Catalytic pyrolysis of lignin in a cascade dual-catalyst system of modified red mud and HZSM-5 for aromatic hydrocarbon production

ZSM-5@ceramic foam composite catalyst derived from spent bleaching clay for continuous pyrolysis of waste oil to produce monocyclic aromatic hydrocarbons

Spent bleaching clay, a solid waste generated during the refining process of vegetable oils, lacks an efficient treatment solution. In this study, spent bleaching clay was innovatively employed to fabricate ceramic foams. The thermal stability analysis, microstructure, and crystal phase composition of the ceramic foams were characterized by TG-DSC, SEM, and XRD. An investigation into the influence of Al2O3 content on the ceramic foams was conducted. Results showed that, as the Al2O3 content increased from 15 wt% to 30 wt%, there was a noticeable decrease in bulk density and linear shrinkage, accompanied by an increase in compressive strength. Additionally, the ceramic foams were used as catalyst supports, to synthesize ZSM-5@ceramic foam composite catalysts for pyrolysis of waste oil. The open pores of the ZSCF catalyst not only reduced diffusion path length but also facilitated the exposure of more acid sites, thereby increasing the utilization efficiency of ZSM-5 zeolite. This, in turn, engendered a significant enhancement in monocyclic aromatic hydrocarbons content from 39.15 % (ZSM-5 powder catalyst) to 78.96 %. Besides, a larger support pore size and a thicker ZSM-5 zeolite coating layer led to an increase in monocyclic aromatic hydrocarbons content. As the time on stream was extended to 56 min, the monocyclic aromatic hydrocarbon content obtained with the composite catalyst remained 12.41 % higher than that of the ZSM-5 powder catalyst. These findings validate the potential of the composite catalyst. In essence, this study advances the utilization of spent bleaching clay and introduces a novel concept for ceramic foam fabrication. Furthermore, it contributes to the scaling up of catalytic pyrolysis technology.

Selective production of phenolic monomer via catalytic depolymerization of lignin over cobalt-nickel-zirconium dioxide catalyst

The utilization of lignin, an abundant and renewable bio-aromatic source, is of significant importance. In this study, lignin oxidation was examined at different temperatures with zirconium oxide (ZrO2)-supported nickel (Ni), cobalt (Co) and bimetallic Ni-Co metal catalysts under different solvents and oxygen pressure. Non-catalytic oxidation reaction produced maximum bio-oil (35.3 wt%), while catalytic oxidation significantly increased the bio-oil yield. The bimetallic catalyst Ni-Co/ZrO2 produced the highest bio-oil yield (67.4 wt%) compared to the monometallic catalyst Ni/ZrO2 (59.3 wt%) and Co/ZrO2 (54.0 wt%). The selectively higher percentage of vanillin, 2-methoxy phenol, acetovanillone, acetosyringone and vanillic acid compounds are found in the catalytic bio-oil. Moreover, it has been observed that the bimetallic Co-Ni/ZrO2 produced a higher amount of vanillin (43.7% and 13.30 wt%) compound. These results demonstrate that the bimetallic Ni-Co/ZrO2 catalyst promotes the selective cleavage of the ether β-O-4 bond in lignin, leading to a higher yield of phenolic monomer compounds.

Catalytic flash pyrolysis of Scenedesmus sp. post-extraction residue using low-cost HZSM-5 catalyst with the perspective to produce renewable aromatic hydrocarbons

Recovering renewable chemicals from de-fatted microalgal residue derived from lipid extraction within the algal-derived biofuel sector is crucial, given the rising significance of microalgal-derived biodiesel as a potential substitute for petroleum-based liquid fuels. As a circular economy strategy, effective valorization of de-fatted biomass significantly improves the energetic and economic facets of establishing a sustainable algal-derived biofuel industry. In this scenario, this study investigates flash catalytic pyrolysis as a sustainable pathway for valorizing Scenedesmus sp. post-extraction residue (SPR), potentially yielding a bio-oil enriched with upgraded characteristics, especially renewable aromatic hydrocarbons. In the scope of this study, volatile products from catalytic and non-catalytic flash pyrolysis were characterized using a micro-furnace type temperature programmable pyrolyzer coupled with gas chromatographic separation and mass spectrometry detection (Py-GC/MS). Flash pyrolysis of SPR resulted in volatile products with elevated oxygen and nitrogen compounds with concentrations of 46.4% and 26.4%, respectively. In contrast, flash pyrolysis of lyophilized microalgal biomass resulted in lower concentrations of these compounds, with 40.9% oxygen and 17.3% nitrogen. Upgrading volatile pyrolysis products from SPR led to volatile products comprised of only hydrocarbons, while completely removing oxygen and nitrogen-containing compounds. This was achieved by utilizing a low-cost HZSM-5 catalyst within a catalytic bed at 500 °C. Catalytic experiments also indicate the potential conversion of SPR into a bio-oil rich in monocyclic aromatic hydrocarbons, primarily BETX, with toluene comprising over one-third of its composition, thus presenting a sustainable pathway for producing an aromatic hydrocarbon-rich bio-oil derived from SPR. Another significant finding was that 97.8% of the hydrocarbon fraction fell within the gasoline range (C5-C12), and 35.5% fell within the jet fuel range (C8-C16). Thus, flash catalytic pyrolysis of SPR exhibits significant promise for application in drop-in biofuel production, including green gasoline and bio-jet fuel, aligning with the principles of the circular economy, green chemistry, and bio-refinery.

Advances in the fabrication, modification, and performance of biochar, red mud, calcium oxide, and bentonite catalysts in waste-to-fuel conversion

Various catalysts are being used in fuel production from biomass and polymeric waste for the obtention of an alternative energy source with both environmental friendliness and economic viability. Biochar, red mud bentonite, and calcium oxide have been shown to play a pertinent role as catalysts in waste-to-fuel conversion processes, such as transesterification and pyrolysis. In this line of thought, this paper has provided a compendium of the fabrication and modification technologies of bentonite, red mud calcium oxide, and biochar, together with their various performances in their application in the waste-to-fuel processes. Additionally, an overview of the structural and chemical attributes of these components is discussed regarding their efficiency. Ultimately, research trends and future points of focus are evaluated, and it is observed that techno-economic optimization of catalyst synthetic routes and investigation of new catalytic formulations, such as biochar and red mud-based nanocatalysts, are potential prospects. This report also offers future research directions that are anticipated to contribute to the development of sustainable green fuel generation systems.

Lignin and spent bleaching clay into mono-aromatic hydrocarbons by a cascade dual catalytic pyrolysis system: Critical role of spent bleaching clay

In the present study, a cascade dual catalytic system was used for the co-pyrolysis of lignin with spent bleaching clay (SBC) to efficiently produce mono-aromatic hydrocarbon (MAHs). The cascade dual catalytic system is composed of calcined SBC (CSBC) and HZSM-5. In this system, SBC not only acts as a hydrogen donor and catalyst in the co-pyrolysis process, but is also used as a primary catalyst in the cascade dual catalytic system after recycling the pyrolysis residues. The effects of different influencing factors (i.e., temperature, CSBC-to-HZSM-5 ratio, and raw materials-to-catalyst ratio) on the system were explored. It was observed that, when the temperature was 550 °C, the CSBC-to-HZSM-5 ratio was 1:1, and when the raw materials-to-catalyst ratio was 1:2, the highest bio-oil yield was 21.35 wt%. The relative MAHs content in bio-oil was 73.34 %, whereas the relative polycyclic aromatic hydrocarbons (PAHs) content was 23.01 %. Meanwhile, the introduction of CSBC inhibited the generation of graphite-like coke as indicated by HZSM-5. This study realizes the full resource utilization of spent bleaching clay and reveals the environmental hazards caused by spent bleaching clay and lignin waste.

Evaluation of Behavior of 13X Zeolite Modified with Transition Metals for Catalytic Applications

This work was intended to develop catalysts based on 13X zeolite modified with transition metals for catalytic applications. In this regard, 13X zeolite was modified by loading of transition metals such as Fe, Co, Cu and various types of catalysts such as Fe-, Co-, Cu-, Fe-Co-, Fe-Cu-, and Co-Cu/13X zeolite were obtained. To prepare these catalysts, the wet impregnation method and metallic precursors were used. The catalysts were characterized by SEM, XRD, BET, and ammonia adsorption. Then the catalytic performance was investigated during upgrading of rapeseed residual biomass pyrolysis vapors using this catalysts and a fixed-bed reactor in two stages. Experimental results showed that the addition of transition metals improved the catalytic selectivity towards aromatic hydrocarbons and Fe-Cu/13X zeolite catalyst was the best and had a high deoxygenation activity (from 62.45% to 20.56%), produced maximum monoaromatic hydrocarbons (of 27.45%), the oxygen content in bio-oil was reduced from 34.98 wt% to 16.06 wt%, the calorific value increased and thus the bio-oil quality was improved.

Synthesis of CaO from waste shells for microwave-assisted catalytic pyrolysis of waste cooking oil to produce aromatic-rich bio-oil

Energy shortage and environmental pollution have attracted long-term attention. In this study, CaO were prepared from waste eggshell (EGC), preserved egg shell (PEC), clam shell (CLC) and crab shell (CRC), which were then compared with commercial CaO (CMC) to catalyze microwave-assisted pyrolysis of waste cooking oil (WCO) for enrichment of aromatics in bio-oil. The characterization results indicated that EGC and CLC contained 95.54% and 95.61% CaO respectively, which were higher than that of CMC (95.11%), and the pore properties of EGC were the best. In addition, the effects of CaO type and catalytic mode on pyrolysis were studied. In CaO catalytic pyrolysis, CMC and CLC in-situ catalysis produced more aromatics than ex-situ catalysis, and PEC and CRC were more conducive to aromatics formation in ex-situ condition. EGC was conducive to produce benzene, toluene and xylene (BTX) both in in-situ (19.04%) and ex-situ (20.76%) catalytic pyrolysis. In CaO/HZSM-5 catalysis, the optimal dual catalytic mode for generating monocyclic aromatic hydrocarbons (MAHs) was Mode A (CaO separated from HZSM-5 for ex-situ catalysis), and EGC/HZSM-5 performed well in benzene, toluene and xylene (BTX) production.

Cr/13X Zeolite and Zn/13X Zeolite Nanocatalysts Used in Pyrolysis of Pretreated Residual Biomass to Produce Bio-Oil with Improved Quality

By loading Cr and Zn on 13X zeolite, efficient nanocatalysts were prepared; they were characterized by different techniques and used for corn cobs pyrolysis to produce bio-oil. The corn cobs biomass (CCB) was washed with sulfuric acid 0.1 M, and the characteristics of the pretreated biomass (PTCCB) were analyzed. Pyrolysis was performed at different catalyst-to-biomass ratios (C/B), and the composition of the obtained bio-oil was determined. The results showed that the crystallinity of the nanocatalysts was slightly lower than that of the pattern 13X zeolite. The surface observation of the nanocatalysts showed the presence of pores and particles, which are quite evenly dispersed on the surface, and no difference was observed in the morphology of the Zn/13X zeolite and Cr /13X zeolite nanocatalysts. In comparison to 13X zeolite, the morphological changes, metal dispersion, and surface area decrease of both Zn/13X and Cr/13X zeolite nanocatalysts could be observed. Pyrolysis tests demonstrated that the use of Zn/13X zeolite and Cr/13X zeolite nanocatalysts could be very profitable to obtain a high conversion to hydrocarbons of the compounds containing oxygen, and consequently, the quality of the bio-oil was improved.

Catalytic pyrolysis of lignocellulosic biomass for bio-oil production: A review

Catalytic pyrolysis has been widely explored for bio-oil production from lignocellulosic biomass owing to its high feasibility and large-scale production potential. The aim of this review was to summarize recent findings on bio-oil production through catalytic pyrolysis using lignocellulosic biomass as feedstock. Lignocellulosic biomass, structural components and fundamentals of biomass catalytic pyrolysis were explored and summarized. The current status of bio-oil yield and quality from catalytic fast pyrolysis was reviewed and presented in the current review. The potential effects of pyrolysis process parameters, including catalysts, pyrolysis conditions, reactor types and reaction modes on bio-oil production are also presented. Techno-economic analysis of full-scale commercialization of bio-oil production through the catalytic pyrolysis pathway was reviewed. Further, limitations associated with current practices and future prospects of catalytic pyrolysis for production of high-quality bio-oils were summarized. This review summarizes the process of bio-oil production from catalytic pyrolysis and provides a general scientific reference for further studies.

Elucidating radical-mediated pyrolysis behaviors of preoxidized lignins

Effect of lignin preoxidation on subsequent radical-mediated pyrolysis was discussed in this study. Technical hot-water-extracted lignin was preoxidized by 2,3-dichloro-5,6-dicyano-1,4-benzoquinone in diverse degrees and pyrolyzed under different temperatures. Characterizations indicated that preoxidation increased lignin oxygen contents and converted α-hydroxyls to α-carbonyls. These structural modifications caused by preoxidation reduced the thermal stability and pyrolysis reactivity of lignin, shifting lignin thermal decomposition to the low temperature region and inhibiting lignin pyrolysis into bio-oil fractions. However, recognition of species and yields of specific compounds via analytical pyrolysis declared that although preoxidation reduced product yields, it did not alter the reaction pathways. The fixed bed experiments proved the above findings and gave the gas compositions, mainly CO₂ derived through decarbonylation. Both radicals in chars and bio-oils were monitored, and char radical concentrations were proportional to the preoxidation degrees. This work sorted out the performances of lignin pyrolysis after preoxidation and determined their negative effects.

BTEX recovery from waste rubbers by catalytic pyrolysis over Zn loaded tire derived char

Recovering valuable chemicals (BTEX: Benzene, toluene, ethylbenzene, and xylene) via catalytic pyrolysis of waste tires is a promising and sustainable approach. Zinc loaded tire derived char (TDC) was used as cheap catalyst for recovering valuable BTEX products from waste tire through pyrolysis in this study. The catalytic capability of TDC on BTEX production were experimentally investigated with respect to Zn content, catalytic temperature, and catalyst-to-tire ratio. Due to the abundant acid sites on the surface, the TDC showed notable catalytic capability for improving BTEX yield which was 2.4 times higher than that from uncatalyzed case. The loading of additional Zn increased the acid sites on the TDC and the catalytic performance was further improved. The increase of catalytic temperature and catalyst-to-tire ratio favored the formation of BTEX, but it also brought undesirable consequences, such as the mass loss of tire pyrolysis oil (TPO) and the formation of polycyclic aromatic hydrocarbons. The optimal TPO products were obtained at 600 °C with catalyst-to-tire ratio of 20. At this condition, the relative content of BTEX reached 54.70% and the cumulative BTEX yield was 10.13 wt%, increasing by 5.95 times compared to that of non-catalytic condition. This work provided a novel strategy of replacing traditional expensive catalysts with low-cost and effective carbon-based materials in the field of catalytic pyrolysis of waste tires.

Catalytic upgrade for pyrolysis of food waste in a bubbling fluidized-bed reactor

Biofuel production via pyrolysis has received increasing interest as a promising solution for utilization of now wasted food residue. In this study, the fast pyrolysis of mixed food waste (MFW) was performed in a bubbling fluidized-bed reactor. This was done under different operating conditions (reaction temperatures and carrier gas flow rate) that influence product distribution and bio-oil composition. The highest liquid yield (49.05 wt%) was observed at a pyrolysis temperature of 475 °C. It was also found that the quality of pyrolysis bio-oils (POs) could be improved using catalysts. The catalytic fast pyrolysis of MFW was studied to upgrade the pyrolysis vapor, using dolomite, red mud, and HZSM-5. The higher heating values (HHVs) of the catalytic pyrolysis bio-oils (CPOs) ranged between 30.47 and 35.69 MJ/kg, which are higher than the HHVs of non-catalytic pyrolysis bio-oils (27.69-31.58 MJ/kg). The major components of the bio-oils were fatty acids, N-containing compounds, and derivatives of phenol. The selectivity for bio-oil components varied depending on the catalysts. In the presence of the catalysts, the oxygen was removed from oxygenates via moisture, CO₂, and CO. The CPOs contained aliphatic hydrocarbons, polycyclic aromatic compounds (such as naphthalene), pyridine derivatives, and light oxygenates (cyclic alkenes and ketones).

Catalytic hydrothermal liquefaction of lignin for production of aromatic hydrocarbon over metal supported mesoporous catalyst

Catalytic hydrothermal liquefaction (HTL) of lignin was examined at various temperature (250-310 °C) and reaction time in the presence of different solvents (water, methanol and ethanol) with different metal supported on MCM-41 mesoporous catalyst. In case of ethanol solvent, the maximum bio-oil yield of 56.2 wt% was obtained with Ni-Al/MCM-41. However in case of water, bio-oil yield was (44.3 wt%); while significantly improves bio-oil yield for methanol solvent (48.1 wt%). It is indicated that alcoholic solvents promoted the lignin decomposition, while in the presence of catalyst; water solvent significantly improves lignin degradation. Loading of Ni and Al on MCM-41, the acid strength of the catalyst increased, which enhanced lignin degradation. From the GC-MS analysis, the main G-type (ca.54%) phenolic compounds were produced with higher percentage of aromatic hydrocarbon compounds. CHNS and GPC analysis showed that catalytic liquefaction encouraged hydrodeoxygenation, which produced lower oxygen content bio-oil with lower molecular weight.

Catalytic cracking of Etek lignin with zirconia supported metal-oxides for alkyl and alkoxy phenols recovery

Alkyl and alkoxy phenols are desirable products from the catalytic depolymerisation of lignin. In this work, ex-situ catalytic pyrolysis of Etek lignin in presence of Na, Ce, NiCe, MgCe, Fe and FePd on ZrO₂ was studied_. The largest combined yield of monomeric phenolics and alkylphenols was produced by Na/ZrO₂ catalysts. A parametric study of the most promising Na/ZrO₂ then resulted in using a catalyst:lignin ratio of 3:1 at 500 °C as the best option, enhancing at 17.5 wt% the recovery of total phenolics including 6 wt% alkyl phenols, which is equivalent to 27.8 wt% and 9.5 wt% of the starting lignin in Etek lignin waste. The study of the catalyst basicity indicates that the mild basicity of Na/ZrO₂ was mostly responsible for the enhanced mono phenols recovery. Due to formation of thermally stable Na₂CO₃ during pyrolysis, successful Na/ZrO₂ regeneration requires temperature of 900 °C or higher.

Novel insight into pyrolysis behaviors of lignin using in-situ pyrolysis-double ionization time-of-flight mass spectrometry combined with electron paramagnetic resonance spectroscopy

In-situ detection on primary volatiles and stable radicals is of great importance for better understanding of lignin pyrolysis mechanisms and utilization. In this study, a novel in-situ pyrolysis time-of-flight mass spectrometry with double ionization sources was taken to in-situ detect primary volatiles and gas products, and the evolution of stable radicals in lignin pyrolysis residues was explored by EPR spectroscopy. The results show that the cleavage of β-O-4 linkage is mainly responsible for lignin depolymerization at 100-300 °C, releasing the G-type compounds. And these G-type compounds can further undergo O-CH₃, C_ar-OCH₃ and C_ar-OH bonds cleavage to form biphenolic hydroxyl compounds, phenols and aromatic hydrocarbons. According to the EPR analysis, the radical concentration increased from 10¹⁷ to 10¹⁹ spins/g with the temperature, and stable free-radical species are mainly composed of the o-methoxy and hydroxyl substituted phenoxy radicals and carbon-centered aromatic radicals, which can well interpret the demethylation, demethoxylation and dehydroxylation mechanisms.

Advances in lignin valorization towards bio-based chemicals and fuels: Lignin biorefinery

Lignin is one of the most promising renewable sources for aromatic hydrocarbons, while effective depolymerization towards its constituent monomers is a particular challenge because of the structural complexity and stability. Intensive research efforts have been directed towards exploiting effective valorization of lignin for the production of bio-based platform chemicals and fuels. The present contribution aims to provide a critical review of key advances in the identification of exact lignin structure subjected to various fractionation technologies and demonstrate the key roles of lignin structures in depolymerization for unique functionalized products. Various technologies (e.g., thermocatalytic approaches, photocatalytic conversion, and mechanochemical depolymerization) are reviewed and evaluated in terms of feasibility and potential for further upgrading. Overall, advances in pristine lignin structure analysis and conversion technologies can facilitate recovery and subsequent utilization of lignin towards tailored commodity chemicals and fungible fuels.

New sight on the lignin torrefaction pretreatment: Relevance between the evolution of chemical structure and the properties of torrefied gaseous, liquid, and solid products

In order to reveal the deoxygenation mechanism of lignin torrefaction, the relevance between evolution of chemical structure of torrefied lignin and the properties of torrefied gaseous, liquid, and solid products was established in this study. Results showed that the contents of oxygen element, βO4 linkages, oxygen-containing functional groups (aliphatic OH, aliphatic COOH, aromatic OCH₃) in lignin decreased with the increase of the torrefaction temperature from 210 to 300 °C. The oxygen removal efficiency of lignin torrefaction reached the maximum value of 25.53% at 300 °C. The removed oxygen in the torrefied lignin was transferred into the torrefied gaseous product (e.g. CO₂, H₂O, and CO) and torrefied liquid product (e.g. G-type and P-type phenols, acids). Among the torrefied gaseous products, CO₂ was the dominant oxygen carrier, followed by CO and H₂O. Among the torrefied liquid products, G-type phenols were the dominant oxygen carrier, followed by P-type phenols and acids.

One-step alcoholysis of lignin into small-molecular aromatics: Influence of temperature, solvent, and catalyst

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The reactant suspension mode is an effective strategy to deoxy-liquefaction of lignin.

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The catalyst Cu-C has the optimal catalytic activity and selectivity in methanol.

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The catalyst Fe-SiC possesses the optimal catalytic deoxygenation in ethanol.

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The cleavages of C—O ether bonds and C—C bonds directly promote the formation of small-molecular aromatics.

Lignin valorization is a challenge because of its complex structure and high thermal stability. Supercritical alcoholysis of lignin without external hydrogen in a self-made high-pressure reactor is investigated under different temperatures (450–500 °C) and solvents as well as catalysts by using a reactant suspension mode. Small-molecular arenes and mono-phenols (C₇-C₁₂) are generated under short residence time of 30 min. High temperature (500 °C) favors efficient deoxy-liquefaction of lignin (70%) and formation of small-molecular arenes (C₆-C₉). Solvents methanol and ethanol demonstrate much more synergistic effect on efficient deoxy-liquefaction of lignin than propanol. The catalyst Cu-C has the optimal activity and selectivity in methanol (70% of conversion, 83.93% of arenes), whereas Fe-SiC possesses the optimal catalytic deoxygenation in ethanol, resulting in the formation of arenes other than phenols. Further analysis indicates that lignin is converted into arenes by efficient cleavages of C—O ether bonds and C—C bonds under high temperature and pressure.