Production of levulinic acid from corn cob residue in a fed-batch acid hydrolysis process

Biotechnological valorization of levulinic acid as a non-sugar feedstock: New paradigm in biorefineries

Due to the severe climate crisis, biorefineries have been highlighted as replacements for fossil fuel-derived refineries. In traditional sugar-based biorefineries, levulinic acid (LA) is a byproduct. Nonetheless, in 2002, the US Department of Energy noted that LA is a significant building block obtained from biomass, and the biorefinery paradigm has shifted from being sugar-based to non-sugar-based. Accordingly, LA is of interest in this review since it can be converted into useful precursors and ultimately can broaden the product spectrum toward more valuable products (e.g., fuels, plastics, and pharmaceuticals), thereby enabling the construction of economically viable biorefineries. This study comprehensively reviews LA production techniques utilizing various bioresources. Recent progress in enzymatic and microbial routes for LA valorization and the LA-derived product spectrum and its versatility are discussed. Finally, challenges and future outlooks for LA-based non-sugar biorefineries are suggested.

Catalytic Transformation of Carbohydrates into Renewable Organic Chemicals by Revering the Principles of Green Chemistry

Adherence to the principles of green chemistry in a biorefinery setting ensures energy efficiency, reduces the consumption of materials, simplifies reactor design, and rationalizes the process parameters for synthesizing affordable organic chemicals of desired functional efficacy and ingrained sustainability. The green chemistry metrics facilitate assessing the relative merits and demerits of alternative synthetic pathways for the targeted product(s). This work elaborates on how green chemistry has emerged as a transformative framework and inspired innovations toward the catalytic conversion of biomass-derived carbohydrates into fuels, chemicals, and synthetic polymers. Specific discussions have been incorporated on the judicious selection of feedstock, reaction parameters, reagents (stoichiometric or catalytic), and other synthetic auxiliaries to obtain the targeted product(s) in desired selectivity and yield. The prospects of a carbohydrate-centric biorefinery have been emphasized and research avenues have been proposed to eliminate the remaining roadblocks. The analyses presented in this review will steer to developing superior synthetic strategies and processes for envisaging a sustainable bioeconomy centered on biomass-derived carbohydrates.

Coupling process for preparing biomass-based furfural and levulinic acid from corncob: Extraction, green chemistry and techno-economic assessment

The purpose of this study is to design and investigate two coupling processes for acid-catalyzed hydrolysis of corncob, achieving the simultaneous preparation of biomass-based furfural and levulinic acid (LA). Meanwhile, high concentration and yield of LA were obtained through a situ feeding strategy of pretreated furfural residue with high solids loading (20%, w/v). In Scenario A, 2-methyltetrahydrofuran was selected as the solvent for the LA extraction process compared with the neutralization process in Scenario B. Techno-economic assessment results show that Scenario A is technically feasible and cost-competitive, with an internal rate of return of 21.92%, a net present value of 121 million US dollars, a carbon efficiency of 72%, an environmental factor of 4.38, and a process mass intensity of 32.19. This study will provide new insights for fully utilizing lignocellulosic biomass to prepare renewable energy resources, comprehensively evaluating the economic feasibility, and promoting green and low-carbon development.

Microwave radiation-assisted synthesis of levulinic acid from microcrystalline cellulose: Application to a melon rind residue

The circular economy considers waste to be a new raw material for the development of value-added products. In this context, agroindustrial lignocellulosic waste represents an outstanding source of new materials and platform chemicals, such as levulinic acid (LA). Herein we study the microwave (MW)-assisted acidic conversion of microcrystalline cellulose (MCC) into LA. The influence of acidic catalysts, inorganic salt addition and ball-milling pre-treatment of MCC on LA yield was assessed. Depolymerization and disruption of cellulose was monitored by FTIR, TGA and SEM, whereas the products formed were analyzed by HPLC and NMR spectroscopy. The parameters that afforded the highest LA yield (48 %, 100 % selectivity) were: ball-milling pre-treatment of MCC for 16 min at 600 rpm, followed by MW-assisted thermochemical treatment for 20 min at 190 °C, aqueous p-toluenesulfonic acid (p-TSA) 0.25 M as catalyst and saturation with KBr. These optimal conditions were further applied to a lignocellulosic feedstock, namely melon rind, to afford a 51 % yield of LA. These results corroborate the suitability of this method to obtain LA from agroindustrial wastes, in line with a circular economy-based approach.

Development of bioprocess for corncob-derived levulinic acid production

Levulinic acid is a significant platform chemical obtained from biomass and can potentially be used to produce value-added biofuels, biopolymers, and biopharmaceuticals. This study aims at statistically optimizing levulinic acid production from agrowastes. Based on the total carbohydrate content (71.93 %), corncob was selected as the target feedstock. A Box-Behnken design with four factors, such as feedstock concentration, reaction time, reaction temperature, and catalyst concentration, was used to optimize the hydrothermal conversion of corncob to levulinic acid at 180 °C for 30 min using 1 M H₂SO₄ as the acid catalyst and 120 g/L corncob. The maximum yield of 19.9 % was obtained. Additionally, 8.1 g/L formic acid was co-produced. The results of this study can contribute toward valorization of levulinic acid. Moreover, our results can be useful in developing strategies to utilize agrowastes as a renewable feedstock for recent biorefineries to cope with the climate crisis.

Integrative process for rubberwood waste digestibility improvement and levulinic acid production by hydrothermal pretreatment with acid wastewater conversion process

This study aimed to develop an integrative process for converting rubberwood waste into sugars, methane, and levulinic acid. Sulfuric acid pretreatment at pH 2.5 yielded the highest glucose of 182.5 g/kg rubberwood waste. Replacing the acid solution with sulfuric acid wastewater led to 11.0% lower glucose yield than that obtained using sulfuric acid. However, the cost reduction equals the difference in revenues between sulfuric acid wastewater and sulfuric acid, resulting in similar total cost and revenue. Furthermore, thermal reactions of the process water resulted in the highest yield of levulinic acid, 17.9% at 220 °C. Meanwhile, anaerobic digestibility of enzymatic hydrolysis residue was increased using inoculum from a digester treating pig farm wastewater owing to the acetoclastic pathway. These co-products potentially returned additional revenues, accounting for 45.8% of the total revenue. These findings highlight the potential pathway for valorization of rubberwood waste via the integrated approach with acid wastewater pretreatment.

Levulinic Acid Production from Macroalgae: Production and Promising Potential in Industry

The development of macroalgal biorefinery products as an alternative source of renewable fuels is an opportunity to solve the dependence on fossil fuels. Macroalgae is a potential biomass that can be developed as a raw material for producing platform chemicals such as levulinic acid (LA). In the industrial sector, LA is among the top 12 biomass-derived feedstocks designated by the U.S. Department of Energy as a high-value chemical. Several studies have been conducted on the production of LA from terrestrial-based biomass, however, there is still limited information on its production from macroalgae. The advantages of macroalgae over terrestrial and other biomasses include high carbohydrate and biomass production, less cultivation cost, and low lignin content. Therefore, this study aims to investigate the potential and challenge of producing LA from macroalgae in the industrial sector and determine its advantages and disadvantages compared with terrestrial biomass in LA production. In this study, various literature sources were examined using the preferred reporting items for systematic reviews and meta-analyses (PRISMA) method to identify, screen, and analyze the data of the published paper. Despite its advantages, there are some challenges in making the production of levulinic acid from macroalgae feasible for development at the industrial scale. Some challenges such as sustainability of macroalgae, the efficiency of pretreatment, and hydrolysis technology are often encountered during the production of levulinic acid from macroalgae on an industrial scale.

Chemoenzymatic valorization of agricultural wastes into 4-hydroxyvaleric acid via levulinic acid

Given that (i) levulinic acid (LA) is one of the most significant platform chemicals derived from biomass and (ii) 4-hydroxyvaleric acid (4-HV) is a potential LA derivative, the aim of this study is to achieve chemoenzymatic valorization of LA, which was obtained from agricultural wastes, to 4-HV. The thermochemical process utilized agricultural wastes (i.e., rice straw and corncob) as feedstocks and successfully produced LA, ranging from 25.1 to 65.4 mM. Additionally, formate was co-produced and used as a hydrogen source for the enzymatic hydrogenation of LA. Finally, engineered 3-hydroxybutyrate dehydrogenase from Alcaligenes faecalis (eHBDH) was applicable for catalyzing the conversion of agricultural wastes-driven LA, resulting in a maximum concentration of 11.32 mM 4-HV with a conversion rate of 48.2%. To the best of our knowledge, this is the first report describing the production of 4-HV from actual biomass, and the results might provide insights into the valorization of agricultural wastes.

Synthesis of a Stable Solid Acid Catalyst from Chloromethyl Polystyrene through a Simple Sulfonation for Pretreatment of Lignocellulose in Aqueous Solution

A stable solid acid catalyst, SCPR140-1, was synthesized from chloromethyl polystyrene resin (CPR) and used for catalytic pretreatment of corncob in aqueous solution. Under the optimized pretreatment condition, 73.07 % of xylose was directly obtained, and the enzymatic digestibility of treated residue reached up to 94.65 %, indicating that the SCPR140-1 had high selectivity for xylose production and effectively deconstructed the structure of corncob. The -CH₂ Cl group of CPR was substituted by -SO₃ H through the sulfonation, and the -SO₃ H was stably bound on the catalyst during the pretreatment process. Compared with other similar reports, the SCPR140-1 was not only synthesized through a simpler process but also had a more stable catalytic activity during multiple recycling runs.

Kinetic investigation of dilute acid hydrolysis of hardwood pulp for microcrystalline cellulose production

This work presents a kinetic investigation of dilute sulfuric acid hydrolysis of bleached hardwood kraft pulp. The temperature-time dependence shows fast xylose extraction during the initial period of the process, while the glucose content increases slowly and permanently over the period. A conversion of xylose into furfural and furfural-derived chromophores is observed. It is established that only a low-brightness microcrystalline cellulose when a degree of polymerization below 300 can be obtained from hardwood pulp. The study of the acid hydrolysis kinetics, with respect to the degree of polymerization of microcrystalline cellulose, shows that the modified Prout-Tompkins equation describes most adequately the process. According to that kinetic model, the hydrolysis rate depends on a combination of chemical interaction and diffusion processes. It is evident that the activation energy does not change in the course of the process, i.e. the cellulose active centers do not change their activity.

Pretreatment and fermentation of lignocellulosic biomass: reaction mechanisms and process engineering

At a time of rapid depletion of oil resources, global food shortages and solid waste problems, it is imperative to encourage research into the use of appropriate pre-treatment techniques using regenerative raw materials such as lignocellulosic biomass.

Microwave-Assisted One-Step Conversion of Wood Wastes into Levulinic Acid

This study aimed to evaluate the use of softwood and hardwood waste for the production of levulinic acid by one-stage conversion using microwave radiation combined with acid catalysis. The analysis demonstrated that the type and concentration of the acid used, the concentration of biomass in the reaction mixture and pressure value had the greatest impact on the yield of levulinic acid. The highest efficiency of carbohydrate conversion to levulinic acid, regardless of the type of raw material, was achieved using a pressure of 225 PSI and sulfuric acid as a catalyst. Maximum yield from biomass, ca. 16.5% for cherry wood chips and ca. 25% for pine chips, was obtained using sulfuric acid at a concentration of 1% v/v and 2% v/v, respectively, for the following process parameters: Exposure time 20 min, biomass concentration 3.3%, and the pressure of 225 PSI. The ratio of actual yield to theoretical yield was high: 64.7% ± 4.5% for pine chips and 43.4% ± 1.0% for cherry wood chips. High efficiency of the presented method of biomass conversion to levulinic acid indicates the possibility of its use for waste management in the wood processing industry. High concentration of levulinic acid in the post-reaction mixture allows for cost-effective extraction and purification of the compound.

Catalytic Production of Levulinic Acid (LA) from Actual Biomass

Catalytic conversion of actual biomass to valuable chemicals is a crucial issue in green chemistry. This review discusses on the recent approach in the levulinic acid (LA) formation from three prominent generations of biomasses. Our paper highlights the impact of the nature of different types of biomass and their complex structure and impurities, different groups of catalyst, solvents, and reaction system, and condition and all related pros and cons for this process.

Catalytic oxidation of biorefinery corncob lignin via zirconium(IV) chloride and sodium hydroxide in acetonitrile/water: A functionality study

In order to realize the efficient utilization of biorefinery corncob lignin, the promising catalytic oxidation strategy was carried out by using ZrCl₄ and NaOH as the co-catalyst and dioxygen as the oxidant in MeCN/H₂O. GC/MS, GC-FID, and MALDI-TOF/MS were employed to recognize the produced monomers and oligomers, and GPC was used to monitor the molecular weight changes of lignin fragments. In addition, specific structural evolution of corncob lignin during ZrCl₄/NaOH-catalyzed oxidation were revealed by quantitative ¹³C (Q¹³C) and 2D HSQC NMR techniques. Results showed that the total yields of produced oxidation monomers reached 6.8 wt%, and aromatic aldehydes were the major species, in which vanillin and 4-hydroxybenzaldehyde were the two dominant products. After ZrCl₄/NaOH-catalyzed oxidation, the weight-average molecular weight of corncob lignin and its products decreased from 2000 Da to 300 Da after oxidation with 16 h. Moreover, Q¹³C NMR analysis showed the decrease percentage of CO aliphatic carbons (including methoxyl carbons), the increase percentage of CC aliphatic and carbonyl carbons, and the relative stable percentage of aromatic carbons with reaction prolonged. These results combined with the further confirmation from HSQC indicated the oxidative cleavage of CO aliphatic linkages and removal of methoxy groups within corncob lignin, as well as the formation of CC aliphatic bonds and carbonyl groups. The work presented a comprehensive insight into the catalytic oxidative depolymerization of biorefinery corncob lignin.

Study of a New Process for the Preparation of Butyl Levulinate from Cellulose

Butyl levulinate (BL) is a versatile chemical utilized widely in food and chemical industries, the production of which by using cellulose in biomass resources is of great significance to its sustainable development. Traditional synthesis processes for n-butyl levulinate are confronted with various problems such as high cost of raw materials, difficulty in separating products, etc. In this paper, a novel process for the preparation of BL from cellulose is proposed. The process is composed of five main unit operations including fed-batch hydrolysis, decolorization, extraction, esterification and purification. A 171.63 g/L concentration of the intermediate levulinic acid was obtained at the fifth feeding through the fed-batch hydrolysis process. The resin-activated carbon secondary decolorization method was adopted to remove the soluble humin byproducts with an accumulative decolorization rate of 89%. In the extraction process, the product BL was chosen as the extractant to avoid the introduction of new impurities. After purification, the purity of the final product BL reaches up to 98 wt %. The proposed technique allows for cost-effective and eco-friendly production of BL from biomass resources.

A novel bio-based AB2 monomer for preparing hyperbranched polyamides derived from levulinic acid and furfurylamine

A new AB₂ type bio-based monomer (FDA-E) with two amino functional groups and one ester functional group was prepared from renewable levulinic acid and furfurylamine using a three-step reaction.