Thermo-catalytic pyrolysis of sewage sludge and techno-economic analysis: The effect of synthetic zeolites and natural sourced catalysts

This work focuses to the value added utilization of animal sewage sludge into gases, bio-oil and char using synthetic zeolite (ZSM-5 and Y-zeolite) and natural sourced (diatomite, kaolin, perlite) materials as catalysts. Pyrolysis was performed in a one-stage bench-scale reactor at temperatures of 400 and 600 °C. The catalyst was mixed with the raw material before the pyrolysis. Catalysts had a significant effect on the yield of products, because the amount of volatile products was higher in their presence, than without them. In case of kaolin, due to the structural transformation occurring between 500-600 °C, a significant increase in activity was observed in terms of pyrolysis reactions resulting in volatiles. The hydrogen content of the gas products increased significantly at a temperature of 600 °C and in thermo-catalysts pyrolysis. In the presence of catalysts, bio-oil had more favourable properties.

Pynta─An Automated Workflow for Calculation of Surface and Gas-Surface Kinetics

Many important industrial processes rely on heterogeneous catalytic systems. However, given all possible catalysts and conditions of interest, it is impractical to optimize most systems experimentally. Automatically generated microkinetic models can be used to efficiently consider many catalysts and conditions. However, these microkinetic models require accurate estimation of many thermochemical and kinetic parameters. Manually calculating these parameters is tedious and error prone, involving many interconnected computations. We present Pynta, a workflow software for automating the calculation of surface and gas-surface reactions. Pynta takes the reactants, products, and atom maps for the reactions of interest, generates sets of initial guesses for all species and saddle points, runs all optimizations, frequency, and IRC calculations, and computes the associated thermochemistry and rate coefficients. It is able to consider all unique adsorption configurations for both adsorbates and saddle points, allowing it to handle high index surfaces and bidentate species. Pynta implements a new saddle point guess generation method called harmonically forced saddle point searching (HFSP). HFSP defines harmonic potentials based on the optimized adsorbate geometries and which bonds are breaking and forming that allow initial placements to be optimized using the GFN1-xTB semiempirical method to create reliable saddle point guesses. This method is reaction class agnostic and fast, allowing Pynta to consider all possible adsorbate site placements efficiently. We demonstrate Pynta on 11 diverse reactions involving monodenate, bidentate, and gas-phase species, many distinct reaction classes, and both a low and a high index facet of Cu. Our results suggest that it is very important to consider reactions between adsorbates adsorbed in all unique configurations for interadsorbate group transfers and reactions on high index surfaces.

Preferential formation of specific hexose and heptose in the formose reaction under microwave irradiation

To realize sustainable societies, the production of organic compounds not based on fossil resources should be developed. Thus, C1 chemistry, utilizing one-carbon compounds as starting materials, has been of increasing importance. In particular, the formose reaction is promising because the reaction produces sugars (monosaccharides) from formaldehyde under basic conditions. On the other hand, since microwave (MW) induces the rotational motion of molecules, MW irradiation often improves the selectivity and efficiency of reactions. In this study, the formose reaction under MW irradiation was thus investigated under various conditions. The formose reaction proceeded very fast using 1.0 mol per kg formaldehyde and 55 mmol per kg calcium hydroxide (Ca(OH)₂) as a catalyst at a high set temperature (150 °C) for a short time (1 min) to form preferentially specific hexose and heptose. The major products were isolated by thin layer chromatography and characterized by mass spectroscopy and NMR. These characterization data elucidated that the hexose and heptose were 2-hydroxymethyl-1,2,4,5-tetrahydroxy-3-pentanone (C6*) and 2,4-bis(hydroxymethyl)-1,2,4,5-tetrahydroxy-3-pentanone (C7*), respectively. On the basis of these observations, as well as density functional theory calculations, a plausible reaction pathway was also discussed; once 1,3-dihydroxyacetone is formed, consecutive aldol reactions favorably occur to form C6* and C7*.

Improving Fuel Properties and Hydrocarbon Content from Residual Fat Pyrolysis Vapors over Activated Red Mud Pellets in Two-Stage Reactor: Optimization of Reaction Time and Catalyst Content

Catalytic upgrading of vapors from pyrolysis of triglycerides materials is a promising approach to achieve better conversions of hydrocarbons and production of liquid biofuels. Catalytic cracking often shows incomplete conversion due to distillation of initial reaction products and the addition of a second catalytic reactor, whereas pyrolytic vapors are made in contact to a solid catalyst was applied to improve the physical-chemical properties and quality of bio-oil. This work investigated the effect of catalyst content and reaction time by catalytic upgrading from pyrolysis vapors of residual fat at 450 °C and 1.0 atmosphere, on the yields of reaction products, physicochemical properties (density, kinematic viscosity, refractive index, and acid value), and chemical composition of organic liquid products (OLP), over a catalyst fixed bed reactor, in semi pilot scale. Pellets of red mud chemically activated with 1.0 M HCl were used as catalysts. The thermal catalytic cracking of residual fat show OLP yields from 54.4 to 84.88 (wt.%), aqueous phase yields between 2.21 and 2.80 (wt.%), solid phase yields (coke) between 1.30 and 8.60 (wt.%), and gas yields from 11.61 to 34.22 (wt.%). The yields of OLP increases with catalyst content while those of aqueous, gaseous and solid phase decreases. For all experiments, the density, kinematic viscosity, and acid value of OLP decreases with reaction time. The GC-MS of liquid reaction products identified the presence of hydrocarbons and oxygenates. In addition, the hydrocarbon content in OLP increases with reaction time, while those of oxygenates decrease, reaching concentrations of hydrocarbons up to 95.35% (area.). The best results for the physicochemical properties and the maximum hydrocarbon content in OLP were obtained at 450 °C and 1.0 atmosphere, using a catalyst fixed bed reactor, with 5.0% (wt.) red mud pellets activated with 1.0 M HCl as catalyst.

Hydro-deoxygenation at atmospheric pressure converts the phenolic-rich pyrolysis liquid fraction into aromatics

Ambient pressure hydro-deoxygenation (HDO) of the phenolic-rich pyrolysis liquid fraction is a complex task due to the presence multiple phenolic compounds and light oxygenates. The phenolic-rich fraction differs from the overall pyrolysis liquid, known to be prone to re-polymerization and coking in the reactor or of the catalyst. In the present research, hydro-deoxygenation of oxygen-containing compounds in the phenolic fraction over Mo-based catalysts was carried out for the first time. It was found that Mo-based catalysts can successfully upgrade the phenolics into aromatics, the conversion rate was nearly 100%. The small amount of light oxygenates in the phenolic-rich fraction had no obvious effect on the hydro-deoxygenation reaction, the phenolic conversion was more than 95%. After assessing the performance for a representative phenolic model compound, the reaction was also successfully carried out on the phenolic fraction of the real pyrolysis liquid. It can be concluded that the catalysts can also be used for the HDO of the real pyrolysis liquid fraction at atmospheric pressure.

Thermo-catalytic co-pyrolysis of ironbark sawdust and plastic waste over strontium loaded hierarchical Y-zeolite

The objective of this research is to synthesize hierarchical strontium loaded Y-zeolite and study its application for ironbark (IB) and plastic waste (PW) co-pyrolysis. Commercial parent Y-zeolite (Si/Al = 2.48) was modified via sequential dealumination-desilication using citric acid and NaOH. Further, strontium (8 wt %) was loaded into the modified Y-zeolite via wet and dry impregnation methods. The prepared catalyst was characterized by N₂ adsorption-desorption isothermal, field emission scanning electron microscopy (FESEM) combined with energy dispersive x-ray spectroscopy (EDS), X-ray diffraction (XRD), Fourier-transform infrared spectroscopy (FTIR), and Thermogravimetric analyzer (TGA). After dealumination (treatment using 0.1 M of citric acid), the external surface area and Si/Al ratio increased from 53.5 to 147.4 m²/g and 2.48 to 5.36, respectively. However, the sequential desilication treatment reduced Si/Al ratio from 5.36 to 2.57. In addition, Y-zeolite enhanced the total aromatic percentage and reduced the acidic group in co-pyrolysis oil.

Biomass Fast Pyrolysis Vapor Upgrading over γ-Alumina, Hydrotalcite, Dolomite and Effect of Na2CO3 Loading: A Pyro Probe GCMS Study

The influence of γ-alumina, hydrotalcite, dolomite and Na2CO3 loaded γ-alumina, hydrotalcite, dolomite on fast pyrolysis vapor upgrading of beechwood was investigated using an analytical pyro probe-gas chromatography/mass spectrometry instrument (Py-GC/MS) at a temperature of 500 °C. Overall, this research showcased that these catalysts can deoxygenate biomass pyrolysis vapors into a mixture of intermediate compounds which have substantially lower oxygen content. The intermediate compounds are deemed to be suitable for downstream hydrodeoxygenation processes and it also means that hydrogen consumption will be reduced as a result of moderate in-situ deoxygenation. Among the support catalysts, the application of hydrotalcite yielded the best results with the formation of moderately deoxygenated compounds such as light phenols, mono-oxy ketones, light furans and hydrocarbons with a TIC area % of 7.5, 44.8, 9.8 and 9.8, respectively. In addition, acids were considerably reduced. Dolomite was the next most effective catalyst as γ-alumina retained most of the acids and other oxygenates. Na2CO3 loading on γ-alumina had a noticeable effect on eliminating more or less all the acids, enhancing the mono-oxy-ketones and producing lighter furans. In contrast, Na2CO3 loading on dolomite and hydrotalcite did not show a major impact on the composition except for further enhancing the mono-oxy-ketones (e.g., acetone and cyclopentenones). Additionally, in the case of hydrotalcite and γ-alumina, Na2CO3 loading suppressed the formation of hydrocarbons. In this research, the composition of pyrolytic vapors as a result of catalysis is elaborated further under the specific oxygenate groups such as acids, phenolics, furanics, ketones and acids. Further the catalysts were also characterized by BET, XRD and TGA analysis.

Conversion of agricultural waste into stable biocrude using spinel oxide catalysts

Biomass, the feedstock for biocrude and ultimately renewable diesel is a low energy density feedstock. The transport of this feedstock over long distance has been proven to be a major burden on the commercialisation of biorefining. Therefore, it has been generally accepted that biomass should be upgraded to biocrude (a relatively high energy density liquid) in close proximity to the biomass sources. The biocrude liquid would then be transported to a biorefinery. Biocrude contains large amounts of oxygen (generally up to 38 wt%) that is removed from the crude in the refining process. In this study, we have synthesised a range of spinel oxide based catalysts to remove oxygen from the biocrude during the catalytic fast pyrolysis. The activity of spinel oxide (MgB₂O₄ where B = Fe, Al, Cr, Ga, La, Y, In) catalysts were screened for the pyrolysis reaction. While all the tested spinel oxides deoxygenated the pyrolysis vapour, MgCr₂O₄ was found to be effective in terms of oxygen removal efficiency relative to the quantity of bio oil produced.

Fractionation of biomass and plastic wastes to value-added products via stepwise pyrolysis: a state-of-art review

Pyrolysis has been considered as a promising thermochemical process that can convert biomass in nonoxidizing atmospheres to value-added liquid bio-oil, solid biochar, and noncondensable gas products. Fast pyrolysis has a better economic return because of the valuable biofuel production (e.g. bio-oil, syngas). Because of the complexity and heterogeneity of the feedstocks, the one-step pyrolysis often leads to the mixed, acidic, and highly oxygenated liquid products. Moreover, the downstream processes (e.g. deoxygenation) for the desired fuels require high costs on energy and catalysts consumption. Stepwise pyrolysis is defined as a temperature-programmed pyrolysis that can separately obtain the products from each temperature step. It is a feasible approach to accomplish the fractionation by optimizing the pyrolysis process based on the decomposition temperature ranges and products among the biomass constituents. In recent years, the stepwise pyrolysis technology has gained attentions in thermochemical conversion of complex organic solid wastes. Through the stepwise pyrolysis of a real waste, oxygenated and acidic products were concentrated in the first-step liquid product, whereas the second-step product normally contained a high portion of hydrocarbon with low acidity. The stepwise pyrolysis of biomass, plastics, and their mixtures is comprehensively reviewed with the objective of fully understanding the related mechanisms, influence factors, and challenges.

Hydrothermal liquefaction of Scenedesmus abundans biomass spent for sorption of petroleum residues from wastewater and studies on recycling of post hydrothermal liquefaction wastewater

In this study Scenedesmus abundans was used as a biosorbent material for removing hydrocarbons from simulated petroleum wastewater. Batch experiments resulted in the removal of 92.16% of hydrocarbons from simulated wastewater within 60 min. The spent biosorbent was converted to bio-oil through hydrothermal liquefaction process (HTL) at temperature range from 220 to 320 °C with 1 h holding time. Liquid hydrocarbons (bio-oil) yield was 43.4 wt% at 300 °C with 15 g of spent sorbent loading and possessed HHV of 39.10 MJ/Kg. Additionally the HTL wastewater (aqueous phase) was recycled as reaction medium and studied for its effects on bio-oil yield which increased till second cycle (47.91 wt%). HTL bio-char was employed as adsorbent to remove heavy metals from wastewater. It showed greater removal efficiency of 86.5% to Ni(II) ions. From the results it was concluded that the petroleum residues can be effectively recycled back into liquid hydrocarbons with simple waste management pathway.

Enhancement of light aromatics from catalytic fast pyrolysis of cellulose over bifunctional hierarchical HZSM-5 modified by hydrogen fluoride and nickel/hydrogen fluoride

Pore structure and accessible active sites of HZSM-5 (Z5) are the key factors for its catalysis. The bifunctional hierarchical Z5 were prepared with leaching agent HF and loading Ni, and their performance for catalytic fast pyrolysis (CFP) of cellulose was investigated in a drop tube quartz reactor. Z5 modified with 0.5 mol/L HF (0.5F-Z5) showed excellent light aromatics (LAs) yield, which can be attributed to the enhancement in the small mesopores (2-10 nm) and the decrease of Brønsted acid sites during dealumination. Simultaneously, the loading of a 1 wt% Ni produced more LAs than 0.5F-Z5, due to the improvement in deoxidation/hydrogenation reactions. The highest LAs yield (31.3%) was obtained over 1%Ni-0.5 mol/LHF-Z5, which increased by 44.9% compared to the parent Z5. In addition, the reaction routes over different active centers and acid-catalyzed reactions were analyzed, based upon the composition of bio-oils and catalyst characterization.

From 3D to 2D zeolite catalytic materials

Research activities and recent developments in the area of three-dimensional zeolites and their two-dimensional analogues are reviewed. Zeolites are the most important industrial heterogeneous catalysts with numerous applications. However, they suffer from limited pore sizes not allowing penetration of sterically demanding molecules to their channel systems and to active sites. We briefly highlight here the synthesis, properties and catalytic potential of three-dimensional zeolites followed by a discussion of hierarchical zeolites combining micro- and mesoporosity. The final part is devoted to two-dimensional analogues developed recently. Novel bottom-up and top-down synthetic approaches for two-dimensional zeolites, their properties, and catalytic performances are thoroughly discussed in this review.

A controlled alkaline treatment of Al-SBA-15: a facile route to adjust the chemical composition and synthesize an ordered mesoporous carbon material, CMK-3, possessing strong pressure resistant capability

Alkaline-treated Al-SBA-15 exhibits excellent catalytic performance in the LDPE degradation reaction and its replica, CMK-3, has excellent structural stability.

Selective production of aromatic hydrocarbons from catalytic pyrolysis of biomass over Cu or Fe loaded mesoporous rod-like alumina

The selective production of aromatic hydrocarbons from bio-oil derived from the fast pyrolysis of sunflower stalks over Cu or Fe-modified mesoporous rod-like alumina catalysts was investigated.

Co-processing of bio-oil from de-oiled Jatropha curcas seed cake with refinery gas–oil over sulfided CoMoP/Al2O3 catalyst

Schematic representation of Co-processing of bio-oil from de-oiled Jatropha curcas seed cake with refinery gas–oil over sulfided CoMoP/Al₂O₃ catalyst.

Progress in the production of biomass-to-liquid biofuels to decarbonize the transport sector – prospects and challenges

Annually the transport sector consumes a quarter of global primary energy and is responsible for related greenhouse gas emissions.

Heterogeneous zirconia-supported ruthenium catalyst for highly selective hydrogenation of 5-hydroxymethyl-2-furaldehyde to 2,5-bis(hydroxymethyl)furans in various n-alcohol solvents

5-Hydroxymethyl-2-furaldehyde (HMF) was hydrogenated to 2,5-bis(hydroxymethyl)furan (BHMF) (>99% yield) in various n-alcohol solvents using a Ru(OH)_x/ZrO₂ catalyst.

In situ synthesis of molybdenum oxide@N-doped carbon from biomass for selective vapor phase hydrodeoxygenation of lignin-derived phenols under H2atmosphere

We report a simple, green method to prepare molybdenum oxide@N-doped carbon (MoO_x@NC)via in situpyrolysis of molybdenum precursor preloaded cellulose and demonstrate its catalytic performance for vapor phase HDO of lignin-derived phenols.

Zeolite-catalysed C–C bond forming reactions for biomass conversion to fuels and chemicals

Biomass conversion to fuels requires elimination of oxygenated functionalities along with formation of C–C bonds to help keeping the largest possible amount of carbon in the fuel range (e.g. C7–C15).

A green method to increase yield and quality of bio-oil: ultrasonic pretreatment of biomass and catalytic upgrading of bio-oil over metal (Cu, Fe and/or Zn)/γ-Al2O3

A green method is developed to increase the yield and quality of bio-oil by ultrasonic pretreatment of biomass followed by in situ catalytic upgrading of bio-oil over metal (Cu, Fe and/or Zn)/γ-Al₂O₃.

Comparison of the oxidative pyrolysis behaviors of black liquor solids, alkali lignin and enzymatic hydrolysis/mild acidolysis lignin

The rough heating rate of the oxidative pyrolysis reaction can be measured, and it's about 720 °C min⁻¹ at 600 °C.