liquid input delivers water into a space between the valve body and the valve needle.

Embodiment 41. The valve assembly of embodiment 34, wherein the nozzle for liquid input delivers liquid other than water into a space between the valve body and the valve needle.

Embodiment 42. The valve assembly of embodiment 41, wherein the liquid is selected from the group consisting of: an acid, a base, an alcohol, a ketone, an aldehyde, a solvent, or a combination thereof.

Embodiment 43. A system for processing biomass through an extruder, comprising:

(a) An extruder comprising one or more screws, wherein an inner plug of biomass is formed as a result of the action of the screws, thereby forming one end of a pressurized reaction zone;

(b) Means for supplying steam and chemicals to the reaction zone;

(c) A valve assembly at the output end of the extruder, the valve assembly forming the downstream end of the reaction zone and adding liquid to the reaction zone; and is also provided with

(d) The valve assembly is capable of rapidly discharging pressurized treated biomass to a non-pressurized discharge zone.

Embodiment 44 the system of embodiment 43, wherein the biomass is selected from the group consisting of: silage, agricultural residues, corn stover, bagasse, sorghum, nuts, nut hulls, coconut shells, distillers dried grains solubles, distillers dried grains with distillers dried solubles, wood material, sawdust, wood chips, wood waste, mill waste, municipal waste, waste paper, recycled toilet paper, yard clippings, and energy crops such as poplar, willow, switchgrass, alfalfa and grassland bluegrass, non-woody plant matter, cellulosic material, lignocellulosic material, hemicellulose material, carbohydrates, corn, sugarcane, grasses, switchgrass, high biomass sorghum, bamboo, corn cobs, and pericarps and kernels.

Embodiment 45 the system of embodiment 43, wherein the biomass is treated in the reaction zone for less than 60, 55, 50, 45, 40, 35, 30, 25, 20, 19, 18, 17, 16, 15, 14, 13, 12, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 second.

Embodiment 46. The system of embodiment 43, wherein the temperature in the reaction zone is increased to 50-500 ℃, 75-400 ℃, 100-350 ℃, 150-300 ℃, 200-250 ℃, 150-300 ℃, 50-1000PSI, 100-750PSI, 200-600PSI, 300-500PSI, or 350-450PSI.

Embodiment 47. The system of embodiment 43, wherein the chemical is an acid.

Embodiment 48 the system of embodiment 47, wherein the acid is sulfuric acid.

Embodiment 49 the system of embodiment 43, wherein the valve assembly comprises:

(a) A housing;

(b) A valve body, the valve body comprising:

i. a large circular portion;

an intermediate conical portion;

a small circular collar containing one or more nozzles for liquid input; and

(c) A valve needle.

Embodiment 50. The valve assembly of embodiment 49, wherein the housing comprises a removable drain collar.

Embodiment 51. The valve assembly of embodiment 50, wherein the drain ring is tapered.

Embodiment 52. The valve assembly of embodiment 49, wherein the valve body comprises an annular ring.

Embodiment 53. The valve assembly of embodiment 52, wherein the annular ring is removable.

Embodiment 54 the valve assembly of embodiment 49 wherein there is a space between the valve body and the valve needle when the valve needle is in place.

Embodiment 55. The valve assembly of embodiment 49, wherein the nozzle for liquid input delivers water into a space between the valve body and the valve needle.

Embodiment 56. The valve assembly of embodiment 55, wherein the nozzle for liquid input delivers liquid other than water into a space between the valve body and the valve needle.

Embodiment 57. The valve assembly of embodiment 56, wherein the liquid is selected from the group consisting of: an acid, a base, an alcohol, a ketone, an aldehyde, a solvent, or a combination thereof.

Embodiment 58 a method for treating slurry or liquid in a pipe or bowl, comprising: a. a pipe or barrel with a plug forms one end of the reaction zone;

b. moving a liquid or slurry through a conduit or bowl;

c. a valve assembly attached to the output end of the pipe or bowl is used to form the downstream end of the reaction zone while maintaining the pressure in the reaction zone.

d. Adding liquid to the upstream end of the valve assembly as the liquid or slurry enters the valve assembly; and is also provided with

e. The treated liquid or slurry is discharged into the non-pressurized region using a valve assembly.

Embodiment 59. A valve assembly attached to a conduit or bowl that inputs liquid into a valve body after the liquid or slurry is output from the conduit or bowl but before the liquid or slurry reaches a valve needle.

Embodiment 60. A valve assembly wherein the valve body has a removable annular ring adjacent to the removable drain ring in the drain housing.

Embodiment 61. The valve assembly of embodiment 60, wherein the drain ring is tapered.

[1] A valve assembly, the valve assembly comprising:

a valve body having an input end, a discharge end, and a chamber formed in the valve body connected to the input end and the discharge end, the input end being attachable to a pipe having a fluid or slurry input flowing through the valve assembly;

a conical valve needle having a cone with a wide end opposite its conical tip and axially movable in a chamber within the valve body; and

a housing attached to the discharge end of the valve body and closing the valve needle when the valve needle is disengaged from the valve body;

wherein the diameter of the valve needle at the wide end is at least 4% greater than the inner diameter of the valve body at its discharge end.

[2] The valve assembly of paragraph 1, wherein the valve body has an annular ring positioned in a recess in an inner surface of the valve body at the discharge end.

[3] The valve assembly of paragraph 2, wherein the annular ring is replaceable.

[4] The valve assembly of paragraph [2] or [3], wherein an inner surface of the annular ring is aligned with an inner surface of the valve body.

[5] The valve assembly of any of paragraphs [2] to [4], wherein the valve needle is located at the annular ring when the valve needle is closed in the valve body.

[6] The valve assembly of any of paragraphs [1] to [5], wherein the housing includes a removable drain collar therein, the drain collar being located near the drain end of the valve body.

[7] The valve assembly of paragraph [6], wherein the drain ring has a tapered shape.

[8] The valve assembly of any one of paragraphs [1] to [7] [8] [9], wherein the valve body comprises a nozzle for inputting a liquid.

[9] The valve assembly of any one of paragraphs [1] to [8], wherein the chamber of the valve body forms a portion of a reaction zone for a biomass pretreatment process with the tube.

[10] The valve assembly of paragraph [9], wherein the tube is an extruder.

[11] The valve assembly of paragraph [10], wherein the extruder is a twin screw extruder.

[12] The valve assembly of any one of paragraphs [1] to [11], wherein the valve needle is operably linked to the actuator via a shaft.

[13] The valve assembly of paragraph [12], wherein the actuator maintains pressure on the valve needle.

[14] The valve assembly of paragraph [12] or [13], wherein the actuator maintains a pressure on the valve needle in excess of 1,800 lbf.

[15] The valve assembly of any one of paragraphs [12] to [14], wherein the actuator maintains a pressure on the valve needle of between 50,000 and 500,000 lbf.

[16] The valve assembly of any one of paragraphs [1] to [15], wherein the valve body has a circular portion at the discharge end, a circular collar having an inner diameter at the input end that is smaller than the circular portion at the discharge end, and an intermediate conical portion therebetween.

[17] The valve assembly of any one of paragraphs [1] to [16], wherein an annular space is formed in the chamber between the valve needle and the valve body when the valve needle is closed on the valve body.

[18] The valve assembly of any one of paragraphs [1] to [17], wherein the housing comprises a discharge conduit.

[19] The valve assembly of any of paragraphs [1] to [18], wherein an inner diameter of the housing at an end of the housing adjacent the valve body is at least 7% greater than an inner diameter of the valve body at a discharge end thereof.

[20] The valve assembly of any of paragraphs [1] to [19], wherein the inner diameter of the housing at the end of the housing adjacent the valve body is about 7% greater than the inner diameter of the valve body at its discharge end.

[21] The valve assembly of any one of paragraphs [1] to [20], wherein the cone angle of the cone of the conical valve needle is in the range of about 45 degrees to about 75 degrees.

[22] The valve assembly of any one of paragraphs [1] to [21], wherein the taper of the conical valve needle is at a taper angle of about 45 degrees.

[23] A conical valve needle for engagement with a valve body, the conical valve needle comprising a valve needle that extends beyond the valve body into a discharge area when the valve is closed.

[24] The valve needle of paragraph [23], wherein the annular ring is part of the valve body.

[25] The valve needle of paragraph [24], wherein the valve needle is located downstream of the annular ring.

[26] The valve needle of paragraph [24] or [25], wherein the annular ring is replaceable.

[27] The valve needle of any one of paragraphs [23] - [26] [27] [28] [30] [31], wherein the housing is attached downstream to the valve body and contains a removable drain ring.

[28] The valve needle of any one of paragraphs [23] to [27], wherein the valve body comprises a nozzle for inputting a liquid.

[29] The valve needle of any one of paragraphs [23] to [28], wherein the valve needle is seated at the drain ring when closed in the valve body.

[30] The valve needle of any one of paragraphs [23] to [29], the valve needle forming part of a reaction zone with a tube.

[31] The valve needle of any one of paragraphs [23] to [30], wherein the valve needle is attached to an actuator. [32] The valve needle of paragraph [31], wherein the actuator maintains pressure on the valve needle.

[33] The valve needle of paragraph [32], wherein the actuator maintains a pressure on the valve needle in excess of 1,800 lbf.

[34] The valve needle of paragraph [33], wherein the pressure on the valve needle is between 50,000 and 500,000 lbf.

[35] The valve needle of any one of paragraphs [23] to [34], wherein the valve body is attached to an extruder. [36] The valve pin of paragraph [35], wherein the extruder is a twin screw extruder.

[37] A valve assembly that together with a tube or pipe forms part of a reaction zone. [38] The valve assembly of paragraph [37], wherein the conduit or tube is an extruder.

[39] The valve assembly of paragraph [38], wherein the extruder is a twin screw extruder.

[40] The valve assembly of paragraph [39], wherein at least a portion of the contents of the extruder are under pressure.

[41] The valve assembly of paragraph [39], wherein the pressurized region extends into the valve assembly.

[42] A valve assembly having an increased inner diameter between an end of a discharge material of a valve body and a diameter of a discharge housing.

[43] A valve assembly, the valve assembly comprising:

a valve body comprising a large circular portion, an intermediate conical portion, and a small circular collar containing one or more nozzles for liquid input, the valve body having a chamber formed therein connecting an input end and a discharge end of the valve body, wherein the small circular collar has an inner diameter smaller than the inner diameter of the large circular portion;

A valve needle axially movable within the chamber of the valve body; and

a housing attached to the discharge end of the valve body and closing the valve needle when the valve needle is disengaged from the valve body.

[44] The valve assembly of paragraph [43], wherein the housing comprises a removable drain collar.

[45] The valve assembly of paragraph [44], wherein the drain ring is tapered.

[46] The valve assembly of any one of paragraphs [43] to [45], wherein the valve body comprises an annular ring. [47] The valve assembly of paragraph [46], wherein the annular ring is removable.

[48] The valve assembly of any one of paragraphs [43] to [47], wherein an annular space is formed in the chamber between the valve body and the valve needle when the valve needle is closed on the valve body.

[49] The valve assembly of any one of paragraphs [43] to [48] [49], wherein a nozzle for liquid input delivers water into the chamber.

[50] The valve assembly of any one of paragraphs [43] to [49], wherein a nozzle for liquid input delivers liquid other than water into the chamber.

[51] The valve assembly of paragraph [50], wherein the liquid is selected from the group consisting of: an acid, a base, an alcohol, a ketone, an aldehyde, a solvent, or a combination thereof.

[52] The valve assembly of any of paragraphs [43] to [51], wherein an inner diameter of the housing at an end of the housing adjacent the valve body is at least 7% greater than an inner diameter of the valve body at a discharge end thereof.

[53] The valve assembly of any of paragraphs [43] to [52], wherein the inner diameter of the housing at the end of the housing adjacent the valve body is about 7% greater than the inner diameter of the valve body at its discharge end.

[54] The valve assembly of any one of paragraphs [43] to [53], wherein the valve needle has a cone with a wide end opposite its conical tip.

[55] The valve assembly of paragraph [54], wherein the cone angle of the cone is in the range of 45 degrees to 75 degrees.

[56] The valve assembly of paragraph [54], wherein the cone is tapered at an angle of about 45 degrees.

[57] The valve assembly of any of paragraphs [54] to [56], wherein the diameter of the valve needle at the wide end is at least 4% greater than the inner diameter of the valve body at the discharge end thereof.

[58] The valve assembly of any of paragraphs [54] to [56], wherein the diameter of the valve needle at the wide end is about 4% greater than the inner diameter of the valve body at the discharge end thereof.

[59] A system for processing biomass through an extruder, the system comprising:

(a) An extruder comprising one or more screws, wherein an internal plug of biomass is formed as a result of the action of the screws, thereby forming one end of a pressurized reaction zone;

(b) Means for supplying steam and chemicals to the reaction zone; and

(c) A valve assembly at the output end of the extruder, the valve assembly forming the downstream end of the reaction zone and adding liquid to the reaction zone;

wherein the valve assembly is capable of rapidly discharging pressurized treated biomass to a non-pressurized discharge zone.

[60] The system of paragraph [59], wherein the biomass is selected from the group consisting of: silage, agricultural residues, corn stover, bagasse, sorghum, nuts, nut hulls, coconut shells, distillers dried grains solubles, distillers dried grains with distillers dried solubles, wood material, sawdust, wood chips, wood waste, mill waste, municipal waste, waste paper, recycled toilet paper, yard clippings, and energy crops such as poplar, willow, switchgrass, alfalfa and grassland bluegrass, non-woody plant matter, cellulosic material, lignocellulosic material, hemicellulose material, carbohydrates, corn, sugarcane, grasses, switchgrass, high biomass sorghum, bamboo, corn cobs, and pericarps and kernels.

[61] The system of paragraph [59] or [60], wherein the biomass is treated in the reaction zone for less than 60, 55, 50, 45, 40, 35, 30, 25, 20, 19, 18, 17, 16, 15, 14, 13, 12, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 second.

[62] The system of any of paragraphs [59] through [61], wherein the temperature in the reaction zone is raised to 50-500 ℃, 75-400 ℃, 100-350 ℃, 150-300 ℃, 200-250 ℃, 150-300 ℃, 50-1000PSI, 100-750PSI, 200-600PSI, 300-500PSI, or 350-450PSI.

[63] The system of any of paragraphs [59] to [62], wherein the chemical is an acid.

[64] The system of paragraph [63], wherein the acid is sulfuric acid.

[65] The system of any of paragraphs [59] to [64], wherein the valve assembly comprises:

a valve needle axially movable within the chamber of the valve body; and

[66] The system of paragraph [65], wherein the housing comprises a removable drain collar.

[67] The system of paragraph [66], wherein the drain ring is tapered.

[68] The system of any of paragraphs [65] to [67], wherein the valve body comprises an annular ring. [69] The system of paragraph [68], wherein the annular ring is removable.

[70] The system of any of paragraphs [65] to [69], wherein an annular space is formed in the chamber between the valve body and the valve needle when the valve needle is closed on the valve body.

[71] The system of any one of paragraphs [65] to [70], wherein a nozzle for liquid input delivers water into the chamber.

[72] The system of any of paragraphs [65] to [71], wherein a nozzle for liquid input delivers liquid other than water into the chamber.

[73] The system of paragraph [72], wherein the liquid is selected from the group consisting of: an acid, a base, an alcohol, a ketone, an aldehyde, a solvent, or a combination thereof.

[74] The system of any of paragraphs [65] to [73], wherein an inner diameter of the housing at an end of the housing adjacent the valve body is at least 7% greater than an inner diameter of the valve body at a discharge end thereof.

[75] The system of any of paragraphs [65] to [74], wherein the inner diameter of the housing at the end of the housing adjacent the valve body is about 7% greater than the inner diameter of the valve body at its discharge end.

[76] The system of any of paragraphs [65] through [75], wherein the valve needle has a cone with a wide end opposite its conical tip.

[77] The system of paragraph [76], wherein the cone angle of the cone is in the range of 45 degrees to 75 degrees.

[78] The system of paragraph [76], wherein the taper is at a taper angle of about 45 degrees.

[79] The system of any of paragraphs [76] through [78], wherein the diameter of the valve needle at the wide end is at least 4% greater than the inner diameter of the valve body at the discharge end thereof.

[80] The system of any of paragraphs [76] to [78], wherein the valve needle has a diameter at the wide end that is about 4% greater than the inner diameter of the valve body at the discharge end thereof.

While preferred embodiments of the present invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Many variations, changes, and substitutions will now occur to those skilled in the art without departing from the disclosure. It should be understood that various alternatives to the embodiments of the disclosure described herein may be employed in practicing the disclosure. The following claims are intended to define the scope of the disclosure and the method and structure within the scope of these claims and their equivalents are covered thereby.

Claims

1. A valve assembly, the valve assembly comprising:

A valve body having an input end, a discharge end, and a chamber formed in the valve body connected to the input end and the discharge end, the input end being attachable to a tube having a fluid or slurry input flowing through the valve assembly;

a conical valve needle having a cone with a wide end opposite its conical tip and axially movable in the chamber within the valve body; and

2. The valve assembly of claim 1, wherein the valve body has an annular ring located in a recess of the valve body on an inner surface of the discharge end.

3. The valve assembly of claim 2, wherein the annular ring is replaceable.

4. The valve assembly of claim 2, wherein an inner surface of the annular ring is aligned with an inner surface of the valve body.

5. The valve assembly of claim 2, wherein the valve needle is located at the annular ring when the valve needle is closed in the valve body.

6. The valve assembly of claim 1, wherein the housing includes a removable drain collar therein, the drain collar being located near the drain end of the valve body.

7. The valve assembly of claim 6, wherein the drain ring has a tapered shape.

8. The valve assembly of claim 1, wherein the valve body comprises a nozzle for inputting a liquid.

9. The valve assembly of claim 1, wherein the chamber of the valve body forms with the tube a portion of a reaction zone for a biomass pretreatment process.

10. The valve assembly of claim 9, wherein the tube is an extruder.

11. The valve assembly of claim 10, wherein the extruder is a twin screw extruder.

12. The valve assembly of claim 1, wherein the valve needle is operably linked to an actuator via a shaft.

13. The valve assembly of claim 12, wherein the actuator maintains pressure on the valve needle.

14. The valve assembly of claim 12, wherein the actuator maintains a pressure on the valve needle in excess of 1,800 lbf.

15. The valve assembly of claim 12, wherein the actuator maintains a pressure on the valve needle of between 50,000 and 500,000 lbf.

16. The valve assembly of claim 1, wherein the valve body has a circular portion at the discharge end, a circular collar having an inner diameter at the input end that is smaller than the circular portion at the discharge end, and an intermediate conical portion therebetween.

17. The valve assembly of claim 1, wherein an annular space is formed in the chamber between the valve needle and the valve body when the valve needle is closed on the valve body.

18. The valve assembly of claim 1, wherein the housing comprises a drain conduit.

19. The valve assembly of claim 1, wherein an inner diameter of the housing at an end of the housing adjacent the valve body is at least 7% greater than an inner diameter of the valve body at a discharge end thereof.

20. The valve assembly of claim 1, wherein an inner diameter of the housing at an end of the housing adjacent the valve body is about 7% greater than an inner diameter of the valve body at a discharge end thereof.

21. The valve assembly of claim 1, wherein a taper angle of the taper of the conical valve needle is in a range of about 45 degrees to about 75 degrees.

22. The valve assembly of claim 1, wherein the taper of the conical valve needle is at a taper angle of about 45 degrees.

23. A conical valve needle for engagement with a valve body, the conical valve needle comprising a valve needle that extends beyond the valve body into a discharge area when the valve is closed.

24. The valve needle of claim 23, wherein an annular ring is part of the valve body.

25. The valve needle of claim 24, wherein the valve needle is located downstream of the annular ring.

26. The valve needle of claim 24, wherein the annular ring is replaceable.

27. The valve needle of claim 23, wherein a housing is attached downstream to the valve body and contains a removable drain ring.

28. The valve needle of claim 23, wherein the valve body comprises a nozzle for inputting a liquid.

29. The valve needle of claim 23, wherein the valve needle seats at a drain collar when closed in the valve body.

30. The valve needle of claim 23, forming a portion of a reaction zone with a tube.

31. The valve needle of claim 23, wherein the valve needle is attached to an actuator.

32. The valve needle of claim 31, wherein the actuator maintains pressure on the valve needle.

33. The valve needle of claim 32, wherein the actuator maintains a pressure on the valve needle in excess of 1,800 lbf.

34. The valve needle of claim 33, wherein the pressure on the valve needle is between 50,000 and 500,000 lbf.

35. The valve needle of claim 23, wherein the valve body is attached to an extruder.

36. The valve needle of claim 35, wherein the extruder is a twin screw extruder.

37. A valve assembly that together with a tube or pipe becomes part of a reaction zone.

38. The valve assembly of claim 37, wherein the conduit or tube is an extruder.

39. The valve assembly of claim 38, wherein the extruder is a twin screw extruder.

40. The valve assembly of claim 39, wherein at least a portion of the contents of the extruder are under pressure.

41. The valve assembly of claim 39, wherein a pressurized zone extends into the valve assembly.

42. A valve assembly having an increased inner diameter between an end of a discharge material of a valve body and a diameter of a discharge housing.

43. A valve assembly, the valve assembly comprising:

a valve needle axially movable within the chamber of the valve body; and

44. The valve assembly of claim 43, wherein the housing comprises a removable drain collar.

45. The valve assembly of claim 44, wherein the drain collar is tapered.

46. The valve assembly of claim 43, wherein the valve body comprises an annular ring.

47. The valve assembly of claim 46, wherein the annular ring is removable.

48. The valve assembly of claim 43, wherein an annular space is formed in the chamber between the valve body and the valve needle when the valve needle closes on the valve body.

49. The valve assembly of claim 43, wherein the nozzle for liquid input delivers water into the chamber.

50. The valve assembly of claim 43, wherein the nozzle for liquid input delivers liquid other than water into the chamber.

51. The valve assembly of claim 50, wherein the liquid is selected from the group consisting of: an acid, a base, an alcohol, a ketone, an aldehyde, a solvent, or a combination thereof.

52. The valve assembly of claim 43, wherein an inner diameter of the housing at an end of the housing adjacent the valve body is at least 7% greater than an inner diameter of the valve body at a discharge end thereof.

53. The valve assembly of claim 43, wherein the inner diameter of the housing at the end of the housing adjacent the valve body is about 7% greater than the inner diameter of the valve body at its discharge end.

54. The valve assembly of claim 43, wherein the valve needle has a cone with a wide end opposite its conical tip.

55. The valve assembly of claim 54, wherein the cone has a cone angle in the range of 45 degrees to 75 degrees.

56. The valve assembly of claim 54, wherein the cone is tapered at about a 45 degree angle.

57. The valve assembly of claim 54, wherein the diameter of the valve needle at the wide end is at least 4% greater than the inner diameter of the valve body at the discharge end thereof.

58. The valve assembly of claim 54, wherein the diameter of the valve needle at the wide end is about 4% greater than the inner diameter of the valve body at the discharge end thereof.

59. A system for processing biomass through an extruder, the system comprising:

(b) Means for supplying steam and chemicals to said reaction zone; and

60. The system of claim 59, wherein the biomass is selected from the group consisting of: silage, agricultural residues, corn stover, bagasse, sorghum, nuts, nut hulls, coconut shells, distillers dried grains solubles, distillers dried grains with distillers dried solubles, wood material, sawdust, wood chips, wood waste, mill waste, municipal waste, waste paper, recycled toilet paper, yard clippings, and energy crops such as poplar, willow, switchgrass, alfalfa and grassland bluegrass, non-woody plant matter, cellulosic material, lignocellulosic material, hemicellulose material, carbohydrates, corn, sugarcane, grasses, switchgrass, high biomass sorghum, bamboo, corn cobs, and pericarps and kernels.

61. The system of claim 59, wherein the biomass is treated in the reaction zone for less than 60, 55, 50, 45, 40, 35, 30, 25, 20, 19, 18, 17, 16, 15, 14, 13, 12, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 second.

62. The system of claim 59, wherein the temperature in the reaction zone is increased to 50-500 ℃, 75-400 ℃, 100-350 ℃, 150-300 ℃, 200-250 ℃, 150-300 ℃, 50-1000PSI, 100-750PSI, 200-600PSI, 300-500PSI, or 350-450PSI.

63. The system of claim 59, wherein the chemical comprises an acid.

64. The system of claim 63, wherein the acid is sulfuric acid.

65. The system of claim 59, wherein the valve assembly comprises:

a valve needle axially movable within the chamber of the valve body; and

66. The system of claim 65, wherein the housing comprises a removable drain collar.

67. The system of claim 66, wherein the drain collar is tapered.

68. The system of claim 65, wherein the valve body comprises an annular ring.

69. The system of claim 68, wherein the annular ring is removable.

70. The system of claim 65, wherein an annular space is formed in the chamber between the valve body and the valve needle when the valve needle closes on the valve body.

71. The system of claim 65, wherein the nozzle for liquid input delivers water into the chamber.

72. The system of claim 65, wherein the nozzle for liquid input delivers liquid other than water into the chamber.

73. The system of claim 72, wherein the liquid is selected from the group consisting of: an acid, a base, an alcohol, a ketone, an aldehyde, a solvent, or a combination thereof.

74. The system of claim 65, wherein an inner diameter of the housing at an end of the housing adjacent the valve body is at least 7% greater than an inner diameter of the valve body at a discharge end thereof.

75. The system of claim 65, wherein the inner diameter of the housing at the end of the housing adjacent the valve body is about 7% greater than the inner diameter of the valve body at its discharge end.

76. The system of claim 65, wherein the valve needle has a cone with a wide end opposite its conical tip.

77. The system of claim 76, wherein the cone has a cone angle in the range of 45 degrees to 75 degrees.

78. The system of claim 76, wherein the cone is at a cone angle of about 45 degrees.

79. The system of claim 76 wherein the diameter of the valve needle at the wide end is at least 4% greater than the inner diameter of the valve body at the discharge end thereof.

80. The system of claim 76 wherein the diameter of the valve needle at the wide end is about 4% greater than the inner diameter of the valve body at the discharge end thereof.