Production of Methyl Lactate with Sn-USY and Sn-ß: Insights into Real Hemicellulose Valorization.

Potassium exchanged Sn-ß and Sn-USY zeolites have been tested for the transformation of various aldoses (hexoses and pentoses), exhibiting outstanding catalytic activity and selectivity toward methyl lactate. Insights into the transformation pathways using reaction intermediates-dihydroxyacetone and glycolaldehyde-as substrates revealed a very high catalytic proficiency of both zeolites in aldol and retro-aldol reactions, showcasing their ability to convert small sugars into large sugars, and vice versa. This feature makes the studied Sn-zeolites outstanding catalysts for the transformation of a wide variety of sugars into a limited range of commercially valuable alkyl lactates and derivatives. [K]Sn-ß proved to be superior to [K]Sn-USY in terms of shape selectivity, exerting tight control on the distribution of produced α-hydroxy methyl esters. This shape selectivity was evident in the transformation of several complex sugar mixtures emulating different hemicelluloses-sugar cane bagasse, Scots pine, and white birch-that, despite showing very different sugar compositions, were almost exclusively converted into methyl lactate and methyl vinyl glycolate in very similar proportions. Moreover, the conversion of a real hemicellulose hydrolysate obtained from Scots pine through a simple GVL-based organosolv process confirmed the high activity and selectivity of [K]Sn-ß in the studied transformation, opening new pathways for the chemical valorization of this plentiful, but underutilized, sugar feedstock.

A Solvent-Free Synthesis of Lignin-Derived Renewable Carbon with Tunable Porosity for Supercapacitor Electrodes.

Synthesis of multiphase materials from lignin, a biorefinery coproduct, offers limited success owing to the inherent difficulty in controlling dispersion of these renewable hyperbranched macromolecules in the product or its intermediates. Effective use of the chemically reactive functionalities in lignin, however, enables tuning morphologies of the materials. Here, we bind lignin oligomers with a rubbery macromolecule followed by thermal crosslinking to form a carbon precursor with phase contrasted morphology at submicron scale. The solvent-free mixing is conducted in a high-shear melt mixer. With this, the carbon precursor is further modified with potassium hydroxide for a single-step carbonization to yield activated carbon with tunable pore structure. A typical precursor with 90 % lignin yields porous carbon with 2120 m2 g-1 surface area and supercapacitor with 215 F g-1 capacitance. The results show a simple route towards manufacturing carbon-based energy-storage materials, eliminating the need for conventional template synthesis.

Enhanced Furfural Yields from Xylose Dehydration in the γ-Valerolactone/Water Solvent System at Elevated Temperatures.

High yields of furfural (>90 %) were achieved from xylose dehydration in a sustainable solvent system composed of γ-valerolactone (GVL), a biomass derived solvent, and water. It is identified that high reaction temperatures (e.g., 498 K) are required to achieve high furfural yield. Additionally, it is shown that the furfural yield at these temperatures is independent of the initial xylose concentration, and high furfural yield is obtained for industrially relevant xylose concentrations (10 wt %). A reaction kinetics model is developed to describe the experimental data obtained with solvent system composed of 80 wt % GVL and 20 wt % water across the range of reaction conditions studied (473-523 K, 1-10 mm acid catalyst, 66-660 mm xylose concentration). The kinetic model demonstrates that furfural loss owing to bimolecular condensation of xylose and furfural is minimized at elevated temperature, whereas carbon loss owing to xylose degradation increases with increasing temperature. Accordingly, the optimal temperature range for xylose dehydration to furfural in the GVL/H2 O solvent system is identified to be from 480 to 500 K. Under these reaction conditions, furfural yield of 93 % is achieved at 97 % xylan conversion from lignocellulosic biomass (maple wood).

Toward biomass-derived renewable plastics: Production of 2,5-furandicarboxylic acid from fructose.

We report a process for converting fructose, at a high concentration (15 weight %), to 2,5-furandicarboxylic acid (FDCA), a monomer used in the production of polyethylene furanoate, a renewable plastic. In our process, fructose is dehydrated to hydroxymethylfurfural (HMF) at high yields (70%) using a γ-valerolactone (GVL)/H2O solvent system. HMF is subsequently oxidized to FDCA over a Pt/C catalyst with 93% yield. The advantage of our system is the higher solubility of FDCA in GVL/H2O, which allows oxidation at high concentrations using a heterogeneous catalyst that eliminates the need for a homogeneous base. In addition, FDCA can be separated from the GVL/H2O solvent system by crystallization to obtain >99% pure FDCA. Our process eliminates the use of corrosive acids, because FDCA is an effective catalyst for fructose dehydration, leading to improved economic and environmental impact of the process. Our techno-economic model indicates that the overall process is economically competitive with current terephthalic acid processes.

Increasing the revenue from lignocellulosic biomass: Maximizing feedstock utilization.

The production of renewable chemicals and biofuels must be cost- and performance- competitive with petroleum-derived equivalents to be widely accepted by markets and society. We propose a biomass conversion strategy that maximizes the conversion of lignocellulosic biomass (up to 80% of the biomass to useful products) into high-value products that can be commercialized, providing the opportunity for successful translation to an economically viable commercial process. Our fractionation method preserves the value of all three primary components: (i) cellulose, which is converted into dissolving pulp for fibers and chemicals production; (ii) hemicellulose, which is converted into furfural (a building block chemical); and (iii) lignin, which is converted into carbon products (carbon foam, fibers, or battery anodes), together producing revenues of more than $500 per dry metric ton of biomass. Once de-risked, our technology can be extended to produce other renewable chemicals and biofuels.

Effects of Water on the Copper-Catalyzed Conversion of Hydroxymethylfurfural in Tetrahydrofuran.

Reaction kinetics were studied to quantify the effects of water on the conversion of hydroxymethylfurfural (HMF) in THF over Cu/γ-Al2 O3 at 448 K using molecular H2 as the hydrogen source. We show that low concentrations of water (5 wt %) in the THF solvent significantly alter reaction rates and selectivities for the formation of reaction products by hydrogenation and hydrogenolysis processes. In the absence of water, HMF was converted primarily to hydrogenolysis products 2-methyl-5-hydroxymethylfuran (MHMF) and 2,5-dimethylfuran (DMF), whereas reactions carried out in THF-H2 O mixtures (THF/H2 O=95:5 w/w) led to the selective production of the hydrogenation product 2,5-bis(hydroxymethyl)furan (BHMF) and inhibition of HMF hydrogenolysis.

Solvent-enabled nonenyzmatic sugar production from biomass for chemical and biological upgrading.

We recently reported a nonenzymatic biomass deconstruction process for producing carbohydrates using homogeneous mixtures of γ-valerolactone (GVL) and water as a solvent. A key step in this process is the separation of the GVL from the aqueous phase, enabling GVL recycling and the production of a concentrated aqueous carbohydrate solution. In this study, we demonstrate that phenolic solvents-sec-butylphenol, nonylphenol, and lignin-derived propyl guaiacol-are effective at separating GVL from the aqueous phase using only small amounts of solvent (0.5 g per g of the original water, GVL, and sugar hydrolysate). Furthermore, using nonylphenol, we produced a hydrolysate that supported robust growth and high yields of ethanol (0.49 g EtOH per g glucose) at an industrially relevant concentration (50.8 g L(-1) EtOH). These results suggest that using phenolic solvents could be an interesting solution for separating and/or detoxifying aqueous carbohydrate solutions produced using GVL-based biomass deconstruction processes.

A lignocellulosic ethanol strategy via nonenzymatic sugar production: process synthesis and analysis.

The work develops a strategy for the production of ethanol from lignocellulosic biomass. In this strategy, the cellulose and hemicellulose fractions are simultaneously converted to sugars using a γ-valerolactone (GVL) solvent containing a dilute acid catalyst. To effectively recover GVL for reuse as solvent and biomass-derived lignin for heat and power generation, separation subsystems, including a novel CO2-based extraction for the separation of sugars from GVL, lignin and humins have been designed. The sugars are co-fermented by yeast to produce ethanol. Furthermore, heat integration to reduce utility requirements is performed. It is shown that this strategy leads to high ethanol yields and the total energy requirements could be satisfied by burning the lignin. The integrated strategy using corn stover feedstock leads to a minimum selling price of $5 per gallon of gasoline equivalent, which suggests that it is a promising alternative to current biofuels production approaches.

Solvent effects in acid-catalyzed biomass conversion reactions.

Reaction kinetics were studied to quantify the effects of polar aprotic organic solvents on the acid-catalyzed conversion of xylose into furfural. A solvent of particular importance is γ-valerolactone (GVL), which leads to significant increases in reaction rates compared to water in addition to increased product selectivity. GVL has similar effects on the kinetics for the dehydration of 1,2-propanediol to propanal and for the hydrolysis of cellobiose to glucose. Based on results obtained for homogeneous Brønsted acid catalysts that span a range of pKa values, we suggest that an aprotic organic solvent affects the reaction kinetics by changing the stabilization of the acidic proton relative to the protonated transition state. This same behavior is displayed by strong solid Brønsted acid catalysts, such as H-mordenite and H-beta.

Nonenzymatic sugar production from biomass using biomass-derived γ-valerolactone.

Widespread production of biomass-derived fuels and chemicals will require cost-effective processes for breaking down cellulose and hemicellulose into their constituent sugars. Here, we report laboratory-scale production of soluble carbohydrates from corn stover, hardwood, and softwood at high yields (70 to 90%) in a solvent mixture of biomass-derived γ-valerolactone (GVL), water, and dilute acid (0.05 weight percent H2SO4). GVL promotes thermocatalytic saccharification through complete solubilization of the biomass, including the lignin fraction. The carbohydrates can be recovered and concentrated (up to 127 grams per liter) by extraction from GVL into an aqueous phase by addition of NaCl or liquid CO2. This strategy is well suited for catalytic upgrading to furans or fermentative upgrading to ethanol at high titers and near theoretical yield. We estimate through preliminary techno-economic modeling that the overall process could be cost-competitive for ethanol production, with biomass pretreatment followed by enzymatic hydrolysis.

A highly selective route to linear alpha olefins from biomass-derived lactones and unsaturated acids.

This work demonstrates the use of Lewis-acid catalysts, such as gamma-alumina and tungstated alumina, for selective production of linear alpha olefins by decarboxylation of lactones and unsaturated carboxylic acids.

Bimetallic catalysts for upgrading of biomass to fuels and chemicals.

Research interest in biomass conversion to fuels and chemicals has increased significantly in the last decade as the necessity for a renewable source of carbon has become more evident. Accordingly, many different reactions and processes to convert biomass into high-value products and fuels have been proposed in the literature. Special attention has been given to the conversion of lignocellulosic biomass, which does not compete with food sources and is widely available as a low cost feedstock. In this review, we start with a brief introduction on lignocellulose and the different chemical structures of its components: cellulose, hemicellulose, and lignin. These three components allow for the production of different chemicals after fractionation. After a brief overview of the main reactions involved in biomass conversion, we focus on those where bimetallic catalysts are playing an important role. Although the reactions are similar for cellulose and hemicellulose, which contain C(6) and C(5) sugars, respectively, different products are obtained, and therefore, they have been reviewed separately. The third major fraction of lignocellulose that we address is lignin, which has significant challenges to overcome, as its structure makes catalytic processing more challenging. Bimetallic catalysts offer the possibility of enabling lignocellulosic processing to become a larger part of the biofuels and renewable chemical industry. This review summarizes recent results published in the literature for biomass upgrading reactions using bimetallic catalysts.

γ-Valerolactone ring-opening and decarboxylation over SiO2/Al2O3 in the presence of water.

γ-Valerolactone (GVL) has been identified as a promising, sustainable platform molecule that can be produced from lignocellulosic biomass. The chemical flexibility of GVL has allowed the development of a variety of processes to prepare renewable fuels and chemicals. In the present work involving a combination of computational and experimental studies, we explore the factors governing the ring-opening of GVL to produce pentenoic acid isomers, as well as their subsequent decarboxylation over acid catalysts or hydrogenation over metal catalysts. The ring-opening of GVL has shown to be a reversible reaction, while both the decarboxylation and hydrogenation reactions are irreversible and kinetically controlled under the conditions studied (temperatures from about 500 to 650 K). The most significant contributor to lactone reactivity toward ring-opening is the size of the ring, with γ- lactones being more stable and less readily opened than δ- and ε-analogues. We have observed that the presence of either a C═C double bond or a lactone (which opens to form a C═C double bond) is necessary for appreciable rates of decarboxylation to occur. Olefinic acids exhibit higher rates of decarboxylation than the corresponding lactones, suggesting that the decarboxylation of alkene acids provides a lower energy pathway to olefin production than the direct decarboxylation of lactones. We observe lower rates of decarboxylation as the chain length of alkene acids increases; however, acrylic acid (3-carbon atoms) does not undergo decarboxylation at the conditions tested. These observations suggest that particular double bond configurations yield the highest rates of decarboxylation. Specifically, we suggest that the formation of a secondary carbenium ion in the ß position leads to high reactivity for decarboxylation. Such an intermediate can be formed from 2- or 3-alkene acids which have at least four carbon atoms.

Integrated catalytic conversion of gamma-valerolactone to liquid alkenes for transportation fuels.

Efficient synthesis of renewable fuels remains a challenging and important line of research. We report a strategy by which aqueous solutions of gamma-valerolactone (GVL), produced from biomass-derived carbohydrates, can be converted to liquid alkenes in the molecular weight range appropriate for transportation fuels by an integrated catalytic system that does not require an external source of hydrogen. The GVL feed undergoes decarboxylation at elevated pressures (e.g., 36 bar) over a silica/alumina catalyst to produce a gas stream composed of equimolar amounts of butene and carbon dioxide. This stream is fed directly to an oligomerization reactor containing an acid catalyst (e.g., H ZSM-5, Amberlyst-70), which couples butene monomers to form condensable alkenes with molecular weights that can be targeted for gasoline and/or jet fuel applications. The effluent gaseous stream of CO2 at elevated pressure can potentially be captured and then treated or sequestered to mitigate greenhouse gas emissions from the process.