Novel Nanostructured Pd/Co-Alumina Materials for the Catalytic Oxidation of Atmospheric Pollutants

Cobalt-doped alumina catalysts were prepared using different methods, either conventional wet impregnation (WI) and/or advanced spray impregnation (SI), and they were evaluated as novel oxidation catalysts for CO and MeOH oxidation. The spray impregnation technique was used with the aim of achieving the synthesis of core-shell catalytic nanostructures to secure the chemical/thermal stability of active sites on the catalyst carrier. The catalysts were further promoted with a low Pd content (0.5 wt.%) incorporated via either incipient wetness impregnation (DI) or spray impregnation. The results revealed the superior performance of the spray-impregnated catalysts (Co/γ-Al2O3-SI) for both reactions. The deposition of Co oxide on the outer surface of the alumina particle (SEM images) and the availability of the active Co phase resulted in the enhancement of the Co/γ-Al2O3 catalysts' oxidation activity. Pd incorporation increased the catalysts' reducibility (TPR-H2) and improved the catalysts' performance for both reactions. However, the Pd incorporation method affected the catalytic performance; with the SI method, the active phase of Co3O4 was probably covered with PdO and was not available for the oxidation reactions. On the contrary, the incorporation of Pd with the DI method resulted in a better dispersion of PdO all over the Co/Al catalyst surface, maintaining available Co active sites and a better Pd-Co interaction. MeOH desorption studies revealed the methanol oxidation mechanism: the Co/Al catalysts promoted the partial oxidation of MeOH to formaldehyde (HCHO) and dehydration to dimethyl ether (DME), while the Pd-based Co/Al catalysts enhanced the complete oxidation of methanol to CO2 and H2O.

Understanding the Upgrading of Sewage Sludge-Derived Hydrothermal Liquefaction Biocrude via Advanced Characterization

Hydrothermal liquefaction (HTL) can thermochemically transform sewage sludge into a biocrude with high energy content, high chemical complexity, and high O and N content. The development of an efficient upgrading process for such complex feedstocks necessitates detailed knowledge of the molecular composition and the specific heteroatom-containing compounds to understand and optimize the hydrotreating reactions. In this study, we present the upgrading of sewage sludge-derived HTL biocrude via a two-stage hydrotreatment process and perform advanced chemical characterization of the feedstock, intermediate, and final upgraded products with gas chromatography-mass spectrometry (GC-MS) and Fourier transform ion cyclotron resonance mass spectrometry (FTICR-MS). We show that hydrotreatment significantly improves the quality of the oil, primarily succeeding in cracking the heavy molecules and removing the sulfur- and oxygen-containing components. FTICR-MS analysis shows that the HTL biocrude has a high concentration of fatty acid amides that readily lose their oxygen and nitrogen during hydrotreating and are converted into saturated hydrocarbons, whereas the aromatic OxNy compounds are converted into N1 and N2 classes, which are more resistant to hydrotreating. We also demonstrate that the upgraded HTL oil can be successfully blended with intermediate refinery streams, such as vacuum gas oil (VGO), for further co-processing to in-spec fuels in conventional processes. This provides an alternative route to introduce renewable carbon in existing fossil-based refineries.

Efficient production of nutraceuticals and lactic acid from lignocellulosic biomass by combining organosolv fractionation with enzymatic/fermentative routes

The aim of this work was to investigate the use of isobutanol as organic solvent for the efficient delignification and fractionation of beechwood through the OxiOrganosolv process in the absence of any catalyst. The results demonstrate that cellulose-rich solid pulp produced after pretreatment is a source of fermentable sugars that can be easily hydrolyzed and serve as a carbon source in microbial fermentations for the production of omega-3 fatty acids and D-lactic acid. The C5 sugars are recovered in the aqueous liquid fractions and comprise a fraction rich in xylo-oligosaccharides with prebiotic potential. The maximum production of optically pure D-lactic from Lactobacillus delbrueckii sp. bulgaricus reached 51.6 g/L (0.57 g/g_biomass), following a simultaneous saccharification and fermentation strategy. Crypthecodenium cohnii accumulated up to 52.1 wt% lipids with a DHA content of 54.1 %, while up to 43.3 % hemicellulose recovery in form of oligosaccharides was achieved in the liquid fraction.

Novel trends in the thermo-chemical recycling of plastics from WEEE containing brominated flame retardants

The amount of plastics from waste electric and electronic equipment (WEEE) has enormously increased nowadays, due to the rapid expansion and consumption of electronic devices and their short lifespan. This, in combination with their non-biodegradability, led to the need to explore environmentally friendly solutions for their safe disposal. One main obstacle when recycling plastics from WEEE is that they usually comprise harmful additives such as brominated flame retardants (BFRs) that need to be removed before or during their recycling. This paper reviews existing techniques for the recycling of plastics from WEEE and focuses specifically on the advantages, disadvantages, and challenges of pyrolysis as an environmentally friendly method for the production of value-added materials (monomers, hydrocarbons, phenols, etc.). Current technological trends available for the recycling of plastics containing brominated flame retardants are reviewed in an attempt to provide insights for future research on the sustainable management of plastics from WEEE. Emphasis is given on conventional pyrolysis, where a pretreatment step for the debromination of products is applied. This is required since brominated compounds treated at high temperatures may result in the production of harmful to health compounds such as dioxins. All current pretreatment methods (solvent extraction, supercritical fluid technology, etc.) are presented and compared in detail. Co-pyrolysis is also investigated, as it seems to be a very interesting approach, since no catalysts or solvents are used, and at the same time, more plastic wastes can be consumed as feedstock. Furthermore, catalytic pyrolysis along with key parameters, such as the type of the catalyst or pyrolysis temperature, are fully analyzed. Catalysts affect the products' distribution and enhance the removal of bromine from pyrolysis oils. Finally, an emerging technique, that of microwave-assisted pyrolysis, is also highlighted, as it offers many advantages over conventional pyrolysis. Of course, there are some impediments, such as the operational costs or other difficulties as regards the industrial implementation of the mentioned techniques that need to be overcome through future works.

Conversion of organosolv pretreated hardwood biomass into 5-hydroxymethylfurfural (HMF) by combining enzymatic hydrolysis and isomerization with homogeneous catalysis

BACKGROUND

Over the last few years, valorization of lignocellulosic biomass has been expanded beyond the production of second-generation biofuels to the synthesis of numerous platform chemicals to be used instead of their fossil-based counterparts. One such well-researched example is 5-hydroxymethylfurfural (HMF), which is preferably produced by the dehydration of fructose. Fructose is obtained by the isomerization of glucose, which in turn is derived by the hydrolysis of cellulose. However, to avoid harsh reaction conditions with high environmental impact, an isomerization step towards fructose is necessary, as fructose can be directly dehydrated to HMF under mild conditions. This work presents an optimized process to produce fructose from beechwood biomass hydrolysate and subsequently convert it to HMF by employing homogeneous catalysis.

RESULTS

The optimal saccharification conditions were identified at 10% wt. solids loading and 15 mg enzyme/g_solids, as determined from preliminary trials on pure cellulose (Avicel® PH-101). Furthermore, since high rate glucose isomerization to fructose requires the addition of sodium tetraborate, the optimum borate to glucose molar ratio was determined to 0.28 and was used in all experiments. Among 20 beechwood solid pulps obtained from different organosolv pretreatment conditions tested, the highest fructose production was obtained with acetone (160 °C, 120 min), reaching 56.8 g/100 g pretreated biomass. A scale-up hydrolysis in high solids (25% wt.) was then conducted. The hydrolysate was subjected to isomerization eventually leading to a high-fructose solution (104.5 g/L). Dehydration of fructose to HMF was tested with 5 different catalysts (HCl, H₃PO₄, formic acid, maleic acid and H-mordenite). Formic acid was found to be the best one displaying 79.9% sugars conversion with an HMF yield and selectivity of 44.6% and 55.8%, respectively.

CONCLUSIONS

Overall, this work shows the feasibility of coupling bio- and chemo-catalytic processes to produce HMF from lignocellulose in an environmentally friendly manner. Further work for the deployment of biocatalysts for the oxidation of HMF to its derivatives could pave the way for the emergence of an integrated process to effectively produce biobased monomers from lignocellulose.

CO2 conversion over Cu–Mo2C catalysts: effect of the Cu promoter and preparation method

Strong interaction between the Cu and Mo₂C phases and formation of Mo₂C–Cu⁺ interfaces is required for the efficient hydrogenation of CO₂ to methanol.

OxiOrganosolv: A novel acid free oxidative organosolv fractionation for lignocellulose fine sugar streams

The valorization of lignocellulosic biomass towards the production of value-added products requires an efficient pretreatment/fractionation step. In this work we present a novel, acid-free, mildly oxidative organosolv delignification process -OxiOrganosolv- which employs oxygen gas to depolymerize and remove lignin. The results demonstrate that the OxiOrganosolv process achieved lignin removal as high as 97% in a single stage, with a variety of solvents; it was also efficient in delignifying both beechwood (hardwood) and pine (softwood), a task in which organosolv pretreatments have failed in the past. Minimal amounts of sugar degradation products were detected, while cellulose recovery was ~100% in the solid pulp. Enzymatic hydrolysis of pulps showed >80 wt% cellulose conversion to glucose. Overall, the OxiOrganosolv pretreatment has significant advantages, including high delignification efficiency of hardwood and softwood biomass, absence of acid homogeneous catalysis and all corresponding challenges involved, and close to zero losses of sugars to degradation products.

Scaling-Up of Bio-Oil Upgrading during Biomass Pyrolysis over ZrO2 /ZSM-5-Attapulgite

Ex situ catalytic biomass pyrolysis was investigated at both laboratory and bench scale by using a zeolite ZSM-5-based catalyst for selectively upgrading the bio-oil vapors. The catalyst consisted of nanocrystalline ZSM-5, modified by incorporation of ZrO₂ and agglomerated with attapulgite (ZrO₂ /n-ZSM-5-ATP). Characterization of this material by means of different techniques, including CO₂ and NH₃ temperature-programmed desorption (TPD), NMR spectroscopy, UV/Vis microspectroscopy, and fluorescence microscopy, showed that it possessed the right combination of accessibility and acid-base properties for promoting the conversion of the bulky molecules formed by lignocellulose pyrolysis and their subsequent deoxygenation to upgraded liquid organic fractions (bio-oil). The results obtained at the laboratory scale by varying the catalyst-to-biomass ratio (C/B) indicated that the ZrO₂ /n-ZSM-5-ATP catalyst was more efficient for bio-oil deoxygenation than the parent zeolite n-ZSM-5, producing upgraded bio-oils with better combinations of mass and energy yields with respect to the oxygen content. The excellent performance of the ZrO₂ /n-ZSM-5-ATP system was confirmed by working with a continuous bench-scale plant. The scale-up of the process, even with different raw biomasses as the feedstock, reaction conditions, and operation modes, was in line with the laboratory-scale results, leading to deoxygenation degrees of approximately 60 % with energy yields of approximately 70 % with respect to those of the thermal bio-oil.

Utilisation of poultry industry wastes for liquid biofuel production via thermal and catalytic fast pyrolysis

The objective of this study was to examine the potential of poultry wastes to be used as feedstock in non-catalytic and catalytic fast pyrolysis processes, which is a continuation of our previous research on their conversion into biofuel via slow pyrolysis and hydrothermal conversion. Both poultry meal and poultry litter were examined, initially in a fixed bed bench-scale reactor using ZSM-5 and MgO as catalysts. Pyrolysis of poultry meal yielded high amounts of bio-oil, while pyrolysis of poultry litter yielded high amounts of solid residue owing to its high ash content. MgO was found to be more effective for the deoxygenation of bio-oil and reduction of undesirable compounds, by converting mainly the acids in the pyrolysis vapours of poultry meal into aliphatic hydrocarbons. ZSM-5 favoured the formation of both aromatic compounds and undesirable nitrogenous compounds. Overall, all bio-oil samples from the pyrolysis of poultry wastes contained relatively high amounts of nitrogen compared with bio-oils from lignocellulosic biomass, ca. 9 wt.% in the case of poultry meal and ca. 5-8 wt.% in the case of poultry litter. This was attributed to the high nitrogen content of the poultry wastes, unlike that of lignocellulosic biomass. Poultry meal yielded the highest amount of bio-oil and was selected as optimum feedstock to be scaled-up in a semi-pilot scale fluidised bed biomass pyrolysis unit with the ZSM-5 catalyst. Pyrolysis in the fluidised bed reactor was more efficient for deoxygenation of the bio-oil vapours, as evidenced from the lower oxygen content of the bio-oil.

Effect of Steam Deactivation Severity of ZSM-5 Additives on LPG Olefins Production in the FCC Process

ZSM-5-containing catalytic additives are widely used in oil refineries to boost light olefin production and improve gasoline octanes in the Fluid Catalytic Cracking (FCC) process. Under the hydrothermal conditions present in the FCC regenerator (typically >700 °C and >8% steam), FCC catalysts and additives are subject to deactivation. Zeolites (e.g., Rare Earth USY in the base catalyst and ZSM-5 in Olefins boosting additives) are prone to dealumination and partial structural collapse, thereby losing activity, micropore surface area, and undergoing changes in selectivity. Fresh catalyst and additives are added at appropriate respective levels to the FCC unit on a daily basis to maintain overall targeted steady-state (equilibrated) activity and selectivity. To mimic this process under accelerated laboratory conditions, a commercial P/ZSM-5 additive was hydrothermally equilibrated via a steaming process at two temperatures: 788 °C and 815 °C to simulate moderate and more severe equilibration industrial conditions, respectively. n-Dodecane was used as probe molecule and feed for micro-activity cracking testing at 560 °C to determine the activity and product selectivity of fresh and equilibrated P-doped ZSM-5 additives. The fresh/calcined P/ZSM-5 additive was very active in C₁₂ cracking while steaming limited its activity, i.e., at catalyst-to-feed (C/F) ratio of 1, about 70% and 30% conversion was obtained with the fresh and steamed additives, respectively. A greater activity drop was observed upon increasing the hydrothermal deactivation severity due to gradual decrease of total acidity and microporosity of the additives. However, this change in severity did not result in any selectivity changes for the LPG (liquefied petroleum gas) olefins as the nature (Brønsted-to-Lewis ratio) of the acid/active sites was not significantly altered upon steaming. Steam deactivation of ZSM-5 had also no significant effect on aromatics formation which was enhanced at higher conversion levels. Coke remained low with both fresh and steam-deactivated P/ZSM-5 additives.

Production of high concentrated cellulosic ethanol by acetone/water oxidized pretreated beech wood

BACKGROUND

Lignocellulosic biomass is an abundant and inexpensive resource for biofuel production. Alongside its biotechnological conversion, pretreatment is essential to enable efficient enzymatic hydrolysis by making cellulose susceptible to cellulases. Wet oxidation of biomass, such as acetone/water oxidation, that employs hot acetone, water, and oxygen, has been found to be an attractive pretreatment method for removing lignin while producing less degradation products. The remaining enriched cellulose fraction has the potential to be utilized under high gravity enzymatic saccharification and fermentation processes for the cost-competing production of bioethanol.

RESULTS

Beech wood residual biomass was pretreated following an acetone/water oxidation process aiming at the production of high concentration of cellulosic ethanol. The effect of pressure, reaction time, temperature, and acetone-to-water ratio on the final composition of the pretreated samples was studied for the efficient utilization of the lignocellulosic feedstock. The optimal conditions were acetone/water ratio 1:1, 40 atm initial pressure of 40 vol% O₂ gas, and 64 atm at reaction temperature of 175 °C for 2 h incubation. The pretreated beech wood underwent an optimization step studying the effect of enzyme loading and solids content on the enzymatic liquefaction/saccharification prior to fermentation. In a custom designed free-fall mixer at 50 °C for either 6 or 12 h of prehydrolysis using an enzyme loading of 9 mg/g dry matter at 20 wt% initial solids content, high ethanol concentration of 75.9 g/L was obtained.

CONCLUSION

The optimization of the pretreatment process allowed the efficient utilization of beech wood residual biomass for the production of high concentrations of cellulosic ethanol, while obtaining lignin that can be upgraded towards high-added-value chemicals. The threshold of 4 wt% ethanol concentration that is required for the sustainable bioethanol production was surpassed almost twofold, underpinning the efficient conversion of biomass to ethanol and bio-based chemicals on behalf of the biorefinery concept.

Catalyst hydrothermal deactivation and metal contamination during the in situ catalytic pyrolysis of biomass

We investigated the effects of hydrothermal deactivation and biomass metal contamination on the properties and catalytic performance of commercial ZSM-5 catalysts.

Pyrolysis and catalytic pyrolysis as a recycling method of waste CDs originating from polycarbonate and HIPS

Pyrolysis appears to be a promising recycling process since it could convert the disposed polymers to hydrocarbon based fuels or various useful chemicals. In the current study, two model polymers found in WEEEs, namely polycarbonate (PC) and high impact polystyrene (HIPS) and their counterparts found in waste commercial Compact Discs (CDs) were pyrolysed in a bench scale reactor. Both, thermal pyrolysis and pyrolysis in the presence of two catalytic materials (basic MgO and acidic ZSM-5 zeolite) was performed for all four types of polymers. Results have shown significant recovery of the monomers and valuable chemicals (phenols in the case of PC and aromatic hydrocarbons in the case of HIPS), while catalysts seem to decrease the selectivity towards the monomers and enhance the selectivity towards other desirable compounds.

An integrated process for the production of platform chemicals and diesel miscible fuels by acid-catalyzed hydrolysis and downstream upgrading of the acid hydrolysis residues with thermal and catalytic pyrolysis

This study evaluates an integrated process for the production of platform chemicals and diesel miscible biofuels. An energy crop (Miscanthus) was treated hydrothermally to produce levulinic acid (LA). Temperatures ranging between 150 and 200 °C, sulfuric acid concentrations 1-5 wt.% and treatment times 1-12 h were applied to give different combined severity factors. Temperatures of 175 and 200 °C and acid concentration of 5 wt.% were found to be necessary to achieve good yield (17 wt.%) and selectivities of LA while treatment time did not have an effect. The acid hydrolysis residues were characterized for their elemental, cellulose, hemicellulose and lignin contents, and then tested in a small-scale pyrolyzer using silica sand and a commercial ZSM-5 catalyst. Milder pretreatment yielded more oil (43 wt.%) and oil O(2) (37%) while harsher pretreatment and catalysis led to more coke production (up to 58 wt.%), less oil (12 wt.%) and less oil O(2) (18 wt.%).

In-situ upgrading of biomass pyrolysis vapors: catalyst screening on a fixed bed reactor

In-situ catalytic upgrading of biomass fast pyrolysis vapors was performed in a fixed bed bench-scale reactor at 500°C, for catalyst screening purposes. The catalytic materials tested include a commercial equilibrium FCC catalyst (E-cat), various commercial ZSM-5 formulations, magnesium oxide and alumina materials with varying specific surface areas, nickel monoxide, zirconia/titania, tetragonal zirconia, titania and silica alumina. The bio-oil was characterized measuring its water content, the carbon-hydrogen-oxygen (by difference) content and the chemical composition of its organic fraction. Each catalytic material displayed different catalytic effects. High surface area alumina catalysts displayed the highest selectivity towards hydrocarbons, yielding however low organic liquid products. Zirconia/titania exhibited good selectivity towards desired compounds, yielding higher organic liquid product than the alumina catalysts. The ZSM-5 formulation with the highest surface area displayed the most balanced performance having a moderate selectivity towards hydrocarbons, reducing undesirable compounds and producing organic liquid products at acceptable yields.

Chemical recycling of plastic wastes made from polyethylene (LDPE and HDPE) and polypropylene (PP)

The recycling of either model polymers or waste products based on low-density polyethylene (LDPE), high-density polyethylene (HDPE) or polypropylene (PP) is examined using the dissolution/reprecipitation method, as well as pyrolysis. In the first technique, different solvents/non-solvents were examined at different weight percent amounts and temperatures using as raw material both model polymers and commercial products (packaging film, bags, pipes, food-retail outlets). The recovery of polymer in every case was greater than 90%. FT-IR spectra and tensile mechanical properties of the samples before and after recycling were measured. Furthermore, catalytic pyrolysis was carried out in a laboratory fixed bed reactor with an FCC catalyst using again model polymers and waste products as raw materials. Analysis of the derived gases and oils showed that pyrolysis gave a mainly aliphatic composition consisting of a series of hydrocarbons (alkanes and alkenes), with a great potential to be recycled back into the petrochemical industry as a feedstock for the production of new plastics or refined fuels.