Saturating wood particles with HCl gas under pressure was found to be an effective pretreatment prior to subjecting wood to dilute acid hydrolysis. Pretreament is necessary to release sugars from wood because of the tight lattice structure of cellulose. The HCl gas makes the cellulose more susceptible to subsequent acid hydrolysis and the glucose yield is doubled when dilute acid hydrolysis is preceded by HCl saturation at high pressure. The saturation was most effectively performed in a fluidized bed reactor, with pure HCl gas fluidizing an equal volume of ground wood plus inert particles. The fluidized bed effectively dissipated the large amount of heat released upon HCl absorption into the wood. Batch reaction times of 1 h at 315 psia gave glucose yields of 80 degrees and xylose yields of 95 degrees after dilute acid hydrolysis. A model was developed which proposed gas diffusing through the solid as limiting the reaction rate and this was found to effectively describe the HCl-wood reaction in the fluidized bed. The HCl was found to form a stable adduct with the lignin residue in the wood, in a ratio of 3.33 mole of lignin monomer. The adduct was broken upon the addition of water.

A range of cellulosic raw materials in the form of agricultural crop residue was analyzed for chemical composition and assessed for potential yields of sugars through chemical pretreatment and enzymatic hydrolysis of these materials. Corn stover was used as a representative raw material for a preliminary process design and economic assessment of the production of sugars and ethanol. With the process as presently developed, 24 gal ethanol can be obtained per ton of corn stover at a processing cost of about $1.80/gal exclusive of by‐product credits. The analysis shows the cost of ethanol to be highly dependent upon: (1) the cost of the biomass, (2) the extent of conversion to glucose, (3) enzyme recovery and production cost, and (4) potential utilization of xylose. Significant cost reduction appears possible through further research in these directions.

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