Amit A. Gokhale

Novel pathways for fuels and lubricants from biomass optimized using life-cycle greenhouse gas assessment

Significance The development of renewable liquid fuels and bioproducts is critical to reducing global reliance on petroleum and mitigating climate change, particularly for applications where few low-carbon alternatives exist. We combine chemical catalysis with life-cycle greenhouse gas (GHG) modeling to create a new platform for producing biobased aviation fuel and automotive lubricant base oils. The recyclable catalysts we developed are capable of converting sugar and biomass-derived alkyl methyl ketones into cyclic enones via condensation reactions. These products can subsequently be hydrodeoxygenated to create a new class of aviation fuel and lubricant candidates with superior cold flow properties, density, and viscosity that substantially reduce GHG emissions relative to conventional petroleum. Decarbonizing the transportation sector is critical to achieving global climate change mitigation. Although biofuels will play an important role in conventional gasoline and diesel applications, bioderived solutions are particularly important in jet fuels and lubricants, for which no other viable renewable alternatives exist. Producing compounds for jet fuel and lubricant base oil applications often requires upgrading fermentation products, such as alcohols and ketones, to reach the appropriate molecular-weight range. Ketones possess both electrophilic and nucleophilic functionality, which allows them to be used as building blocks similar to alkenes and aromatics in a petroleum refining complex. Here, we develop a method for selectively upgrading biomass-derived alkyl methyl ketones with >95% yields into trimer condensates, which can then be hydrodeoxygenated in near-quantitative yields to give a new class of cycloalkane compounds. The basic chemistry developed here can be tailored for aviation fuels as well as lubricants by changing the production strategy. We also demonstrate that a sugarcane biorefinery could use natural synergies between various routes to produce a mixture of lubricant base oils and jet fuels that achieve net life-cycle greenhouse gas savings of up to 80%.

Upgrading Lignocellulosic Products to Drop‐In Biofuels via Dehydrogenative Cross‐Coupling and Hydrodeoxygenation Sequence

Life-cycle analysis (LCA) allows the scientific community to identify the sources of greenhouse gas (GHG) emissions of novel routes to produce renewable fuels. Herein, we integrate LCA into our investigations of a new route to produce drop-in diesel/jet fuel by combining furfural, obtained from the catalytic dehydration of lignocellulosic pentose sugars, with alcohols that can be derived from a variety of bio- or petroleum-based feedstocks. As a key innovation, we developed recyclable transition-metal-free hydrotalcite catalysts to promote the dehydrogenative cross-coupling reaction of furfural and alcohols to give high molecular weight adducts via a transfer hydrogenation-aldol condensation pathway. Subsequent hydrodeoxygenation of adducts over Pt/NbOPO4 yields alkanes. Implemented in a Brazilian sugarcane biorefinery such a process could result in a 53-79% reduction in life-cycle GHG emissions relative to conventional petroleum fuels and provide a sustainable source of low carbon diesel/jet fuel.

From Sugars to Wheels: The Conversion of Ethanol to 1,3‐Butadiene over Metal‐Promoted Magnesia‐Silicate Catalysts

1,3-Butadiene (1,3-BD) is a high-value chemical intermediate used mainly as a monomer for the production of synthetic rubbers. The ability to source 1,3-BD from biomass is of considerable current interest because it offers the potential to reduce the life-cycle greenhouse gas (GHG) impact associated with 1,3-BD production from petroleum-derived naphtha. Herein, we report the development and investigation of a new catalyst and process for the one-step conversion of ethanol to 1,3-BD. The catalyst is prepared by the incipient impregnation of magnesium oxide onto a silica support followed by the deposition of Au nanoparticles by deposition-precipitation. The resulting Au/MgO-SiO2 catalyst exhibits a high activity and selectivity to 1,3-BD and low selectivities to diethyl ether, ethylene, and butenes. Detailed characterization of the catalyst shows that the desirable activity and selectivity of Au/MgO-SiO2 are a consequence of a critical balance between the acidic-basic sites associated with a magnesium silicate hydrate phase and the redox properties of the Au nanoparticles. A process for the conversion of ethanol to 1,3-BD, which uses our catalyst, is proposed and analyzed to determine the life-cycle GHG impact of the production of this product from biomass-derived ethanol. We show that 1,3-BD produced by our process can reduce GHG emissions by as much as 155 % relative to the conventional petroleum-based production of 1,3-BD.

Role of lignin in reducing life-cycle carbon emissions, water use, and cost for United States cellulosic biofuels.

Cellulosic ethanol can achieve estimated greenhouse gas (GHG) emission reductions greater than 80% relative to gasoline, largely as a result of the combustion of lignin for process heat and electricity in biorefineries. Most studies assume lignin is combusted onsite, but exporting lignin to be cofired at coal power plants has the potential to substantially reduce biorefinery capital costs. We assess the life-cycle GHG emissions, water use, and capital costs associated with four representative biorefinery test cases. Each case is evaluated in the context of a U.S. national scenario in which corn stover, wheat straw, and Miscanthus are converted to 1.4 EJ (60 billion liters) of ethanol annually. Life-cycle GHG emissions range from 4.7 to 61 g CO2e/MJ of ethanol (compared with ∼ 95 g CO2e/MJ of gasoline), depending on biorefinery configurations and marginal electricity sources. Exporting lignin can achieve GHG emission reductions comparable to onsite combustion in some cases, reduce life-cycle water consumption by up to 40%, and reduce combined heat and power-related capital costs by up to 63%. However, nearly 50% of current U.S. coal-fired power generating capacity is expected to be retired by 2050, which will limit the capacity for lignin cofiring and may double transportation distances between biorefineries and coal power plants.

Novel Strategies for the Production of Fuels, Lubricants, and Chemicals from Biomass

Growing concern with the environmental impact of CO2 emissions produced by combustion of fuels derived from fossil-based carbon resources has stimulated the search for renewable sources of carbon. Much of this focus has been on the development of methods for producing transportation fuels, the major source of CO2 emissions today, and to a lesser extent on the production of lubricants and chemicals. First-generation biofuels such as bioethanol, produced by the fermentation of sugar cane- or corn-based sugars, and biodiesel, produced by the transesterification reaction of triglycerides with alcohols to form a mixture of long-chain fatty esters, can be blended with traditional fuels in limited amounts and also arise in food versus fuel debates. Producing molecules that can be drop-in solutions for fossil-derived products used in the transportation sector allows for efficient use of the existing infrastructure and is therefore particularly interesting. In this context, the most viable source of renewable carbon is abundantly available lignocellulosic biomass, a complex mixture of lignin, hemicellulose, and cellulose. Conversion of the carbohydrate portion of biomass (hemicellulose and cellulose) to fuels requires considerable chemical restructuring of the component sugars in order to achieve the energy density and combustion properties required for transportation fuels-gasoline, diesel, and jet. A different set of constraints must be met for the conversion of biomass-sourced sugars to lubricants and chemicals. This Account describes strategies developed by us to utilize aldehydes, ketones, alcohols, furfurals, and carboxylic acids derived from C5 and C6 sugars, acetone-butanol-ethanol (ABE) fermentation mixtures, and various biomass-derived carboxylic acids and fatty acids to produce fuels, lubricants, and chemicals. Oxygen removal from these synthons is achieved by dehydration, decarboxylation, hydrogenolysis, and hydrodeoxygenation, whereas reactions such as aldol condensation, etherification, alkylation, and ketonization are used to build up the number of carbon atoms in the final product. We show that our strategies lead to high-octane components that can be blended into gasoline, C9-C22 compounds that possess energy densities and properties required for diesel and jet fuels, and lubricants that are equivalent or superior to current synthetic lubricants. Replacing a fraction of the crude-oil-derived products with such renewable sources can mitigate the negative impact of the transportation sector on overall anthropogenic greenhouse gas (GHG) emissions and climate change potential. While ethanol is a well-known fuel additive, there is significant interest in using ethanol as a platform molecule to manufacture a variety of valuable chemicals. We show that bioethanol can be converted with high selectivity to butanol or 1,3-butadiene, providing interesting alternatives to the current production from petroleum. Finally, we report that several of the strategies developed have the potential to reduce GHG emissions by 55-80% relative to those for petroleum-based processes.

Production of renewable lubricants via self-condensation of methyl ketones

Self-condensation of biomass-derived methyl ketones catalyzed by solid bases or acids produces corresponding cyclic trimers exclusively in excellent yields. Condensates containing 24–45 carbon atoms are shown to be suitable lubricant base-oils after the removal of residual unsaturation and oxygen. Properties of cycloalkanes produced from biomass are very similar to those of conventional lubricant base-oils. The process reported here offers an environmentally benign alternative to the current non-selective production of lubricant base-oils from α-olefins, and avoids the production of corrosive waste products.

Production of Biomass-Based Automotive Lubricants by Reductive Etherification

Growing concern with the effects of CO2 emissions due to the combustion of petroleum-based transportation fuels has motivated the search for means to increase engine efficiency. The discovery of ethers with low viscosity presents an important opportunity to improve engine efficiency and fuel economy. We show here a strategy for the catalytic synthesis of such ethers by reductive etherification/O-alkylation of alcohols using building blocks that can be sourced from biomass. We find that long-chain branched ethers have several properties that make them superior lubricants to the mineral oil and synthetic base oils used today. These ethers provide a class of potentially renewable alternatives to conventional lubricants produced from petroleum and may contribute to the reduction of greenhouse gases associated with vehicle emissions.

ABE Condensation over Monometallic Catalysts: Catalyst Characterization and Kinetics

Herein, we present work on the catalyst development and the kinetics of acetone‐butanol‐ethanol (ABE) condensation. After examining multiple combinations of metal and basic catalysts reported in the literature, Cu supported on calcined hydrotalcites (HT) was found to be the optimal catalyst for the ABE condensation. This catalyst gave a six‐fold increase in reaction rates over previously reported catalysts. Kinetic analysis of the reaction over CuHT and HT revealed that the rate‐determining step is the C−H bond activation of alkoxides that are formed from alcohols on the Cu surface. This step is followed by the addition of the resulting aldehydes to an acetone enolate formed by deprotonation of the acetone over basic sites on the HT surface. The presence of alcohols reduces aldol condensation rates, as a result of the coverage of catalytic sites by alkoxides.

Integrated catalytic sequences for catalytic upgrading of bio-derived carboxylic acids to fuels, lubricants and chemical feedstocks

In the late 1850s, Charles Friedels dry distillation of calcium acetate gave the world a novel route to the commercial production of acetone, a process that would later be referred to as decarboxylative dehydration (ketonization). While the subsequent development of the petrochemical industry made this route to acetone uncompetitive, today there is considerable interest in ketonization as means for converting biomass-derived fatty acids to produce longer-chained ketones, which could serve as precursors to fuels and lubricants. However, the lack of strategies beyond direct hydrogenation of the ketones into hydrocarbons has limited the practical application of ketonization for producing biofuels. We describe here integrated catalytic sequences for converting a range of biomass-derived carboxylic acids, sourced through fermentation of sugars, hydrolysis of lipids, or biomass pyrolysis, to compounds that are fully compatible with the existing energy infrastructure and require minimal hydrogen input.

Correction: Novel pathways for fuels and lubricants from biomass optimized using life-cycle greenhouse gas assessment (Proceedings of the National Academy of Sciences of the United States of America (2015) 112, 25 (7645-7649) DOI: 10.1073/pnas.1508274112)

Author(s): Balakrishnan, M; Sacia, ER; Sreekumar, S; Gunbas, G; Gokhale, AA; Scown, CD; Toste, FD; Bell, AT