WO2024233761A2

WO2024233761A2 - Propagation of one or more types of soil microbes using at least one bioprocessing facility composition, and related compositions, systems, and methods

Info

Publication number: WO2024233761A2
Application number: PCT/US2024/028538
Authority: WO
Inventors: Tapaswy MUPPANENI; Steve BLY; Steve Lewis
Original assignee: Poet Research Inc
Current assignee: Poet Research Inc
Priority date: 2023-05-10
Filing date: 2024-05-09
Publication date: 2024-11-14
Anticipated expiration: 2025-11-10
Also published as: WO2024233761A3

Abstract

Reproducing one or more types of soil microbes in a propagation media to form a microbial composition, where the propagation media is formed from at least one bioprocessing facility composition. Related facilities that include a bioprocessing facility configured to generate at least one bioprocessing facility composition, and a propagation system that is co-located with the bioprocessing facility.

Description

PROPAGATION OF ONE OR MORE TYPES OF SOIL MICROBES USING AT LEAST ONE BIOPROCESSING FACILITY COMPOSITION, AND RELATED COMPOSITIONS, SYSTEMS, AND METHODS

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This nonprovisional patent application claims the benefit of U.S. Provisional Patent Application Serial Number 63/465,348, filed on May 10, 2023, wherein said provisional patent application is incorporated herein by reference in its entirety.

BACKGROUND

[0002] The present disclosure relates to propagation of one or more types of soil microbes. There is a continuing need for improved methods and system of applying beneficial soil microbes to soil, especially to promote plant growth.

SUMMARY

[0003] The present disclosure includes embodiments of a method of reproducing one or more types of soil microbes. The method includes reproducing one or more types of soil microbes in a propagation media to form a microbial composition. The propagation media is formed from at least one bioprocessing facility composition.

[0004] The present disclosure also includes embodiments of a facility that includes a bioprocessing facility configured to generate at least one bioprocessing facility composition, and a propagation system that is co-located with the bioprocessing facility and configured to receive at least a portion of the at least one bioprocessing facility composition. The propagation system is configured to form a propagation media from the at least a portion of the at least one bioprocessing facility composition, and reproduce one or more types of soil microbes in the propagation media to form a microbial composition.

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Various examples of the present disclosure will be discussed with reference to the appended drawings. These drawings depict only illustrative examples of the disclosure and are not to be considered limiting of its scope.

[0006] FIG. 1 shows a process-flow graphic of a non-limiting embodiment of a bioprocessing facility co-located and integrated with a propagation system configured to reproduce one or more types of soil microbes;

[0007] FIG. 2 shows a pan granulator (also known as a disc pelletizer) that can be used to form pellets according to the present disclosure; [0008] FIG. 3A shows a process-flow diagram of a non-limiting embodiment of a dry-grind com ethanol bioprocessing facility configured to form a plurality of stillage compositions; and

[0009] FIG. 3B shows a process-flow diagram of a non-limiting embodiment of the corn oil separation system shown in FIG. 3A.

DETAILED DESCRIPTION

[0010] Healthy soil includes a healthy, active biology beneath the surface, which includes soil microbes. The present disclosure relates to propagating one or more types of soil microbes that are beneficial to soil and/or plant health. As used herein, “propagating,” “propagation,” and “propagate” mean reproducing a microbe to increase the number of microbes to generate a large population of microbes. As discussed below, large populations of microbes reproduced according to the present disclosure can then be applied to soil for the purpose of growing agricultural crops. Growth of a microbe in size may also occur during propagation.

[001 1] Soil includes a wide variety of types of microbes that can be beneficial for growing plants. Soil microbes include bacteria and/or fiingi. Non-limiting examples of soil bacteria that are beneficial in growing plants include bacteria that are rich in nitrogen, nitrogenmineralization bacteria, nitrogen-fixing bacteria, bacteria that break down organic matter (e.g., lignin), bacteria that dissolve or solubilize phosphorus so that is available for use by plants, bacteria (e.g., Acidithiobacillus) that dissolve potassium so that is available for use by plants, and combinations thereof.

[0012] Bacteria that are rich in nitrogen can decompose or be consumed by other organisms (e.g., protozoa), thereby releasing nitrogen to the soil for plants to use.

[0013] Nitrogen-mineralization bacteria convert atmospheric nitrogen gas into inorganic forms such as ammonium and/or nitrate, which is available for plants to use.

[0014] Nitrogen-fixing bacteria also convert atmospheric nitrogen into a form that is available for plants to use. Non-limiting examples of nitrogen-fixing bacteria include Azotobacter, Azospirillum, Rhizobia, Cyanobacteria, and combinations thereof.

[0015] Beneficial soil microbes also include bacteria that break down organic matter such as lignin and make cellulose and other sources of carbon more available for plants to use. In some embodiments, one or more species of such bacteria may be able to breakdown complex carbon molecules present in one or more stillage compositions and/or one or more anaerobic digestion digestate compositions. A non-limiting example of such bacteria includes Actinomycetes. [0016] In some embodiments, a beneficial soil microbe that can be reproduced according to the present disclosure includes any strain of Bacillus subtilis.

[0017] A non-limiting example of fungi in soil that is beneficial in growing plants includes Mychorrhizal fungi, which can infect the roots of a plant and form hyphae that reach out further to help absorb water and nutrients from the soil.

[0018] As discussed below, one or more types of soil microbes can be sourced from soil at a given location, reproduced according to the present disclosure to create a larger population of the microbes, and then applied to soil, incorporated into a seed coating, and/or incorporated into a fertilizer composition.

[0019] With respect to applying the reproduced soil microbes to a soil, the reproduced soil microbes can be applied to soil at any desired location. In some embodiments, the reproduced soil microbes can be applied to a soil that is located very far from location where the soil microbes were sourced from for reproduction/propagation. In some embodiments, one or more types of soil microbes can be sourced from soil, reproduced according to the present disclosure, and then returned to soil that is within a radius of 300 miles or more, 500 miles or more, or even 1000 miles or more from where the microbes were sourced.

[0020] In some embodiments, the soil microbes may be applied to soil in the general area from where the microbes were sourced. While not being bound by theory, it is believed that using soil microbes as “seed” microbes for propagation and application to the soil in the area that the microbes were sourced from can beneficially provide biological feedback to the soil for subsequent growing seasons. In some embodiments, one or more types of soil microbes can be sourced from soil, reproduced according to the present disclosure, and then returned to soil that is within a radius of 300 miles or less, 200 miles or less, 100 miles or less, 75 miles or less, or even 50 miles or less from where the microbes were sourced. As discussed below, FIG. 1 shows non-limiting illustration of obtaining and reproducing one or more types of soil microbes 116 from a given location to create a larger population of the microbes, and then applying the reproduced soil microbes to soil in the general area from where the microbes were sourced.

[0021] As also discussed below, at least one bioprocessing facility composition produced at a bioprocessing facility can be used to reproduce one or more types of soil microbes. In some embodiments, one or more types of soil microbes can be “locally” sourced relative to the bioprocessing facility. For example, one or more types of soil microbes that are reproduced can be applied to soil that is used to grow biomass (e.g., corn) that is used as feedstock for the bioprocessing facility. In this way, at least a portion of the biomass can be used “locally” for microbe propagation, which can advantageously reduce carbon intensity (CI) of the microbe propagation process. For example, reproducing soil microbes locally can reduce transportation costs and emissions that may otherwise be associated with one or more commercially available soil microbes. In some embodiments, one or more types of soil microbes that are used as “seed” microbes for a soil microbe propagation process according to the present disclosure can be obtained from soil that is within a radius of 300 miles or less, 200 miles or less, 100 miles or less, 75 miles or less, or even 50 miles or less from the bioprocessing facility. As discussed below, FIG. 1 shows non-limiting illustration of obtaining one or more types of soil microbes 116 “locally” relative to a bioprocessing facility 102, propagating the soil microbes, and then applying the propagated soil microbes to soil that is used to grow biomass (e.g., com plants 1 14) that is used as feedstock 117 for the bioprocessing facility 102.

[0022] According to the present disclosure at least one type of soil microbe obtained from a soil sample is reproduced using at least one bioprocessing facility composition in the propagation media. In some embodiments, one or more types of soil microbes can be isolated from one or more other soil microbes prior to propagation. Isolating one or more microbes refers to separating a strain from a natural, mixed population of living microbes, as they are present in soil, in order to obtain the one or more microbes of interest. Isolating one or more microbes from one or more other microbes prior to propagation can permit different propagation conditions to be used in a manner that is tailored to the microbes. Also, isolating one or more microbes from one or more other microbes prior to propagation can permit resources related to propagation and/or other processing to be used more efficiently. Also, isolating one or more microbes from one or more other microbes prior to propagation can permit one or more microbes to be selected to promote crop growth, crop yield, and/or crop protection against pathogens. Microbes can be isolated using a variety of techniques. Nonlimiting examples of isolating one or more microbes from a sample of soil microbes include one or more of pour plate technique, spread plate technique, membrane filtration technique, mud-pie (soil plate) technique, streak plate technique, and combinations thereof.

[0023] A propagation media can be inoculated with one or more types of soil microbes obtained from a sample of soil so that the microbes can reproduce and form a microbial composition, which can be applied to soil as described herein.

[0024] According to the present disclosure, a propagation media can be formed from at least one bioprocessing facility composition, which is produced at a bioprocessing facility. As used herein, a bioprocessing facility refers to a facility that can produce one or more bioproducts by converting biomass feedstock via one or more physical processes, one or more chemical processes, one or more bioprocesses, and combinations thereof. Non-limiting examples of bioprocessing facilities include dry mills, wet mills, biofuel production facilities, anaerobic digestion facilities, pharmaceutical production facilities, soy processing facilities, breweries, bakeries, and the like. A bioproduct refers to a product derived from a biological, renewable resource. For example, a bioproduct can be a component of biomass feedstock that is liberated from the biomass feedstock (e.g., corn oil from com grain) and/or can include a chemical (“biochemical” or “ target biochemical”) that is produced by a biocatalyst (e.g., microorganism and/or enzyme) such as, for example, alcohol produced by yeast fermenting sugar. Non-limiting examples of bioproducts produced in a bioprocessing facility include one or more of fuel, feed, food, pharmaceuticals, beverages and precursor chemicals. In some embodiments, a bioproduct includes, among others, one or more monomeric sugars, one or more enzymes, one or more oils, one or more alcohols (e.g., ethanol, butanol, and the like), one or more biogases (e.g., methane), fungal biomass, amino acids, and one or more organic acids (e.g., lactic acid), and combinations thereof.

[0025] In some embodiments, a bioprocessing facility composition can include at least one stillage composition, at least one anaerobic digestion digestate composition, at least one bioash composition, and combinations thereof.

[0026] As used herein, a “stillage composition” refers to a back-end composition of a fermentation process after separating (e.g., via distillation) one or more bioproducts from beer to form at least one target bioproduct stream (e.g., ethanol) and one or more co-product streams (e.g., whole stillage). A stillage composition can include whole stillage, at least one stillage composition derived from whole stillage, and combinations thereof. Non-limiting examples of a stillage composition derived from whole stillage include thin stillage, concentrated thin stillage (syrup), defatted syrup, defatted emulsion, clarified thin stillage, distiller’s oil, distiller’s grain, distiller’s yeast, and the like. Defatted syrup and defatted emulsion are examples of stillage compositions that remain after fat (e.g., corn oil) has been separated from syrup and emulsion, respectively, and can be referred to as “defatted stillage compositions.” Non-limiting examples of methods and systems for processing stillage streams are described in U.S. Pat. No. 8,702,819(Bootsma); U.S. Pat. No.

9,061 ,987(Bootsma); U.S. Pat. No. 9,290,728(Bootsma); U.S. Pat. No. 10,059,966 (Bootsma); U.S. Pat. No. 11,248,197 (Bootsma); and U.S. Pub. No. 2020/0140899 (Bootsma); wherein the entirety of each of said patent documents is incorporated herein by reference. An example of forming stillage compositions at a bioprocessing facility is described below with respect to FIGS. 3A and 3B.

[0027] A stillage composition can be selected for incorporation into a propagation media based on a variety of factors such as nutrient content for microbe propagation, adjusting pH of the propagation media, combinations of these, and the like.

[0028] A stillage composition can provide one or more nutrients for microbe propagation. For illustration purposes, an example of a nutrient that a stillage composition may provide to a propagation media is carbon (C), which can be used as an energy source by microbes. One or more soil microbes and/or one or more exogenous enzymes can be selected to breakdown one or more polysaccharides (e.g., cellulose) and/or one or more oligosaccharides into one or more monosaccharides, which can be relatively more available for uptake by one or more soil microbes.

[0029] In some embodiments, a stillage composition may contribute one or more nutrients to propagation media, and at least a portion of the one or more nutrients may remain in the microbial composition after propagation. At least a portion of the remaining one or more nutrients in the microbial composition can serve as fertilizer for plants after microbial composition is applied to soil.

[0030] In some embodiments, depending on the stillage composition selected, a stillage composition may reduce the concentration of one or more nutrients or elements by diluting the propagation media. For example, sodium present in bio-ash composition may be present at a concentration that is undesirable for one or more soil microbes when included in a propagation media. One or more stillage compositions may be incorporated into the fermentation media to dilute the sodium concentration to an acceptable level.

[0031 ] In some embodiments, a stillage composition may be selected to adjust the pH of the propagation media. The pH of the propagation media can also affect propagation of one or more microbes. The pH of a stillage composition can vary but tends to be acidic. In some embodiments, a stillage composition can have a pH of 6.5 or less, 6 or less, 5.5 or less, 5 or less, 4.5 or less, 4 or less, or even 3.5 or less. The pH of a stillage composition may or may not be adjusted when forming a propagation media. For example, mixing a highly acidic composition and a highly basic composition can be an exothermic process, which may be undesirable. In some embodiments, if an acidic stillage composition is to be combined with a component that has a relatively high pH (e.g., a bio-ash composition having a pH of 12 or greater), the pH of the acidic stillage composition may be increased to reduce the difference in pH prior to combining the stillage composition with the component that has a relatively high pH.

[0032] In some embodiments, a stillage composition is combined with one or more other components in a weight ratio from 0:100% to 100:0%, from 20:80% to 80:20%, from 40:60% to 60:40%, or even 50:50% to form a propagation media. In some embodiments, a weight ratio of at least one stillage composition to at least one bio-ash composition in the propagation media is 5 or less, 1 or less, 0.5 or less, or even 0.1 or less.

[0033] For illustration purposes, Table 1 below includes compositional data for three stillage compositions resulting from a dry grind ethanol process: syrup (concentrated thin stillage); defatted syrup; and distillers’ dried grain with solubles (DDGS).

[0034] As used herein, an “anaerobic digestion digestate composition” refers to one or more effluent compositions discharged from, or derived from, an anaerobic digestion process that breaks down organic matter via bacteria in the absence of oxygen to produce biogas. Biogas is a mixture of methane, carbon dioxide, hydrogen sulfide, water vapor, and trace amounts of other gases. Non-limiting examples of organic matter that can be fed to an anaerobic digestion process include at least one of one or more manure compositions, one or more food waste compositions, one or more energy crops, one or more crop residues, one or more stillage compositions (e.g., thin stillage and/or syrup and/or defatted syrup), one or more fats, one or more oils, and the like. Effluent compositions discharged from an anaerobic digestion process include anaerobic digestion liquid effluent, anaerobic digestion solid effluent, and combinations thereof. Organic nitrogen may be converted to ammonia during anaerobic digestion and be present in an anaerobic digestion digestate composition. If desired the ammonia may be separated from the anaerobic digestion digestate composition via distillation and the like. The separated ammonia can be relatively more concentrated and can be used in making a propagation media according to the present disclosure and/or applied to soil separately from any that may end up in soil via propagation media.

[0035] Like a stillage composition discussed above, an anaerobic digestion digestate composition can be selected for incorporation into a propagation media based on a variety of factors such as nutrient content for microbe propagation, adjusting pH of the propagation media, combinations of these, and the like.

[0036] An anaerobic digestion digestate composition can provide one or more nutrients for microbe propagation. For illustration purposes, an example of a nutrient that an anaerobic digestion digestate composition may provide to a propagation media is carbon (C), which can be used as an energy source by microbes. [0037] In some embodiments, depending on the anaerobic digestion digestate composition selected, an anaerobic digestion digestate composition may reduce the concentration of one or more nutrients or elements by diluting the propagation media. For example, sodium present in bio-ash composition may be present at a concentration that is undesirable for one or more soil microbes when included in a propagation media. One or more anaerobic digestion digestate compositions may be incorporated into the fermentation media to dilute the sodium concentration to an acceptable level.

[0038] In some embodiments, an anaerobic digestion digestate composition may be selected to adjust the pH of the propagation media. The pH of the propagation media can also affect propagation of one or more microbes. The pH of an anaerobic digestion digestate composition can vary (e.g., depending on concentration of an anaerobic digestion digestate composition). In some embodiments, an anaerobic digestion digestate composition can have a pH of 7.5 or less, 7 or less, 6.5 or less, 6 or less, 5.5 or less, 5 or less, or even 4.5 or less. The pH of an anaerobic digestion digestate composition may or may not be adjusted when forming propagation media. For example, mixing a highly acidic composition and a highly basic composition can be an exothermic process, which may be undesirable. In some embodiments, if an acidic anaerobic digestion digestate composition is to be combined with a component that has a relatively high pH (e.g., a bio-ash composition having a pH of 12 or greater), the pH of the acidic anaerobic digestion digestate composition may be increased to reduce the difference in pH prior to combining the anaerobic digestion digestate composition with the component that has a relatively high pH.

[0039] In some embodiments, an anaerobic digestion digestate composition is combined with one or more other components in a weight ratio from 0: 100% to 100:0%, from 20:80% to 80:20%, from 40:60% to 60:40%, or even 50:50% to form a propagation media.

[0040] For illustration purposes, Table 1 includes compositional data for two anaerobic digestion digestate composition: AD effluent and AD mineral syrup. AD effluent was concentrated by removing water to form the AD mineral syrup.

[0041] As used herein, a “bio-ash composition” refers to an ash derived from the combustion of biomass to produce a flue gas and a bio-ash composition. While the bio-ash composition can be considered a waste product that needs to be disposed, the present disclosure involves using the bio-ash composition in some embodiments to make a propagation media (and/or fertilizer composition as discussed below) because of the nutrient value in the bio-ash composition, thereby creating a stream of revenue. [0042] Like a stillage composition discussed above, a bio-ash composition can be selected for incorporation into a propagation media based on a variety of factors such as nutrient content for microbe propagation, adjusting pH of the propagation media, combinations of these, and the like.

[0043] A bio-ash composition can include nutrients suitable for soil microbe propagation. Non-limiting examples of nutrients that can be present in a bio-ash composition include nitrogen (N), phosphorus (P), potassium (K), calcium (Ca), sulfur (S), magnesium (Mg), carbon (C), oxygen (O), iron (Fe), boron (B), chlorine (Cl), manganese (Mn), zinc (Zn), and copper (Cu). The content of one or more nutrients in a bio-ash composition can be determined by nutrient analysis via one or more of calorimetric testing, extraction testing, and the like.

[0044] Nitrogen can be reported in terms “total nitrogen,” which is the sum of all forms of nitrogen and can be described as total nitrogen = ammonia nitrogen (NH3) + organic nitrogen (nitrogen in amino acids and proteins, which includes urea and uric acid) + nitrite (NO2) + nitrate (NO3). In some embodiments, a bio-ash composition has a total nitrogen content of 0.1% or greater, 0.2% or greater, 0.3% or greater, or even 0.4% or greater by total weight of the bio-ash composition.

[0045] Phosphorus can be reported in terms of “phosphate (P2O5)” content, which is often used interchangeably with elemental phosphorus (P) in soil science and fertilizer science. Phosphorus pentoxide (P2O5) is also referred to as diphosphonate, which is a divalent inorganic anion obtained by removal of both protons from diphosphonic acid. Phosphorus pentoxide (P2O5) is a ciystal form that occurs in soil. Phosphorus (P) is actually taken up by plants in the form of phosphate compounds such as dihydrogen phosphate [H2PO4]²' and/or hydrogen phosphate [HPO4]'. In some embodiments, a bio-ash composition has a phosphate (P2O5) content of 0.5% or greater, 1 % or greater, 1 .2% or greater, or even 1 .3% or greater by total weight of the bio-ash composition.

[0046] The potassium content in a bio-ash composition can be reported in terms of K2O (or K2O equivalent). In some embodiments, a bio-ash composition has a potassium oxide (K2O) equivalent content of 1% or greater, 2% or greater, 3% or greater, 4% or greater, 5% or greater, or even 6% or greater by total weight of the bio-ash composition.

[0047] The carbon content can be reported in terms of “total carbon.” Total carbon is the combined amount of inorganic and organic carbon. One method of determining total carbon content is by using a laboratory elemental analyzer to analyze a sample of bio-ash composition. In some embodiments, a bio-ash composition has a total carbon content of 5% or less, 4% or less, 3% or less, or even 2% or less by total weight of the bio-ash composition. In some embodiments, a bio-ash composition has a total carbon content in a range from 0.1% to 5%, from 0.5% to 4%, or even from 1% to 3% by total weight of the bio-ash composition. [0048] A bio-ash composition tends to have a pH greater than 7. In some embodiments, a bio-ash composition has a pH of 10 or greater, 11 or greater, or even 12 or greater.

[0049] A bio-ash composition is produced via combustion of biomass that results in solid ash powder. In some embodiments, the solid ash powder can accumulate at the bottom of a combustion chamber (bio-ash bottoms ash) and/or be present as entrained powder (bio-ash fly ash) in flue gas. A bio-ash composition can be recovered from flue gas. Non-limiting examples of recovering bio-ash fly ash from a flue gas include filtration (e.g., a fabric baghouse), electrostatic precipitation, and combinations thereof.

[0050] The average particle size of a bio-ash composition can depend on a variety of factors such as the biomass and/or the form of the biomass that is used in combustion. In some embodiments, the average particle size of a bio-ash composition can vary among the bio-ash fly ash and bio-ash bottoms ash. In some embodiments, a bio-ash composition has an average particle size of 200 microns or less, 175 microns or less, 150 microns or less, 125 microns or less, or even 100 microns or less. In some embodiments, a bio-ash composition has an average particle size from 100-150 microns.

[0051 ] In some embodiments, the average particle size of a bio-ash composition can be adjusted as desired, e.g., to make nutrients relatively more available in a propagation media for uptake by microbes. In some embodiments, the average particle size of a bio-ash composition can also be adjusted as desired, e.g., to make nutrients relatively more available to a plant and/or to improve formation of a fertilizer composition (discussed below). Adjusting the average particle size of a bio-ash composition can performed via one or more of blending two or more bio-ash compositions having different average particle sizes, particle size reduction (e.g., via grinding), and the like.

[0052] A bio-ash composition can be produced by exposing biomass to one or more combustion conditions to generate heat and form solid ash powder. In some embodiments, one or more combustion conditions can be selected to generate energy as the primary goal. Under such conditions, carbon tends to be consumed to a relatively high degree such that the resulting ash tends to have a relatively very low carbon content as compared to the biomass prior to combustion. Also, under such conditions, nutrient content in the form of minerals tends to be concentrated in the resulting ash as compared to the biomass prior to combustion. Non-limiting examples of combustion conditions include oxygen source for combustion, combustion temperature, and the like. In some embodiments, the combustion temperature can be from 300-600°C. The oxygen content provided to the combustion process can also influence the chemical composition of the ash. For example, as the oxygen content provided to combustion increases, one or more nutrients can be relatively more available in the ash. In some embodiments, oxygen can be provided to combustion via air (which is about 21% oxygen). In some embodiments, a relatively higher concentration of oxygen can be provided to combustion. In some embodiments, combustion conditions include those used for a typical solid-fuel boiler designed to generate energy. In some embodiments, the combustion conditions will be selected based on generating energy only and not necessarily for one or more properties of the resulting bio-ash composition.

[0053] For illustration purposes, biomass can be burned at a bioprocessing facility to generate energy for the bioprocessing facility. In some embodiments, biomass can be burned as solid fuel in a steam boiler system and/or in a power generation system at a bioprocessing facility. A steam boiler system can generate steam using heat from the combustion of biomass. A power generation system can generate electricity using steam-generated power. Steam-generated power can generate electrical power using a steam turbine system that receives steam from a steam boiler system. Non-limiting examples of steam turbine systems include condensing turbine systems, non-condensing turbine systems, reheat turbine systems, extracting turbine systems, and combinations thereof.

[0054] A wide variety of biomass can be used to generate a bio-ash composition according to the present disclosure. In some embodiments, the biomass used to generate a bio-ash composition is the same as biomass feedstock used in a bioprocessing facility to form a bioproduct as discussed above. In some embodiments, the biomass used to generate a bio-ash composition is different from the biomass feedstock used in a bioprocessing facility to form a bioproduct as discusses above. In some embodiments, a bio-ash composition is derived from combustion of one or more plant-based feedstocks. Non-limiting examples plant-based feedstocks that can be used as fuel in combustion and form a bio-ash composition include crop residues (e.g., husks, stems, corn stover, wheat straw), grasses, straw, and woody plants (firewood), bioprocessing residue (e.g., bran, whole stillage, wet cake, sugarcane bagasse, pulp, and the like) derived from sugar beets, sugar cane, grains, legumes, com, sorghum, wheat, rice, barley, soybean, rapeseed, oats, millet, rye, and the like, and/or bio-char produced from one or more of the aforementioned plant-based feedstocks. In some embodiments, a bio-ash composition is derived from combustion of municipal waste. [0055] A plant-based feedstock can be processed prior to combustion as desired. For example, a plant-based feedstock such as a bale of straw or com stover could be simply unbaled and fed into a solid-fuel boiler. As another example, a plant-based feedstock can be dried to reduce its moisture content. As another example, the plant-based feedstock can be size-reduced to increase its surface area to volume ratio for combustion purposes.

[0056] In some embodiments, a bio-ash composition is combined with one or more other components in a weight ratio from 0: 100% to 50:50%, from 20:80% to 40:60%, or even from 40:60% to 60:40% to form a propagation media.

[0057] For illustration purposes, Table 1 includes compositional data for bio-ash fly ash from burning wood and bio-ash fly ash from burning corn stover. The bio-ash fly ash from burning wood included burning wood pallets (obtained from Mueller Pallets, Sioux Falls, SD) and tree waste in a solid fuel boiler at a dry-grind com ethanol bioprocessing facility.

Table 1

[0058] As mentioned above, according to the present disclosure, a propagation media for reproducing soil microbes is formed using at least one bioprocessing facility composition. In some embodiments, a propagation media is formed from at least one stillage composition, at least one anaerobic digestion digestate composition, at least one bio-ash composition, and combinations thereof. In some embodiments, a bioprocessing facility composition can be selected and mixed with one or more other bioprocessing facility compositions to form a propagation media based on a variety of factors such as processing properties when forming a propagation media, nutrient value of the propagation media, equipment-based application properties when applying a microbial composition to soil, and/or properties (e.g., fertilizer quality, and the like) after the microbial composition has been applied to soil.

[0059] In some embodiments, a bio-ash composition can be mixed with at least one stillage composition and/or at least one anaerobic digestion digestate composition to form a fertilizer composition at a weight ratio based on a variety of factors such as those discussed above when selecting a stillage composition and/or an anaerobic digestion digestate composition. For example, the weight ratio can depend on the composition of the bio-ash composition, the stillage composition, the anaerobic digestion digestate composition, and/or the target composition of the fertilizer composition. In some embodiments a bio-ash composition is combined with a stillage composition in a weight ratio from 0:100% to 100:0%, from 20:80% to 80:20%, from 40:60% to 60:40%, or even 50:50%. In some embodiments a bio-ash composition is combined with an anaerobic digestion digestate composition in a weight ratio from 0:100% to 100:0%, from 20:80% to 80:20%, from 40:60% to 60:40%, or even 50:50%. In some embodiments a stillage composition is combined with an anaerobic digestion digestate composition in a weight ratio from 0:100% to 100:0%, from 20:80% to 80:20%, from 40:60% to 60:40%, or even 50:50%.

[0060] In some embodiments, one or more additional, exogenous ingredients can be combined with a bioprocessing facility composition to form a propagation media. Nonlimiting examples of such materials include one or more supplemental carbon sources, one or more of enzymes, phosphate, citric acid, ionic additives, and the like. For example, one or more sources of supplemental carbon can be added to a propagation media to provide energy for microbial propagation. Non-limiting examples of supplemental carbon include supplemental sugar derived from a biomass feedstock at a bioprocessing facility, commercially available sugar ingredients (e.g., glucose), combinations of these, and the like. A non-limiting example providing supplemental sugar derived from a biomass feedstock at a bioprocessing facility is described in U.S. Pat. App. No. 18/086,350 (Sarks et al.), wherein the entirety of said patent application is incorporated herein by reference. Another nonlimiting example of converting raw biomass feedstock into sugar is described in U.S. Pat. No. 10,233,466 (Redford), wherein the entirety of said patent is incorporated herein by reference. Supplemental carbon may also be provided in the form of starch derived form a biomass feedstock at a bioprocessing facility. A non-limiting example of converting raw biomass feedstock into a starch stream is described in U.S. Pat. No. 10,793,879 (Redford et al.), wherein the entirety of said patent is incorporated herein by reference.

[0061] A propagation media may be formulated to include sufficient nitrogen when undecomposed organic material is present in the propagation media. For example, if the relative amount of carbon is too high, then as the carbon containing material breaks down the nitrogen can be consumed in the process, thereby making less nitrogen available for the soil microbes. In some embodiments, a propagation media can have a carbon (C): nitrogen (N) ratio in a range from 40: 1, from 30:1, from 25: 1, or even from 20:1 parts by weight.

[0062] A propagation system can be used to reproduce soil microbes according to the present disclosure. A propagation system can include one or more vessels that are adapted to expose a propagation media to conditions suitable for reproducing soil microbes. As used herein, a “vessel” refers to any vessel that permits soil microbes to reproduce. Non-limiting examples of vessels that can expose a propagation media to propagation conditions include propagation tanks and the like. Two or more vessels may be arranged in any desired configuration such as parallel or series.

[0063] A propagation system is configured to expose propagation media to propagation conditions to reproduce one or more types of soil microbes in the propagation media to form a microbial composition. Propagation conditions include one or more conditions such as pH, time, temperature, aeration, stirring, and the like.

[0064] As mentioned above, the number of microbes in a propagation media can increase due to propagation as compared to an inoculum introduced to the propagation media. Depending on the microbe or microbes selected for propagation, the number of microbes in a microbial composition is at least 200 times greater, at least 1000 times greater, at least 2000 times greater, least 3000 times greater, or even at least 10,000 times greater as compared to an inoculum introduced to the propagation media.

[0065] In some embodiments, the cell density of microbes is 1x10^A7 cells per milliliter of microbial composition or more, 5X10^A7 cells per milliliter of microbial composition or more, 1X10^A8 cells per milliliter of microbial composition or more, 5X10^A8 cells per milliliter of microbial composition or more, or even 1x10^A9 cells per milliliter of microbial composition or more.

[0066] In some embodiments, a propagation system is co-located with the bioprocessing facility and in fluid communication with the bioprocessing facility to receive at least a portion of at least one bioprocessing facility composition.

[0067] The pH of a propagation media during propagation can be selected based on, e.g., the microbes being reproduced. For example, one or more soil microbes prefer neutral to alkaline conditions. In some embodiments, the pH of a propagation media is greater than 6, e.g., from 6 to 9, from 6.5 to 8, or even from 6.5 to 7.5. The pH of the propagation media can be adjusted and/or maintained by, e.g., adding one or more acidic materials and/or adding one or more basic materials to the propagation media.

[0068] With respect to temperature and time, the contents of a propagation media can be maintained at a temperature for a time period to facilitate soil microbe propagation to form a desired population. In some embodiments, the temperature of a propagation media can be at a temperature in a range from 20°C to 45°F, from 25°C to 40°C, or even from 30°C to 40°C. In some embodiments, propagation can occur for a time period up to 72 hours, e.g., from 1 hour to 48 hours, from 2 hours to 48 hours, or even from 10 hours to 30 hours.

[0069] Propagation can be performed under aerobic conditions. Aerobic conditions means that propagation is performed with intentional introduction of one or more oxygen-containing gasses (“aeration”) to create an aerobic environment suitable for propagation so that oxygen can be consumed by one or more soil microbes and selectively favor an aerobic metabolic pathway as compared to an anaerobic pathway. A propagation system may incorporate aeration by including one or more blowers, spargers, gas compressors, mixing devices, and the like, that are in fluid communication with one or more propagation vessels and that can introduce an oxygen-containing gas (e.g., air) into a propagation media during at least a portion of propagation. For example, an oxygen-containing gas can be sparged into a propagation media so that the gas bubbles up and through the propagation media and oxygen transfers into the propagation media. As another example, an oxygen-containing gas can be introduced into the headspace of a propagation tank so that the gas diffuses into the propagation media.

[0070] Optionally, in addition to aeration, a propagation media can be agitated or mixed to facilitate transferring oxygen into and throughout the propagation media so as to achieve an aerobic enviromnent. For example, a continuous stirred tank reactor (CSTR) can be used as a propagation vessel to agitate or mix the propagation media. The speed of the stirring mechanism (rpms) can be adjusted based on a variety of factors such as tank size, slurry viscosity, and the like. As mentioned above, in addition to mixing the contents of a vessel, mixing can be selected, if desired, to intentionally incorporate oxygen to a propagation media to facilitate propagation.

[0071 ] A propagation system can be operated according to batch, fed-batch, or continuous propagation (continuous feed and discharge from a vessel such as a propagation tank.

[0072] Applying soil microbes to soil may be performed one or more times per year. For example, once in the spring and once in the fall. In light of this, a propagation system for soil microbial propagation can be operated intermittently on an as-needed basis. In some embodiments, a propagation system configured for soil microbial propagation can be designed to be modular so that it can be shared among two or more bioprocessing facilities throughout the year. Also, a propagation system configured for soil microbial propagation can be adapted to tie into one or more piping systems at a bioprocessing facility to receive at least a portion of a stillage composition, an anaerobic digestion digestate composition, a bioash composition, and combinations thereof.

[0073] After propagation, a microbial composition can be directly applied to soil for soil health purposes and growing plants or a microbial composition can be further processed and/or modified prior to being applied to soil. For example, a microbial composition can be further processed by being exposed to one or more separation techniques to concentrate soil microbes. In some embodiments, a separation system can be configured to separate at least a portion of liquid from the microbial composition to concentrate the soil microbes in the microbial composition. A separation system according to the present disclosure can separate at least a portion of liquid from a microbial composition using one or more of distillation, evaporation, separation based on particle size (e.g., filtration), or separation based on density (e.g., centrifugation). In some embodiments, a separation system can include one or more centrifuges (e.g., two-phase vertical disk stack centrifuge, three-phase vertical disk stack centrifuge, filtration centrifuge), one or more decanters (e.g., filtration decanters), one or more filters (e.g., fiber filter, rotary vacuum drum filter, filter device having one or more membrane filters), one or more screens (e.g., a “DSM” screen, which refers to a Dutch State Mines screen or sieve bend screen, and is a curved concave wedge bar type of stationary screen; a pressure screen; paddle screen; rotary drum screen; centrifugal screener; linear motion screen; vacu-deck screen; etc.), one or more brush strainers, one or more vibratory separators, one or more hydrocyclones, one or more presses, combinations of these and the like. Multiple separation systems can be used together and arranged in a parallel and/or series configuration. If desired, a separation system can include one or more evaporators and/or one or more dryers to further concentrate an output stream from any of the devices just mentioned.

[0074] In some embodiments, if liquid is separated from a microbial composition, at least a portion of the separated liquid may be recycled to one or more locations in a bioprocessing facility and/or to the propagation system as a diluent to help form propagation media. Nonlimiting examples of locations in a bioprocessing facility that may benefit from receiving separated liquid include a slurry tank, a fermentation vessel (fermentor), and/or a beer well in the front-end of a dry-grind ethanol bioprocessing facility. Optionally, if desired, the separated liquid portion may be exposed to a heating step to destroy (kill) microbes in the liquid before recycling the liquid.

[0075] As another example, after forming the microbial composition, the microbial composition or concentrated microbial composition may be combined with one or more additional components prior to being applied to soil. For example, microbial composition or concentrated microbial composition may be combined with one or more of at least one bioprocessing facility composition and/or at least one non-bioprocessing facility composition (e.g., commercial fertilizers, etc.). Non-limiting examples of a bioprocessing facility composition that can be added after forming a microbial composition in a propagation system include at least one stillage composition, at least one anaerobic digestion digestate composition, at least one bio-ash composition, and combinations thereof. For example, a bioash composition can be added to provide nutrients for the microbes after being applied to soil and/or nutrients for any plants that may be grown in the soil. As another example, a stillage composition such as syrup can be added to increase the carbon content as an energy source for microbes after being applied to soil.

[0076] A microbial composition and/or concentrated microbial composition can be applied to soil and/or plant foliage in a liquid form using a wide variety of liquid fertilizer spray or drip applicators, liquid manure spreaders, and the like.

[0077] In some embodiments, a microbial composition and/or concentrated microbial composition can be used to treat seeds prior to planting the seeds in soil. Treating seeds with microbial composition and/or concentrated microbial composition can advantageously provide an efficient technique for delivering microbes to soil so that the microbes can successfully colonize and benefit the growth of plants.

[0078] For example, a microbial composition and/or concentrated microbial composition can be used to coat seeds prior to planting the seeds in soil. For example, a mixture that includes one or more types of soil microbes can be applied onto the surface of seeds to help precisely deliver the soil microbes and/or one or more of seed appearance, handling characteristics (e.g., seed weight, shape, and/or size), and/or delivering compounds (e.g., plant growth regulators and/or nutrients) at the seed/soil interface to help protect the seed against phytopathogens, increase germination, plant yield, and/or plant growth.

[0079] A coating material can include at least a microbial composition and/or concentrated microbial composition. In some embodiments, a coating can also include at least one binder. A binder can help adhere the coating to the seed and/or reduce the tendency to form dust. A binder can be natural and/or synthetic. Non-limiting examples of binder that can be used in a seed coating include methyl cellulose, carboxymethyl cellulose, gum arabic, xanthan gum, polysaccharide, at least one stillage composition, at least one anaerobic digestion digestate composition, at least one bio-ash composition, and combinations thereof.

[0080] A coating material can also include one or more fillers to function as a bulking agent to extend the survival of soil microbes. Non-limiting examples of filler include peat, talc, lime, biochar, alginate, chitosan, and the like.

[0081] A method of coating a seed includes covering at least a portion of the seed surface with a coating, which can be in solid form or a liquid form containing dissolved and/or suspended solids. Tn some embodiments, a coating can form approximately a continuous layer. In some embodiments, a continuous layer can form a physical barrier.

[0082] Non-limiting seed coating techniques include seed dressing, film coating, pelleting, combinations of these, and the like.

[0083] Seed dressing involves dusting a powder onto the surface of the seeds.

[0084] Film coating involves applying a thin layer of coating to the surface of seed with relatively little change in the shape, size, and weight of the coated seed as compared to the uncoated seed. For example, seeds can be spun in a hopper in a manner that causes the seeds to tumble or roll while dispensing a liquid (e.g., spraying a mist) onto the seeds as they tumble and rotate, thereby causing a thin coating to be formed on the surface of the seeds. [0085] Another example treating seeds with a microbial composition and/or concentrated microbial composition prior to planting the seeds in soil includes immersion of seeds in a microbial composition and/or concentrated microbial composition (seed soaking).

[0086] Seeds that can be treated with a microbial composition and/or concentrated microbial composition include any seed for an agricultural crop. Non-limiting examples of agricultural crop seeds include beet seeds, sugar cane seeds, grain seeds, legume seeds, com seeds, sorghum seeds, wheat seeds, rice seeds, barley seeds, soybean seeds, rapeseed seeds, oat seeds, millet seeds, rye seeds, combinations thereof, and the like.

[0087] Seeds treated with a microbial composition and/or concentrated microbial composition can be planted in soil using any desired technique. Non-limiting examples of commercial seed planting equipment that can be used include broadcast seeders, air seeders, box drill seeders, planters, and the like.

[0088] In some embodiments, the microbial composition or concentrated microbial composition may be combined with one or more additional components to form pellets prior to being applied to soil. Non-limiting examples of equipment that can be used to form pellets include a cement mixer, a fluidized bed, an agglomerator (rotating drum), a pan granulator, and the like. FIG. 2 shows an example of a pan granulator (also known as a disc pelletizer) that can be used to make pellets. A pan granulator is a type of agitation agglomeration equipment that can form pellets via tumble growth.

[0089] Referring to FIG. 2, a pan 202 is tiltably and rotatably mounted on base 201. Pan 202 has an inner side surface 203, an inner bottom surface 208 and a chamfer 204 between the inner side surface and the inner bottom surface. Frame 205 is supported above pan 202. An arm 206 (scraper or plow) is a vane-type component that can control the material layer as it tumbles over the bottom surface of pan 202. As shown, arm 206 is adjustable by being movable about pin 210. Motor (not shown) can cause pan 202 to rotate so that cause material to form pellets via tumble growth as pan 202 rotates. For illustration purposes, using the pan agglomerator shown in FIG. 2 to make pellets including a microbial composition will be described in the context of coating seeds. However, pellets including a microbial composition could be made without seeds (e.g., fertilizer pellets). Referring back to FIG. 2, seeds and seed coating material (e.g., microbial composition, binder, filler, etc.) can be fed onto the pan 202 as it rotates, thereby causing the materal to tumble and grow to form pellets. The arm 206 helps to remove buildup on the ban bottom and directs the pellets into separate streams as they grow in size. Eventually, the pellets grow to a size that causes them to exit over the side of the pan for collection. Pellet size can be controlled by adjusting the arm spacing from the inner bottom surface, the pan slope angle, rotation speed, time, moisture, temperature and feed rate of material onto the pan. Pelleting can form coated seeds as discrete units (pellets) having a noticeable change the shape, size, and/or weight of the coated seed as compared to the uncoated seed.

[0090] As mentioned above, in some embodiments, a propagation system can be co-located with a bioprocessing facility and in fluid communication with the bioprocessing facility to receive at least a portion of at least one bioprocessing facility composition. A non-limiting example is shown in FIG. 1. In more detail, FIG. 1 illustrates a method 100 of reproducing one or more types of soil microbes using a bioprocessing facility 102 that is co-located with a propagation system 122. Bioprocessing facility 102 is illustrated as a dry-grind com ethanol bioprocessing facility. Method 100 includes isolating one or more types of soil microbes 116 from soil that is used to grow biomass feedstock 117 shown as com grain from com plants 114. The biomass feedstock 117 is used in bioprocessing facility 102 to produce bioprocessing facility compositions. As shown in FIG. 1, the bioprocessing facility compositions derived from biomass feedstock 1 17 include bioethanol 104, com oil 106, DDGS 108, thin stillage and/or condensed thin stillage (syrup) 110, and supplemental sugar 112. In some embodiments, as shown in FIG. 1, bioprocessing facility 102 can include a feedstock system 111 configured to produce a stream that includes supplemental sugar 1 12 and/or supplemental starch.

[0091] The propagation system 122 is configured to form a propagation media from the soil microbes 116 that are isolated, thin stillage and/or condensed thin stillage (syrup) 110, and/or supplemental sugar 112. Propagation system 122 is illustrated as a propagation tank (bioreactor) that is co-located (integrated) with the bioprocessing facility 102. As shown, the bioreactor is in fluid communication with the bioprocessing facility 102 to receive thin stillage and/or condensed thin stillage (syrup) 110, and/or supplemental sugar 112 and reproduce the soil microbes to form a microbial composition.

[0092] As shown in FIG. 1 , microbial composition 123 discharged from the propagation system 122 can pass through a solid/liquid separator 124 to separate liquid 128 from the microbial composition 123. If desired, the liquid 128 can be used in bioprocessing facility 102 (e.g., returned to a beer well after fermentation). Optionally, the liquid 128 can be heated, e.g. in heat-exchanger 130, to destroy any soil microbes present in liquid 128 before introducing liquid 128 into a process stream in bioprocessing facility 102.

[0093] A fertilizer composition production system 145 that is co-located with the bioprocessing facility 102 can be configured to form a fertilizer composition 146. A shown in FIG. 1, fertilizer composition production system 145 receives and mixes microbial composition 123 and bio-ash composition 144 to form fertilizer composition 146, which can be applied to soil for growing com plants 114. As shown in FIG. 1, bio-ash composition 144 is com-stover ash, which can be formed at a thermal energy generating system 140 such as a solid fuel boiler. Thermal generating system 140 can be configured to generate thermal energy 142 for the bioprocessing facility 102 and produce a bio-ash composition 144 via a combustion process such as the combustion of corn stover 120.

[0094] FIG. 3 A illustrates an example of a dry-grind com ethanol bioprocessing facility 300 as an example of a bioprocessing facility 102 that can be co-located with a propagation system 122 according to the present disclosure. FIG. 3 A illustrates an example of dry-grind com ethanol bioprocessing facility 300 that produces stillage compositions described above. The bioprocessing facility 300 includes a “front end” and a “back end.” The front end includes distillation 305 and upstream from distillation 305. As shown in FIG. 3A, the front end starts with adding ground corn and water 301 to a slurry tank 302, which is fed to a fermentation system 303 that ferments sugars into a beer that includes ethanol and carbon dioxide. Beer is transferred to a beer well 304 and eventually to a distillation system 305 where ethanol 307 is separated from beer to form whole stillage 306.

[0095] Whole stillage 306 is fed to decanter 330 to separate whole stillage 306 into wet cake 332 and thin stillage 355. The wet cake 332 and syrup 359 is dried in dryer system 360 to form dried distillers’ grain with solubles (DDGS).

[0096] A portion 326 of the thin stillage 355 is transferred to the slurry tank 302 as backset, while the rest 327 of the thin stillage 355 is transferred to an evaporation train 329 that may include 4 to 8 evaporators in series (depending on plant size) to remove water and form syrup 359. Prior to reaching the end of the evaporator train 329, a semi-concentrated syrup (“skim feed”) 371 is removed and sent to com oil separation system 370 which removes com oil product 392.

[0097] The com oil separation system 370 is described in more detail using FIG. 3B. As shown in FIG. 3B, the skim feed 371 is separated in a “skim” centrifuge 373 into an emulsion 378 and defatted syrup 374. The defatted syrup 374 can accumulate in defatted syrup tank 375 and defatted syrup 374 is eventually returned to the evaporator train 329 via pump 377, where a final syrup 359 is sent to dryer 360 to form DDGS 361 as shown in FIG. 3A. The emulsion 378 is combined with caustic 382 in emulsion tank 380 to help “break” the emulsion into an oil phase and aqueous phase that are more easily separated from each other. The treated emulsion 384 is pumped via pump 383 to oil centrifuge 386, wherein the treated emulsion 384 is separated into a com oil product 392 and defatted emulsion 388. The defatted emulsion 388 can accumulate in defatted emulsion tank 389 and defatted emulsion 388 can be pumped via pump 390 to any desired location. The skim centrifuge 371 and oil centrifuge 386 can be disk-stack centrifuges. EXAMPLES

Example 1

[0098] Example 1 demonstrates that a soil microbe such as Bacillus subtilis can be propagated on bioprocessing facility compositions such as defatted syrup (DFS) or a supplemental sugar composition from a dry-grind com ethanol bioprocessing facility. The Bacillus subtilis used was the strain B-4219 (catalog code B-4219), which was obtained from Agricultural Research Service culture collection.

[0099] In one set of experiments, Bacillus subtilis was combined with DFS only or DFS (as a primary carbon source) and varying amounts of a bio-ash composition (as a primary nutrient source) formed from corn stover to form a propagation media. After combining, the media was exposed to a temperature of 37°C for 16 hours. Then a series of dilutions up to 10⁸ were made and plated on YPD plates. These plates were placed in a shaker at 37°C for 16 hours to observe growth and count the colonies. As shown in Table 2 below, Bacillus subtilis could be successfully propagated on DFS and DFS plus com stover ash.

[00100] In another set of experiments, Bacillus subtilis was combined with supplemental sugar only or supplemental sugar (as a primary carbon source) and varying amounts of a bio-ash composition (as a primary nutrient source) formed from com stover to fomi a propagation media. After combining, the media was exposed to a temperature of 37°C for 16 hours. Then a series of dilutions up to 10⁸ were made and plated on YPD plates. These plates were placed in a shaker at 37°C for 16 hours to observe growth and count the colonies. As shown in Table 2 below, Bacillus subtilis could be successfully propagated on supplemental sugar and supplemental sugar plus corn stover ash.

Table 2

Example 2

[00101] Example 2 demonstrates that a soil microbe such as Bacillus subtilis can be propagated on defatted syrup (DFS) from two different dry-grind com ethanol bioprocessing facilities. The Bacillus subtilis used was the strain B-4219 (catalog code B-4219), which was obtained from Agricultural Research Service culture collection.

[00102] Bacillus subtilis was combined with DFS only or DFS (as a primary carbon source) to form a propagation media. After combining, the media was exposed to a temperature of 37°C for 16 hours. Then a series of dilutions up to 10⁸ were made and plated on YPD plates. These plates were placed in the shaker at 37°C for 16 hours to observe growth and count the colonies. As shown in Table 3 below, Bacillus subtilis could be successfully propagated on DFS from each dry-grind com ethanol bioprocessing facility. Table 3

Claims

WHAT IS CLAIMED IS:

1 . A method of reproducing one or more types of soil microbes, wherein the method comprises reproducing the one or more types of soil microbes in a propagation media to form a microbial composition, wherein the propagation media is formed from at least one bioprocessing facility composition.

2. The method of claim 1, wherein the one or more types of soil microbes are chosen from bacteria (e.g., bacteria that are rich in nitrogen, nitrogen-mineralization bacteria, nitrogenfixing bacteria (e.g., Azopbacter, Azospirillum, Rhizobia, Cyanobacteria, and combinations thereof), bacteria (e.g., Actinomycetes) that break down organic matter (e.g., lignin), bacteria that dissolve or solubilize phosphorus so that is available for use by plants, bacteria (e.g., Acidithiobacillus) that dissolve potassium so that is available for use by plants), fungi (e.g., Mychorrhizal fungi), and combinations thereof.

3. The method of any preceding claim, wherein the at least one bioprocessing facility composition is chosen from at least one stillage composition, at least one anaerobic digestion digestate composition, at least one bio-ash composition, and combinations thereof.

4. The method of any preceding claim, wherein the at least one bioprocessing facility composition further comprises a supplemental sugar composition having at least 0.1% sugar by weight of the supplemental sugar composition.

5. The method of any preceding claim, further comprising applying at least a portion of the microbial composition to soil.

6. The method of any preceding claim, further comprising separating at least a portion of liquid from the microbial composition.

7. The method of claim 6, further comprising using at least a portion of the liquid in a bioprocessing facility.

8. The method of any preceding claim, further comprising, after forming the microbial composition, combining at least a portion of the microbial composition with at least one bioprocessing facility composition.

9. The method of any preceding claim, further comprising isolating at least one of the one or more types of soil microbes from soil that is used to grow biomass feedstock that is used in a bioprocessing facility to produce the at least one bioprocessing facility composition.

10. The method of claim 9, wherein the soil that is used to grow biomass feedstock is 300 miles or less from the bioprocessing facility.

11. The method of any preceding claim, further comprising treating agricultural seed with the microbial composition prior to planting the agricultural seed in soil (e.g., coating agricultural seed with microbial composition).

12. The method of any preceding claim, further comprising applying at least a portion of the microbial composition to soil.

13. The method of any preceding claim, wherein the at least one bioprocessing facility composition comprises at least one stillage composition.

14. The method of any preceding claim, wherein the at least one bioprocessing facility composition comprises at least one bio-ash composition.

15. The method of any preceding claim, wherein the at least one bioprocessing facility composition comprises at least one stillage composition and at least one bio-ash composition, wherein the at least one stillage composition is chosen from thin stillage, syrup, defatted syrup, defatted emulsion, and combinations thereof, and wherein the at least one bio-ash composition is formed by combustion of com stover.

16. The method of claim 15, wherein a weight ratio of the at least one stillage composition to the at least one bio-ash composition in the propagation media is 0.5 or less.

17. A facility comprising: a bioprocessing facility configured to generate at least one bioprocessing facility composition; and a propagation system that is co-located with the bioprocessing facility and configured to receive at least a portion of the at least one bioprocessing facility composition, wherein the propagation system is configured to form a propagation media from the at least a portion of the at least one bioprocessing facility composition, and reproduce one or more types of soil microbes in the propagation media to form a microbial composition.

18. The facility of claim 17, further comprising at least one thermal energy generating system configured to generate thermal energy for the bioprocessing facility and produce a bio-ash composition via a combustion process, wherein the bioprocessing facility is configured to use at least a portion of the thermal energy in one or more systems in the bioprocessing facility, and wherein the at least one bioprocessing facility composition comprises bio-ash composition.

19. The facility of any preceding claim, further comprising a fertilizer composition production system that is co-located with the bioprocessing facility, wherein the fertilizer composition production system is configured to receive at least a portion of the at least one bioprocessing facility composition, and wherein the fertilizer composition production system is configured to mix the at least a portion of microbial composition and at least a portion of the at least one bioprocessing facility composition to form a fertilizer composition.

20. The facility of any preceding claim, further comprising a feedstock system configured to form at least one stream from grain feedstock, wherein the at least one stream comprises supplemental sugar and/or supplemental starch, and wherein the at least one stream is in fluid communication with the propagation system to form the propagation media.