Is biomass fractionation by Organosolv-like processes economically viable? A conceptual design study

Unraveling the structural aspects of microwave-assisted OrganoCat-based coconut shell lignins: An eco-friendly route for obtaining bio-based antioxidants

New routes for biomass valorization have been developing by the scientific community. The aim of this work was developing a novel OrganoCat-based protocol and deeply understand the structure of the obtained lignins. Microwave-assisted OrganoCat-based process was performed using a biphasic system (ethyl acetate and oxalic acid or HCl) at mild conditions. OrganoCat-based lignins (OCLs) were characterized by compositional analysis, FTIR, 1H, 13C, 1H13C HSQC, 31P NMR, TGA and GPC. The solubility of OCLs in different organic solvents and their antioxidant capacity against DPPH were investigated. The spectroscopic analyses showed that OCLs have high residual extractives and the lignin motifs were preserved. OCLs have presented lower thermal stability than MWL, but showed great antioxidant activities and high solubility in a wide range of organic solvents. A novel biorefinery protocol yielded coconut shell lignins with peculiar structural and compositional features and several technological applications through an eco-friendly, sustainable and relatively low-cost biphasic pulping process.

Building the bioeconomy: A targeted assessment approach to identifying biobased technologies, challenges and opportunities

The authors explore opportunities, challenges, and strategies to translate and responsibly scale innovative biobased technologies to build more sustainable bioeconomies. The pandemic and other recent disruptions increased exposure to issues of resilience and regional imbalance, highlighting a need for production and consumption regimes centred more on local biobased resources and dispersed production. The authors review potential biobased technology strategies and identify promising and feasible options for the United Kingdom. Initial landscape and bibliometric analysis identified 50 potential existing and emerging biobased technologies, which were assessed for their ability to fulfil requirements related to biobased production, national applicability, and economic-, societal-, and environmental-benefits, leading to identification of 18 promising biobased production technologies. Further analysis and focus-group discussion with industrial, governmental, academic, agricultural, and social stakeholders, identified three technology clusters for targeted assessment, drawing on cellulose-, lignin-, and seaweed feedstocks. Case studies were developed for each cluster, addressing conversations around sustainable management, use of biomass feedstocks, and associated environmental-, social-, and economic challenges. Cases are presented with discussion of insights and implications for policy. The approach presented is put forward as a scalable assessment method that can be useful in prompting, informing, and advancing discussion and deliberation on opportunities and challenges for biobased transformations.

Furan Distribution as a Severity Indicator upon Organosolv Fractionation of Hardwood Sawdust through a Novel Ternary Solvent System

Beech sawdust was treated with a ternary solvent system based on binary aqueous ethanol with partial substitution of ethanol by acetone at four different water contents (60, 50, 40, and 30%v/v). In addition to standard, i.e., noncatalyzed treatments, the application of inorganic acid in the form of 20 mm H2SO4 was evaluated. The various solvent systems were applied at 180 °C for 60 min. The obtained biomass fractions were characterized by standard biomass compositional methods, i.e., sugar monomer and oligomer contents, dehydration product contents of the aqueous product, and lignin, cellulose, and hemicellulose contents in isolated solid fractions. More advanced analyses were performed on the lignin fractions, including quantitative 13C NMR analyses, 1H-13C HSQC analysis, size exclusion chromatography, and pyrolysis-GC/MS, and the aqueous product, in the form of size exclusion chromatography and determination of total phenol contents. The picture emerging from the thorough analytical investigation performed on the lignin fractions is consistent with that resulting from the characterization of the other fractions: results point toward greater deconstruction of the lignocellulosic recalcitrance upon higher organic solvent content, replacing ethanol with acetone during the extraction, and upon addition of mineral acid. A pulp with cellulose content of 94.23 wt % and 95% delignification was obtained for the treatment employing a 55/30/15 EtOH/water/acetone mixture alongside 20 mm H2SO4. Furthermore, the results indicate the formation of two types of organosolv furan families during treatment, which differ in the substitution of their C1 and C5. While the traditional lignin aryl-ether linkages present themselves as indicators for process severity for the nonacid catalyzed systems, the distribution of these furan types can be applied as a severity indicator upon employment of H2SO4, including their presence in the isolated lignin fractions.

Advances on Cellulose Manufacture in Biphasic Reaction Media

Cellulose is produced industrially by the kraft and sulfite processes. The evolution of these technologies in biorefineries is driven by the need to obtain greater added value through the efficient use of raw materials and energy. In this field, organosolv technologies (and within them, those using liquid phases made up of water and one partly miscible organic solvent, known as "biphasic fractionation" in reference to the number of liquid phases) represent an alternative that is receiving increasing interest. This study considers basic aspects of the composition of lignocellulosic materials, describes the fundamentals of industrial cellulose pulp production processes, introduces the organosolv methods, and comprehensively reviews published results on organosolv fractionation based on the use of media containing water and an immiscible solvent (1-butanol, 1-pentanol or 2-methyltetrahydrofuran). Special attention is devoted to aspects related to cellulose recovery and fractionation selectivity, measured through the amount and composition of the treated solids.

Analysis of the routes for biomass processing towards sustainable development in the conceptual design step: Strategy based on the compendium of bioprocesses portfolio

Process sustainability has been one of the most challenging issues faced by process designers. Conceptual designed processes do not overcome this stage because aspects such as context and technological readiness level are left aside. This paper proposes a strategy to consider different processing routes for biomass (compendium of existing routes) towards sustainable development. The strategy comprises five stages where a supported bioprocesses selection is made by considering the chemical composition of the raw material and the context where biomass is produced and processed. This strategy aims to give decision tools to designers to filter and reduce the number of options to be considered when proposing an alternative biomass use. The proposed strategy was applied to upgrade orange peel waste and sugarcane bagasse to demonstrate how it can be applied. In conclusion, selecting of bioprocesses and considering the proposed strategycould improve the biorefineries design. Even so, more bioprocesses must be included.

Simulation and optimization of organosolv based lignocellulosic biomass refinery: A review

Organosolv pretreatment can be considered as the core of the lignocellulosic biomass fractionation within the biorefinery concept. Organosolv facilitates the separation of the major fractions (cellulose, hemicelluloses, lignin), and their use as renewable feedstocks to produce bioenergy, biofuels, and added-value biomass derived chemicals. The efficient separation of these fractions affects the economic feasibility of the biorefinery complex. This review focuses on the simulation of the organosolv pretreatment and the optimization of (i) feedstock delignification, (ii) sugars production (mainly from hemicelluloses), (iii) enzymatic digestibility of the cellulose fraction and (iv) quality of lignin. Simulation is used for the technoeconomic optimization of the biorefinery complex. Simulation and optimization implement a holistic approach considering the efficient technological, economic, and environmental performance of the biorefinery operational units. Consequently, an optimized organosolv stage is the first step for a sustainable, economically viable biorefinery complex in the concept of industrial ecology and zero waste circular economy.

Removal of wood extractives as pulp (pre-)treatment: a technological review

Wood extractives usually do not exceed five percent of dry wood mass but can be a serious issue for pulping as well as for the pulp itself. They cause contamination and damages to process equipment and negatively influence pulp quality. This paper addresses not only the extractives-related problems but also different solutions for these issues. It is an extensive review of different technologies for removing wood extractives, starting with methods prior to pulping. Several wood yard operations like debarking, knot separation, and wood seasoning are known to significantly decreasing the amount of wood extractives. Biological treatment has also been proven as a feasible method for reducing the extractives content before pulping, but quite hard to handle. During pulping, the extractives reduction efficiency depends on the pulping method. Mechanical pulping removes the accessory compounds of wood just slightly, but chemical pulping, on the other hand, removes them to a large extent. Organosolv pulping even allows almost complete removal of wood extractives. The residual extractives content can be significantly reduced by pulp bleaching. Nevertheless, different extraction-based methods have been developed for removing wood extractives before pulping or bleaching. They range from organic-solvent-based extractions to novel processes like supercritical fluid extractions, ionic liquids extractions, microwave technology, and ultrasonic-assisted extraction. Although these methods deliver promising results and allow utilization of wood extractives in most cases, they suffer from many drawbacks towards an economically viable industrial-scale design, concluding that further research has to be done on these topics.

Graphical abstract

Recent advances in organosolv fractionation: Towards biomass fractionation technology of the future

Organosolv treatment is among the most promising strategies for valorising lignocellulosic biomass and could facilitate the transition towards enhanced utilization of renewable feedstocks. However, issues such as inefficient solvent recycle and fractionation has to be overcome. The present review aims to address these issues and discuss the role of the components present during organosolv treatment and their influence on the overall process. Thus, the review focuses not only on how the choice of solvent and catalyst affects lignocellulosic fractionation, but also on how the choice of treatment liquor influences the possibility for solvent recycling and product isolation. Several organic solvents have been investigated in combination with water and acid/base catalysts; however, the lack of a holistic approach often compromises the performance of the different operational units. Thus, an economically viable organosolv process should optimize biomass fractionation, product isolation, and solvent recycling.

Improving the economy of lignocellulose-based biorefineries with organosolv pretreatment

Lignocellulose-based processes for production of value-added products still face bottlenecks to attain feasibility. The key might lie on the biorefining of all lignocellulose main polymers, that is, cellulose, hemicellulose and lignin. Lignin, considered an impediment in the access of cellulose and normally considered for energy recovery purposes, can give a higher contribution towards profitability of lignocellulosic biorefineries. Organosolv pretreatment allows selective fractionation of lignocellulose into separate cellulose-, hemicellulose- and lignin-rich streams. Ethanol organosolv and wood substrates dominated the research studies, while a wide range of substrates need definition on the most suitable organosolv pretreatment systems. Techno-economic and environmental analyses of organosolv-based processes as well as proper valorization strategies of the hemicellulose-rich fraction are still scarce. In view of dominance of ethanol organosolv with high delignification yields and high-purity of the recovered cellulose-rich fractions, close R & D collaboration with 1st generation ethanol plants might boost commercialization.

Lignocellulosic Biomass Fractionation by Mineral Acids and Resulting Extract Purification Processes: Conditions, Yields, and Purities

Fractionation of lignocellulose is a fundamental step in the valorization of cellulose, hemicelluloses, and lignin to produce various sustainable fuels and chemicals. Mineral acid fractionation is one of the most applied process and leads to the solubilization and hydrolysis of cellulose and hemicelluloses, whereas most of the lignin remains insoluble and can be separated from the extract. The obtained monomeric sugars in the acid extract are in solution with salts, sugar degradation products, and phenolic molecules. Downstream processing is required to purify the sugars and further valorize them into fuels or chemicals with the use of chemical or biochemical reactions. This purification step also allows the recycling of the mineral acid and the valorization of the sugar degradation products and the co-extracted phenolic molecules, adding value to the whole biorefinery scheme. Many purification techniques have been studied, providing several options in terms of yields, purities, and cost of the process. This review presents the conditions used for the mineral acid fractionation step and a wide variety of purification techniques applied on the obtained hydrolysate, with a focus on the associated yields and purities. Values from the literature are expressed in a standard way in order to simplify comparison between the different processes.

Multiscale dynamic modeling and simulation of a biorefinery

A biorefinery comprises a variety of process steps to synthesize products from sustainable natural resources. Dynamic plant‐wide simulation enhances the process understanding, leads to improved cost efficiency and enables model‐based operation and control. It is thereby important for an increased competitiveness to conventional processes. To this end, we developed a Modelica library with replaceable building blocks that allow dynamic modeling of an entire biorefinery. For the microbial conversion step, we built on the dynamic flux balance analysis (DFBA) approach to formulate process models for the simulation of cellular metabolism under changing environmental conditions. The resulting system of differential‐algebraic equations with embedded optimization criteria (DAEO) is solved by a tailor‐made toolbox. In summary, our modeling framework comprises three major pillars: A Modelica library of dynamic unit operations, an easy‐to‐use interface to formulate DFBA process models and a DAEO toolbox that allows simulation with standard environments based on the Modelica modeling language. A biorefinery model for dynamic simulation of the OrganoCat pretreatment process and microbial conversion of the resulting feedstock by Corynebacterium glutamicum serves as case study to demonstrate its practical relevance.

Membrane Fractionation of Liquors from Lignin-First Biorefining

For the utilization of each lignin fraction in the lignin liquors, the development of separation strategies to fractionate the lignin streams by molecular weight ranges constitutes a timely challenge to be tackled. Herein, membrane filtration was applied to the refining of lignin streams obtained from a lignin-first biorefining process based on H-transfer reactions catalyzed by Raney Ni, by using 2-PrOH as a part of the lignin extraction liquor and as an H-donor. A two-stage membrane cascade was considered to separate and concentrate the monophenol-rich fraction from the liquor. Building on the results, an economic evaluation of the potential of membrane filtration for the refining of lignin streams was undertaken. In this proof-of-concept report, a detailed analysis is presented of future developments in the performance required for the utilization of membrane filtration for lignin refining and, more aspiringly, solvent reclamation.

Conversion of Sugars and Biomass to Furans Using Heterogeneous Catalysts in Biphasic Solvent Systems

Within the last decade, interest in using biphasic systems for producing furans from biomass has grown significantly. Biphasic systems continuously extract furans into the organic phase, which prevents degradation reactions and potentially allows for easier separations of the products. Several heterogeneous catalyst types, including zeolites, ion exchange resins, niobium-based, and others, have been used with various organic solvents to increase furan yields from sugar dehydration reactions. In this minireview, we summarized the use of heterogeneous catalysts in biphasic systems for furfural and 5-hydroxymethylfurfural production from the past five years, highlighting trends in chemical and physical properties that effect catalytic activity. Additionally, the selection of an organic solvent for a biphasic system is extremely important and we review and discuss properties of the most commonly used organic solvents.

Chemical Recovery of γ-Valerolactone/Water Biorefinery

We introduce the optimization of the pulping conditions and propose different chemical recovery options for a proven biorefinery concept based on γ-valerolactone (GVL)/water fractionation. The pulping process has been optimized whereby the liquor-to-wood (L:W) ratio could be reduced to 3 L/kg without compromising the pulp properties as raw material for textile fibers production. The recovery of the pulping solvent was performed through combinations of lignin precipitation by water addition, distillation at reduced pressure, and liquid CO₂ extraction. With a two-step lignin precipitation coupled with vacuum distillation, more than 90% of lignin and GVL could be recovered from the spent liquor. However, a significant part of GVL remained unrecoverable in the residue, which was a highly viscous liquid with complicated phase behavior. The recovery by lignin precipitation combined with liquid CO₂ extraction could recover more than 85% GVL and 90% lignin without forming any problematic residue as in the distillation process. The remaining GVL remained in the raffinate containing a low amount of lignin and other compounds, which can be further processed to isolate the GVL and improve the recovery rate.

From beech wood to itaconic acid: case study on biorefinery process integration

Renewable raw materials in sustainable biorefinery processes pose new challenges to the manufacturing routes of platform chemicals. Beside the investigations of individual unit operations, the research on process chains, leading from plant biomass to the final products like lactic acid, succinic acid, and itaconic acid is increasing. This article presents a complete process chain from wooden biomass to the platform chemical itaconic acid. The process starts with the mechanical pretreatment of beech wood, which subsequently is subjected to chemo-catalytic biomass fractionation (OrganoCat) into three phases, which comprise cellulose pulp, aqueous hydrolyzed hemicellulose, and organic lignin solutions. Lignin is transferred to further chemical valorization. The aqueous phase containing oxalic acid as well as hemi-cellulosic sugars is treated by nanofiltration to recycle the acid catalyst back to the chemo-catalytic pretreatment and to concentrate the sugar hydrolysate. In a parallel step, the cellulose pulp is enzymatically hydrolyzed to yield glucose, which-together with the pentose-rich stream-can be used as a carbon source in the fermentation. The fermentation of the sugar fraction into itaconic acid can either be performed with the established fungi Aspergillus terreus or with Ustilago maydis. Both fermentation concepts were realized and evaluated. For purification, (in situ) filtration, (in situ) extraction, and crystallization were investigated. The presented comprehensive examination and discussion of the itaconate synthesis process-as a case study-demonstrates the impact of realistic process conditions on product yield, choice of whole cell catalyst, chemocatalysts and organic solvent system, operation mode, and, finally, the selection of a downstream concept.

One-Step Lignocellulose Fractionation by using 2,5-Furandicarboxylic Acid as a Biogenic and Recyclable Catalyst

To develop novel biorefinery concepts, the use of bio-based catalysts and solvents must be aligned with the principles of green chemistry. In this context, biogenic 2,5-furandicarboxylic acid (FDCA) is a very promising yet underused molecule with high potential for application as an acid catalyst, combining feasibility and sustainability with efficient and straightforward recovery. In this study, FDCA was evaluated as a catalyst in the recently developed OrganoCat pretreatment, a biphasic lignocellulose fractionation system. The catalyst was investigated for the efficient fractionation of the three main components-lignin, cellulose and noncellulosic sugars-with particular focus on the lignin quality, on the effect on enzymatic hydrolysis of the cellulosic residue, and on the noncellulosic sugar extraction. To address recovery of FDCA from the OrganoCat system, a method was developed, leading to the recovery of >97 % of FDCA with a spectroscopic purity of >99 %, maintaining full activity in consecutive runs.

Biphasic 2-methyltetrahydrofuran/oxalic acid/water pretreatment to enhance cellulose enzymatic hydrolysis and lignin valorization

A biphasic pretreatment was adopted to disturb the recalcitrant structure of bamboo for further enzymatic hydrolysis and to obtain easily valorized lignin by-product. The biphasic system consisted of biomass-derived chemicals-2-methyltetrahydrofuran and oxalic acid as well as water, and the reactions were conducted at 120-180°C for 20min. The treatment resulted in notable removal of hemicelluloses and lignin. After the pretreatment, the cellulose conversion rate during enzymatic hydrolysis was enhanced by 6.7-fold as compared to the unpretreated raw material. Comprehensive analysis of the lignin product indicated that it exhibited representative structure (such as β-O-4, β-β linkages) as compared to native lignin, contained a very low amount of contaminated sugars (0.67-2.39%), and had a relatively medium molecular weight (Mw 2240-3730g/mol) and good solubility in many organic solvents. This indicated that the lignin showed great potential application in conversion into materials and liquid fuels.

A co-solvent hydrolysis strategy for the production of biofuels: process synthesis and technoeconomic analysis

We develop an integrated strategy for the production of ethanol from lignocellulosic biomass.

Highly efficient organosolv fractionation of cornstalk into cellulose and lignin in organic acids

In this study, effects of fractionation solvents, catalysts, temperatures and residence time on yields, purity and chemical composition of the products were investigated at the solid/solvent ratio of 1:5 (g/g). It was revealed that mixture of acetic acid/formic acid/water at the ratio of 3:6:1 (v/v/v) resulted in crude cellulose and lignin products of relatively high purity. The use of HCl catalyst contributed to a high crude cellulose yield, while H2SO4 showed an adverse effect on cellulose yield. However, both of these acidic catalysts contributed to much lower hemicellulose contents in the resulted crude cellulose products compared with those obtained without a catalyst. Fractionation at 90°C for 180min in mixed solvents of acetic acid/formic acid/water (3:6:1, v/v/v) with or without catalyst produced crude cellulose with very low residual lignin contents (<4%).

Paving the Way for Lignin Valorisation: Recent Advances in Bioengineering, Biorefining and Catalysis

Lignin is an abundant biopolymer with a high carbon content and high aromaticity. Despite its potential as a raw material for the fuel and chemical industries, lignin remains the most poorly utilised of the lignocellulosic biopolymers. Effective valorisation of lignin requires careful fine-tuning of multiple "upstream" (i.e., lignin bioengineering, lignin isolation and "early-stage catalytic conversion of lignin") and "downstream" (i.e., lignin depolymerisation and upgrading) process stages, demanding input and understanding from a broad array of scientific disciplines. This review provides a "beginning-to-end" analysis of the recent advances reported in lignin valorisation. Particular emphasis is placed on the improved understanding of lignin's biosynthesis and structure, differences in structure and chemical bonding between native and technical lignins, emerging catalytic valorisation strategies, and the relationships between lignin structure and catalyst performance.

Recent advances in alcohol and organic acid fractionation of lignocellulosic biomass

Organosolv fractionation is a promising process to separate lignocellulosic biomass for the preparation of multiply products including biofuels, chemicals, and materials. This review presents the state of art of different processes applying alcohols and organic acids to treat lignocellulosic biomass for the production of ethanol, lignin, xylose, etc. The major organosolv technologies using ethanol, formic acid, and acetic acid, are intensively introduced and discussed in depth. In addition, the structural modifications of the major components of lignocelluloses, the technical processes, and the applications of the products were also summarized. The object of the review is to provide recent information in the field of organosolv process for the integrated biorefinery. The perspectives of the challenge and opportunity related to this topic are also presented.

Advanced process for precipitation of lignin from ethanol organosolv spent liquors

An advanced process for lignin precipitation from organosolv spent liquors based on ethanol evaporation was developed. The process avoids lignin incrustations in the reactor, enhances filterability of the precipitated lignin particles and significantly reduces the liquor mass in downstream processes. Initially, lignin solubility and softening properties were understood, quantified and exploited to design an improved precipitation process. Lignin incrustations were avoided by targeted precipitation of solid lignin at specific conditions (e.g. 100 mbar evaporation pressure, 43°C and 10%wt. of ethanol in lignin dispersion) in fed-batch operation at lab and pilot scale. As result of evaporation the mass of spent liquor was reduced by about 50%wt., thus avoiding large process streams. By controlled droplet coalescence the mean lignin particle size increased from below 10 μm to sizes larger than 10 μm improving the significantly filterability.

Pretreatment and conversion of lignocellulose biomass into valuable chemicals

Lignocellulose biomass can be utilized in many sectors of industry such as energy, chemical, and transportation. However, pretreatment is needed to break down the intricate bonding before converting it into wanted product.

Current Pretreatment Technologies for the Development of Cellulosic Ethanol and Biorefineries

Lignocellulosic materials, such as forest, agriculture, and agroindustrial residues, are among the most important resources for biorefineries to provide fuels, chemicals, and materials in such a way to substitute for, at least in part, the role of petrochemistry in modern society. Most of these sustainable biorefinery products can be produced from plant polysaccharides (glucans, hemicelluloses, starch, and pectic materials) and lignin. In this scenario, cellulosic ethanol has been considered for decades as one of the most promising alternatives to mitigate fossil fuel dependence and carbon dioxide accumulation in the atmosphere. However, a pretreatment method is required to overcome the physical and chemical barriers that exist in the lignin-carbohydrate composite and to render most, if not all, of the plant cell wall components easily available for conversion into valuable products, including the fuel ethanol. Hence, pretreatment is a key step for an economically viable biorefinery. Successful pretreatment method must lead to partial or total separation of the lignocellulosic components, increasing the accessibility of holocellulose to enzymatic hydrolysis with the least inhibitory compounds being released for subsequent steps of enzymatic hydrolysis and fermentation. Each pretreatment technology has a different specificity against both carbohydrates and lignin and may or may not be efficient for different types of biomasses. Furthermore, it is also desirable to develop pretreatment methods with chemicals that are greener and effluent streams that have a lower impact on the environment. This paper provides an overview of the most important pretreatment methods available, including those that are based on the use of green solvents (supercritical fluids and ionic liquids).

A hierarchical approach for the design improvements of an Organocat biorefinery

Lignocellulosic biomass has emerged as a potentially attractive renewable energy source. Processing technologies of such biomass, particularly its primary separation, still lack economic justification due to intense energy requirements. Establishing an economically viable and energy efficient biorefinery scheme is a significant challenge. In this work, a systematic approach is proposed for improving basic/existing biorefinery designs. This approach is based on enhancing the efficiency of mass and energy utilization through the use of a hierarchical design approach that involves mass and energy integration. The proposed procedure is applied to a novel biorefinery called Organocat to minimize its energy and mass consumption and total annualized cost. An improved heat exchanger network with minimum energy consumption of 4.5 MJ/kgdry biomass is designed. An optimal recycle network with zero fresh water usage and minimum waste discharge is also constructed, making the process more competitive and economically attractive.

Enzymatic degradation of (ligno)cellulose

Glycoside-degrading enzymes play a dominant role in the biochemical conversion of cellulosic biomass into low-price biofuels and high-value-added chemicals. New insight into protein functions and substrate structures, the kinetics of recognition, and degradation events has resulted in a substantial improvement of our understanding of cellulose degradation.