Integrating Separation and Conversion—Conversion of Biorefinery Process Streams to Biobased Chemicals and Fuels
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catalysis (homogeneous), catalysis (heterogeneous)↗
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Moving Beyond Drop-In Replacements: Performance-Advantaged Biobased Chemicals Workshop Summary Report
BETO held the Moving beyond Drop-In Replacements: Performance-Advantaged Biobased Chemicals Workshop on June 1, 2017, in Denver, Colorado. Approximately 90 stakeholders attended, representing companies, national laboratories, government agencies, and academic institutions. A list of workshop attendees who agreed to share their contact information can be found in Appendix A. The breakdown of stakeholders is shown in Figure 3 below. The day began with a keynote presentation from Nichole Fitzgerald of BETO to give participants an overview of the Office’s current work on functional replacements, as well as to outline the goals of the workshop. This was followed by two keynote presentations from industry representatives—Dale McIntyre (Behr Masco) and Michael Saltzberg (DuPont Industrial Biosciences)—on their current work with performance-enhanced biobased chemicals. Participants then attended two breakout sessions in smaller groups to provide feedback. In the afternoon, a third and final keynote—given by Dr. Brent Shanks (Center for Biorenewable Chemicals, Iowa State University)— covered potential strategies for targeting future research in this area, followed by a final breakout session on the same topic. A detailed agenda can be found in Appendix B.
09 BIOMASS FUELS↗
Enhanced Catalyst Durability for the Oxidative Production of Biobased Chemicals (Cooperative Research and Development Final Report)
This CRADA will facilitate technology maturation for NREL-developed atomic layer deposition (ALD) coated catalyst materials that are tailored for durability during the oxidative production of biobased chemicals. This project will address optimizing process parameters for scaling aluminum oxide (Al 2 O 3 ) ALD coated catalysts, demonstrating ALD coated catalyst performance for biomass oxidation, and validating economic models that project significant cost benefits for ALD-enhanced catalytic processes. This work will strengthen private-public partnerships in the area of advanced catalyst manufacturing for energy-related technology. Critical information will be collected to elevate the Technology Readiness Level and increase our competitiveness for cooperative R&D agreements and licensing. Success of this work will be crosscutting as it can facilitate advanced catalyst development for both renewable and conventional processes.
09 BIOMASS FUELS↗
Identifying Performance Advantaged Biobased Chemicals Utilizing Bioprivileged Molecules
Two technology areas were advanced; a) novel molecules with improved performance in the end use application of organic corrosion inhibitors and flame retardant nylon polymers and b) development of a systematic process for identifying biomass-derived molecules with improved performance in end use applications. In total 17 novel organic corrosion inhibitors were identified that had significantly better performance than the commercial reference organic corrosion inhibitor and 7 novel nylons were synthesized with improved flame retardant properties relative to standard nylon-6,6. While an end-to-end systematic process for identifying biomass-derived molecules with improved end use performance was not completed, important progress was made computational tools for mining chemical structures from the literature and databases as well as establishing reaction network generation algorithms to aid in the discovery of novel molecules.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Biobased chemical recycling: aminolysis of PET using renewable reagents and monomers to synthesize new semi-aromatic polyamides
Chemical recycling of PET is a method of depolymerizing polymer chains to monomeric components enabling the synthesis of second-generation materials with virgin-like quality. Commercial chemical recycling techniques rely upon high pressure methanolysis to create precursors capable of synthesizing a second-generation PET resin. However, despite the circular approach of methanolysis, a product with a very short lifespan and similar value is created. The approach of the current study is to utilize aminolysis as an ambient pressure technique to create precursors for higher value materials with longer lifespans to address the current crisis in plastic waste. Semi-aromatic polyamides (SAP) are desired in this circumstance because of their high melting point and heat resistance combined with good melt-processability similar to aliphatic polyamides. In this study SAPs were synthesized using precursors recovered from the aminolysis of PET employing biobased diamines and dicarboxylic acids. While aminolysis has been explored in previous studies, this work investigated the use of biobased components from castor oil: decamethylene diamine during recycling and sebacic acid during polymerization. Polymer synthesis resulted in the formation of SAPs similar to polyphthalamides (PPA) with novel structures given the aromatic portion from terephthalic acid (TPA) and aliphatic portion from the diamines and diacids. The synthesized materials exhibited excellent thermal stability with high glass transition temperatures. Novel polymers were created with varying aliphatic chain length to understand fundamental parameters needed to produce a valuable polymer from post-consumer waste.
High performance Applications↗
Recent Advances in the Use of Ionic Liquids and Deep Eutectic Solvents for Lignocellulosic Biorefineries and Biobased Chemical and Material Production
Biorefineries, which process biomass feedstocks into valuable (bio)products, aim to replace fossil fuel-based refineries to produce energy and chemicals, reducing environmental and health hazards, including climate change, and supporting a sustainable economy. In particular, lignocellulose-based biorefineries, utilizing the most abundant renewable feedstock on Earth, have significant potential to supply sustainable energy, chemicals and materials. Ionic liquids (ILs, organic salts with low melting temperatures) and deep eutectic solvents (DESs, mixtures with eutectic points lower than the ideal mixture) are capable of dissolving some of the key lignocellulose polymers, and even the whole biomass. Furthermore, they have intrinsic advantages over molecular solvents, including safer usage profiles and high tunability, which allow tailored physicochemical properties. Such properties provide unique opportunities for the development of new processes that could unlock the full potential of future biorefineries. Here, we review the current state of lignocellulosic biomass processing with ILs and DESs, with a specific focus on the pretreatment chemistry, process flow and products from each component; followed by discussions on sustainability assessments and technological challenges. We aim to inform the research community about the opportunities, challenges and perspectives in developing truly sustainable lignocellulose-based biorefineries.
09 BIOMASS FUELS↗
Development of the University of Washington Biofuels and Biobased Chemicals Process Laboratory
The funding from this research grant enabled us to design and build a bioconversion steam explosion reactor and ancillary equipment such as a high pressure boiler and a fermenter to support the bioconversion process research. This equipment has been in constant use since its installation in 2012. Following are research projects that it has supported: (1) Investigation of novel chip production method in biofuels production; (2) Investigation of biomass refining following steam explosion; (3) Several studies on use of different biomass feedstocks; (4) Investigation of biomass moisture content on pretreatment efficacy; and (5) Development of novel instruments for biorefinery process control. Having this equipment was also instrumental in the University of Washington receiving a $40 million grant from the US Department of Agriculture for biofuels development as well as several other smaller grants. The research that is being done with the equipment from this grant will facilitate the establishment of a biofuels industry in the Pacific Northwest and enable the University of Washington to launch a substantial biofuels and bio-based product research program.
09 BIOMASS FUELS↗
Identifying Performance Advantaged Biobased Chemicals Utilizing Bioprivileged Molecules (Final Report)
Two technology areas were advanced; a) novel molecules with improved performance in the end use application of organic corrosion inhibitors and flame retardant nylon polymers and b) development of a systematic process for identifying biomass-derived molecules with improved performance in end use applications. In total 17 novel organic corrosion inhibitors were identified that had significantly better performance than the commercial reference organic corrosion inhibitor and 7 novel nylons were synthesized with improved flame retardant properties relative to standard nylon-6,6. While an end-to-end systematic process for identifying biomass-derived molecules with improved end use performance was not completed, important progress was made computational tools for mining chemical structures from the literature and databases as well as establishing reaction network generation algorithms to aid in the discovery of novel molecules.
36 MATERIALS SCIENCE↗
2019 Biomass to Biobased Chemicals and Materials GRC
Final program and registration list
Gross, Richard↗
Enhanced Catalyst Durability for Bio-Based Adipic Acid Production by Atomic Layer Deposition
Harsh reaction environments challenge the lifetime productivity of conventional catalysts and impede emerging biobased chemical processes. Condensed-phase processing of muconic acid, a biobased platform chemical, leads to problematic levels of catalyst leaching and fouling. Atomic layer deposition (ALD) can improve catalyst durability using protective metal oxide coatings; however, a targeted coating strategy and cost models thereof are needed for application-specific deactivation challenges that can surmount these challenges while accounting for process implications. Herein, we utilize thin (<5 wt% Al) Al2O3 ALD coatings to increase the lifetime productivity of Pd/TiO2 during muconic acid hydrogenation to adipic acid. The ALD coating decreases Pd leaching by >3x and markedly improves the thermal stability of Pd and TiO2. Economic analysis for an adipic acid biorefinery supports that increased material costs and reduced catalyst productivity can be justified through lifetime extension. Broadly, this work lays the foundation for reducing the cost of biobased chemical processes through catalyst stability.
Settle, Amy↗
Life-Cycle Assessment of Sustainable Aviation Fuel Derived from Paper Sludge
Converting waste paper sludge to sustainable aviation fuel (SAF) offers a circular economy strategy to decarbonize the aviation sector. Here, this study develops a life-cycle assessment (LCA) for converting high-ash paper sludge to SAF in the U.S. using a catalytic sugar upgrading system that consists of ash removal, enzymatic hydrolysis, dehydration, aldol condensation, and hydroprocessing. The LCA is coupled with a process simulation for an industrial-scale biorefinery based on experimental data. We quantified the carbon intensity as 35.7–41.8 gCO 2 eq MJ –1 SAF (–636 to –584 gCO 2 eq per dry kg paper sludge) with acetone as a solvent, renewable fuel, and biobased chemicals; this is further reduced to 5.1–11.1 gCO 2 eq MJ –1 (–925 to –873 gCO 2 eq per dry kg paper sludge) if ash is recycled and used for substituting cement. Converting 1 dry kg paper sludge to SAF with acetone, renewable fuel, and biobased chemicals (–925 to –584 gCO 2 eq) is more climate beneficial than landfilling without landfill gas recovery (791 gCO 2 eq) and with landfill gas recovery (–294 gCO 2 eq). More than 330 million gallons of SAF can be produced annually (>4 million dry t paper sludge/year in the U.S.), resulting in a reduction of 2–7 million tCO 2 eq.
09 BIOMASS FUELS↗
Iodine-Catalyzed Isomerization of Dimethyl Muconate
cis,cis -Muconic acid is a platform biobased chemical that can be upgraded to drop-in commodity and novel monomers. Among the possible drop-in products, dimethyl terephthalate can be synthesized via esterification, isomerization, Diels-Alder cycloaddition, and dehydrogenation. The isomerization of cis,cis -dimethyl muconate ( cc DMM) to the trans,trans -form ( tt DMM) can be catalyzed by iodine; however, studies have yet to address (i) the mechanism and reaction barriers unique to DMM, and (ii) the influence of solvent, potential for catalyst recycle, and recovery of high-purity tt DMM. To address this gap, we apply a joint computational and experimental approach to investigate iodine-catalyzed isomerization of DMM. Density functional theory calculations identified unique regiochemical considerations due to the large number of halogen-diene coordination schemes. Both transition state theory and experiments estimate significant barrier reductions with photodissociated iodine. Solvent selection was critical for rapid kinetics, likely due to solvent complexation with iodine. Under select conditions, tt DMM yields of 95% were achieved in <1 h with methanol, followed by high purity recovery (>98%) with crystallization. Lastly, post-reaction iodine can be recovered and recycled with minimal loss of activity. Altogether, these findings provide new insight into the mechanism and conditions necessary for DMM isomerization with iodine to advance the state-of-the-art for biobased chemicals.
09 BIOMASS FUELS↗
Understanding and Mitigating Stickiness in Biochar Produced through Acid Hydrolysis and Dehydration
Levulinic acid is a platform chemical with significant potential for conversion into a wide range of biobased chemicals and fuels. A common process for producing levulinic acid from lignocellulosic feedstocks involves acid hydrolysis and dehydration (AHDH), where hexose polymers are hydrolyzed into monomeric sugars and subsequently dehydrated to levulinic acid and formic acid in the presence of dilute sulfuric acid. However, scaling the AHDH process is challenging because of the formation of byproducts such as sticky biochar, which accumulates in continuous-flow reactors, reducing effective reaction volume and increasing process downtime. This study investigates the effect of a chemical preconditioning step on mitigating sticky biochar formation. Woody biomass was preconditioned at 170 °C with 0.26 wt % sulfuric acid for 30 min, resulting in substantial removal of hemicellulose and acid-soluble lignin. AHDH of these preconditioned solids produced biochar that did not adhere to reactor surfaces. TGA analysis confirmed that the chemical preconditioning step minimized interactions between hemicellulose-derived degradation products and lignin side chains, reducing sticky char formation. Additionally, the study observed a 6% higher yield of organic acids from softwood species compared to hardwoods, with bark content shown to negatively impact yield. These findings suggest that targeted preconditioning of lignocellulosic biomass can enhance reactor operability and improve organic acid production efficiency in AHDH processes.
biopolymers↗
Advanced nuclear reactor integration opportunities for the pulp and paper industry in the U.S. context: Technical perspectives, gap analysis, and preliminary technoeconomic assessment
Pulp and paper (P&P) manufacturing requires a large amount of low-pressure (LP) steam to digest, wash wood fibers and dry pulp into paper. Most of the LP steam is extracted from backpressure turbines that produce power from high-pressure (HP) steam. This HP steam is generated from burning wood waste material; bark is burned in hog boilers, and lignin is boiled in a black liquor recovery boiler. In a typical integrated P&P mill, 50–100% of the steam is produced from these sources, while additional steam is produced in natural gas (NG), fuel oil, or coal boilers. The other energy-intensive process in the plant is the chemical-recovery section (e.g., lime kiln), which requires high-temperature processing from NG combustion to retrieve and recirculate spent chemicals. This paper assesses the energy and heat demand and material balances of a typical generic kraft pulp mill, along with the nuclear heat, steam, and power integration opportunities to replace conventional combustion systems. The paper also addresses steam and electricity generation through a comprehensive technical and engineering gap analysis of five different nuclear-integration opportunities and their process economics, thus enabling the lignin and bark to be further processed into biobased chemicals or fuels, as well as the potential to reduce overall emissions from kraft pulping. Preliminary findings have shown that the P&P industry could achieve technological benefits by integrating their current manufacturing process with small modular nuclear reactors (SMNRs) on a national level. This research aims to set the path forward for a cleaner and more resilient P&P industry.
Advanced nuclear reactor↗
The Transcriptome and Flux Profiling of Crabtree-Negative Hydroxy Acid-Producing Strains of Saccharomyces cerevisiae Reveals Changes in the Central Carbon Metabolism
Saccharomyces cerevisiae (S. cerevisiae) is the yeast cell factory of choice for the production of many biobased chemicals. However, it is a Crabtree-positive yeast and so shuttles a large portion of carbon into ethanol. Ethanol formation can be eliminated by deleting pyruvate decarboxylase (PDC) activity. It is not yet well understood how PDC-negative yeasts are affected when engineered to produce other products than ethanol. In this study, pathways are introduced for the production of three hydroxy acids (lactic, malic, or 3-hydroxypropionic acid [3HP]) into an evolved PDC-negative strain. These strains are characterized via transcriptome and flux profiling to elucidate the effects that the production of these hydroxy acids has on the host strain. Expression of lactic and malic acid biosynthesis pathways improved the maximum specific growth rate (μ max ) of the strain by 64% and 20%, respectively, presumably due to nicotinamide adenine dinucleotide regeneration. All strains show a very high flux (> 90% of glucose uptake) into the oxidative pentose phosphate pathway under batch fermentation conditions. The study, for the first time, directly compares the flux and transcriptome profiles of several hydroxy acid-producing strains of an evolved PDC-negative S. cerevisiae and suggests directions for future metabolic engineering.
13C-based metabolic flux analysis↗
Synthesis of polyketides from low cost substrates by the thermotolerant yeast Kluyveromyces marxianus
Kluyveromyces marxianus is a promising nonconventional yeast for biobased chemical production due to its rapid growth rate, high TCA cycle flux, and tolerance to low pH and high temperature. Unlike Saccharomyces cerevisiae, K. marxianus grows on low-cost substrates to cell densities that equal or surpass densities in glucose, which can be beneficial for utilization of lignocellulosic biomass (xylose), biofuel production waste (glycerol), and whey (lactose). Additionally, we have evaluated K. marxianus for the synthesis of polyketides, using triacetic acid lactone (TAL) as the product. The 2-pyrone synthase (2-PS) was expressed on a CEN/ARS plasmid in three different strains, and the effects of temperature, carbon source, and cultivation strategy on TAL levels were determined. The highest titer was obtained in defined 1% xylose medium at 37°C, with substantial titers at 41 and 43°C. The introduction of a high-stability 2-PS mutant and a promoter substitution increased titer four-fold. 2-PS expression from a multi-copy pKD1-based plasmid improved TAL titers a further five-fold. Combining the best plasmid, promoter, and strain resulted in a TAL titer of 1.24 g/L and a yield of 0.0295 mol TAL/mol carbon for this otherwise unengineered strain in 3 ml tube culture. This is an excellent titer and yield (on xylose) before metabolic engineering or fed-batch culture relative to other hosts (on glucose), and demonstrates the promise of this rapidly growing and thermotolerant yeast species for polyketide production.
59 BASIC BIOLOGICAL SCIENCES↗
Towards the sustainable conversion of corn stover into bioenergy and bioproducts through biochemical route: Technical, economic and strategic perspectives
Corn stover (CS) is one of the most abundant agricultural wastes and is ubiquitous around the world that is left over after grain harvest and accounts for 47–50% dry mass of the total grain yield. The global CS yield is 1661.25 million tons/year, which is 27.2% of the total agricultural waste. CS consists of about 34.5% stems, 32.3% leaves, 14.3% husks, 12.3% cobs and 6.6% flowers, with up to 45% cellulose, 30% hemicellulose and 20% lignin. Further, due to its favorable economic and environmental potential, CS is considered an ideal raw material for producing biofuels and biobased chemicals, which can largely be divided into carbohydrate and lignin platforms. However, the techno-economic perspectives of CS-based biorefineries have remained questionable due to the inadequate supply chain logistics, lack of cost-effective conversion technologies, limited scale-up of the product-specific technologies, and lower competitiveness in the market compared to their counterparts, such as sugar and starch-based biorefineries. While CS is converted by thermochemical and biochemical approaches, the latter is considered to be more sustainable for its selective conversion under mild conditions using microorganisms. This review aimed to critically discuss the latest research and developments on the biochemical conversion of CS into biofuels and chemicals. In particular, this paper covers the market potential of biofuels and chemicals to which CS can make a significant contribution, technological developments in the microbial conversion of CS, major biofuels and chemicals produced from CS-derived carbohydrates and lignin, and the technoeconomic perspectives of CS-based biorefinery.
09 BIOMASS FUELS↗
Ultrasound-Assisted Nonthermal, Nonequilibrium Separation of Organic Molecules from Their Binary Aqueous Solutions: Effect of Solute Properties on Separation
The separation of organic molecules in downstream processes, such as distillation, plays a vital role in biobased chemical production. A comprehensive study was performed here using ultrasonic energy to separate 11 organic molecules from their binary aqueous solutions under nonthermal, nonequilibrium, and phase-change free conditions. A batch sonoseparator with a three-stage mist collection unit allowed direct analysis of ultrasound-generated mist with an HPLC/GC and differentiation and quantification of the vapor and mist. The results showed that the alcohols (1-butanol, ethanol, 1-propanol, and methanol) and acetone were enriched in the ultrasound-generated mist with enrichment ratios of 3.2–5. On the other hand, ethylene glycol, glycerol, γ-valerolactone (GVL), glucose, and sucrose were diluted with dilution ratios in the range of 2.04–15.7 in the mist and vapor generated by ultrasound (or concentrated in the bulk solution). No enrichment nor dilution of acetic acid was observed. The role of various physicochemical parameters such as dynamic viscosity, surface tension, Henry’s law of solubility constant, vapor pressure, and octanol–water partition coefficient in the enrichment was examined. Furthermore, the hydrophobicity of the organic molecules represented by the octanol–water partition coefficient was found to play a crucial role in determining the separation characteristics of the molecules in ultrasound-generated mist and vapor.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗