Mary J. Biddy

Lignin Valorization: Improving Lignin Processing in the Biorefinery

Background Lignin, nature’s dominant aromatic polymer, is found in most terrestrial plants in the approximate range of 15 to 40% dry weight and provides structural integrity. Traditionally, most large-scale industrial processes that use plant polysaccharides have burned lignin to generate the power needed to productively transform biomass. The advent of biorefineries that convert cellulosic biomass into liquid transportation fuels will generate substantially more lignin than necessary to power the operation, and therefore efforts are underway to transform it to value-added products. Production of biofuels from cellulosic biomass requires separation of large quantities of the aromatic polymer lignin. In planta genetic engineering, enhanced extraction methods, and a deeper understanding of the structure of lignin are yielding promising opportunities for efficient conversion of this renewable resource to carbon fibers, polymers, commodity chemicals, and fuels. [Credit: Oak Ridge National Laboratory, U.S. Department of Energy] Advances Bioengineering to modify lignin structure and/or incorporate atypical components has shown promise toward facilitating recovery and chemical transformation of lignin under biorefinery conditions. The flexibility in lignin monomer composition has proven useful for enhancing extraction efficiency. Both the mining of genetic variants in native populations of bioenergy crops and direct genetic manipulation of biosynthesis pathways have produced lignin feedstocks with unique properties for coproduct development. Advances in analytical chemistry and computational modeling detail the structure of the modified lignin and direct bioengineering strategies for targeted properties. Refinement of biomass pretreatment technologies has further facilitated lignin recovery and enables catalytic modifications for desired chemical and physical properties. Outlook Potential high-value products from isolated lignin include low-cost carbon fiber, engineering plastics and thermoplastic elastomers, polymeric foams and membranes, and a variety of fuels and chemicals all currently sourced from petroleum. These lignin coproducts must be low cost and perform as well as petroleum-derived counterparts. Each product stream has its own distinct challenges. Development of renewable lignin-based polymers requires improved processing technologies coupled to tailored bioenergy crops incorporating lignin with the desired chemical and physical properties. For fuels and chemicals, multiple strategies have emerged for lignin depolymerization and upgrading, including thermochemical treatments and homogeneous and heterogeneous catalysis. The multifunctional nature of lignin has historically yielded multiple product streams, which require extensive separation and purification procedures, but engineering plant feedstocks for greater structural homogeneity and tailored functionality reduces this challenge. The Lignin Landscape Lignin is a chemically complex polymer that lends woody plants and trees their rigidity. Humans have traditionally either left it intact to lend rigidity to their own wooden constructs, or burned it to generate heat and sometimes power. With the advent of major biorefining operations to convert cellulosic biomass into ethanol and other liquid fuels, researchers are now exploring how to transform the associated leftover lignin into more diverse and valuable products. Ragauskas et al. (10.1126/science.1246843) review recent developments in this area, ranging from genetic engineering approaches that tune lignin properties at the source, to chemical processing techniques directed toward extracting lignin in the biorefinery and transforming it into high-performance plastics and a variety of bulk and fine chemicals. Research and development activities directed toward commercial production of cellulosic ethanol have created the opportunity to dramatically increase the transformation of lignin to value-added products. Here, we highlight recent advances in this lignin valorization effort. Discovery of genetic variants in native populations of bioenergy crops and direct manipulation of biosynthesis pathways have produced lignin feedstocks with favorable properties for recovery and downstream conversion. Advances in analytical chemistry and computational modeling detail the structure of the modified lignin and direct bioengineering strategies for future targeted properties. Refinement of biomass pretreatment technologies has further facilitated lignin recovery, and this coupled with genetic engineering will enable new uses for this biopolymer, including low-cost carbon fibers, engineered plastics and thermoplastic elastomers, polymeric foams, fungible fuels, and commodity chemicals.

A perspective on oxygenated species in the refinery integration of pyrolysis oil

Pyrolysis offers a rapid and efficient means to depolymerize lignocellulosic biomass, resulting in gas, liquid, and solid products with varying yields and compositions depending on the process conditions. With respect to manufacture of “drop-in” liquid transportation fuels from biomass, a potential benefit from pyrolysis arises from the production of a liquid or vapor that could possibly be integrated into existing refinery infrastructure, thus offsetting the capital-intensive investment needed for a smaller scale, standalone biofuels production facility. However, pyrolysis typically yields a significant amount of reactive, oxygenated species including organic acids, aldehydes, ketones, and oxygenated aromatics. These oxygenated species present significant challenges that will undoubtedly require pre-processing of a pyrolysis-derived stream before the pyrolysis oil can be integrated into the existing refinery infrastructure. Here we present a perspective of how the overall chemistry of pyrolysis products must be modified to ensure optimal integration in standard petroleum refineries, and we explore the various points of integration in the refinery infrastructure. In addition, we identify several research and development needs that will answer critical questions regarding the technical and economic feasibility of refinery integration of pyrolysis-derived products.

Lignin depolymerisation by nickel supported layered-double hydroxide catalysts

Lignin depolymerisation is traditionally facilitated with homogeneous acid or alkaline catalysts. Given the effectiveness of homogeneous basic catalysts for lignin depolymerisation, here, heterogeneous solid-base catalysts are screened for C–O bond cleavage using a model compound that exhibits a common aryl–ether linkage in lignin. Hydrotalcite (HTC), a layered double hydroxide (LDH), is used as a support material as it readily harbours hydroxide anions in the brucite-like layers, which are hypothesised to participate in catalysis. A 5 wt% Ni/HTC catalyst is particularly effective at C–O bond cleavage of a model dimer at 270 °C without nickel reduction, yielding products from C–O bond cleavage identical to those derived from a base-catalysed mechanism. The 5% Ni-HTC catalyst is shown to depolymerise two types of biomass-derived lignin, namely Organosolv and ball-milled lignin, which produces alkyl-aromatic products. X-ray photoelectron spectroscopy and energy dispersive X-ray spectroscopy show that the nickel is well dispersed and converts to a mixed valence nickel oxide upon loading onto the HTC support. The structure of the catalyst was characterised by scanning and transmission electron microscopy and X-ray diffraction, which demonstrates partial dehydration upon reaction, concomitant with a base-catalysed mechanism employing hydroxide for C–O bond cleavage. However, the reaction does not alter the overall catalyst microstructure, and nickel does not appreciably leach from the catalyst. This study demonstrates that nickel oxide on a solid-basic support can function as an effective lignin depolymerisation catalyst without the need for external hydrogen and reduced metal, and suggests that LDHs offer a novel, active support in multifunctional catalyst applications.

Cellulosic ethanol: status and innovation

Although the purchase price of cellulosic feedstocks is competitive with petroleum on an energy basis, the cost of lignocellulose conversion to ethanol using todays technology is high. Cost reductions can be pursued via either in-paradigm or new-paradigm innovation. As an example of new-paradigm innovation, consolidated bioprocessing using thermophilic bacteria combined with milling during fermentation (cotreatment) is analyzed. Acknowledging the nascent state of this approach, our analysis indicates potential for radically improved cost competitiveness and feasibility at smaller scale compared to current technology, arising from (a) R&D-driven advances (consolidated bioprocessing with cotreatment in lieu of thermochemical pretreatment and added fungal cellulase), and (b) configurational changes (fuel pellet coproduction instead of electricity, gas boiler(s) in lieu of a solid fuel boiler).

Chemicals from Biomass: A Market Assessment of Bioproducts with Near-Term Potential

Production of chemicals from biomass offers a promising opportunity to reduce U.S. dependence on imported oil, as well as to improve the overall economics and sustainability of an integrated biorefinery. Given the increasing momentum toward the deployment and scale-up of bioproducts, this report strives to: (1) summarize near-term potential opportunities for growth in biomass-derived products; (2) identify the production leaders who are actively scaling up these chemical production routes; (3) review the consumers and market champions who are supporting these efforts; (4) understand the key drivers and challenges to move biomass-derived chemicals to market; and (5) evaluate the impact that scale-up of chemical strategies will have on accelerating the production of biofuels.

Single-step syngas-to-distillates (S2D) process based on biomass-derived syngas – A techno-economic analysis

This study compared biomass gasification based syngas-to-distillate (S2D) systems using techno-economic analysis (TEA). Three cases, state of technology (SOT), goal, and conventional, were compared in terms of performance and cost. The SOT case represented the best available experimental results for a process starting with syngas using a single-step dual-catalyst reactor for distillate generation. The conventional case mirrored a conventional two-step S2D process consisting of separate syngas-to-methanol and methanol-to-gasoline (MTG) processes. The goal case assumed the same performance as the conventional, but with a single-step S2D technology. TEA results revealed that the SOT was more expensive than the conventional and goal cases. The SOT case suffers from low one-pass yield and high selectivity to light hydrocarbons, both of which drive up production cost. Sensitivity analysis indicated that light hydrocarbon yield and single pass conversion efficiency were the key factors driving the high cost for the SOT case.

Whole Algae Hydrothermal Liquefaction Technology Pathway

In support of the Bioenergy Technologies Office, the National Renewable Energy Laboratory (NREL) and the Pacific Northwest National Laboratory (PNNL) are undertaking studies of biomass conversion technologies to hydrocarbon fuels to identify barriers and target research toward reducing conversion costs. Process designs and preliminary economic estimates for each of these pathway cases were developed using rigorous modeling tools (Aspen Plus and Chemcad). These analyses incorporated the best information available at the time of development, including data from recent pilot and bench-scale demonstrations, collaborative industrial and academic partners, and published literature and patents. This pathway case investigates the feasibility of using whole wet microalgae as a feedstock for conversion via hydrothermal liquefaction. Technical barriers and key research needs have been assessed in order for the hydrothermal liquefaction of microalgae to be competitive with petroleum-derived gasoline, diesel and jet range blendstocks.

A low-cost solid–liquid separation process for enzymatically hydrolyzed corn stover slurries

Solid-liquid separation of intermediate process slurries is required in some process configurations for the conversion of lignocellulosic biomass to transportation fuels. Thermochemically pretreated and enzymatically hydrolyzed corn stover slurries have proven difficult to filter due to formation of very low permeability cakes that are rich in lignin. Treatment of two different slurries with polyelectrolyte flocculant was demonstrated to increase mean particle size and filterability. Filtration flux was greatly improved, and thus scaled filter unit capacity was increased approximately 40-fold compared with unflocculated slurry. Although additional costs were accrued using polyelectrolyte, techno-economic analysis revealed that the increase in filter capacity significantly reduced overall production costs. Fuel production cost at 95% sugar recovery was reduced by

Algal Lipid Extraction and Upgrading to Hydrocarbons Technology Pathway

1.35 US per gallon gasoline equivalent for dilute-acid pretreated and enzymatically hydrolyzed slurries and

Techno-economic analysis for upgrading the biomass-derived ethanol-to-jet blendstocks

3.40 for slurries produced using an additional alkaline de-acetylation preprocessing step that is even more difficult to natively filter.