Innovative parallel synthesis of 5-nonanone and furfural from lignocellulosic biomass accompanied by deep economic analysis

An integrated strategy is developed to utilize all three primary components (cellulose, hemicellulose, and lignin) of lignocellulosic biomass for the coproduction of hydrocarbon fuel (5-nonanone) and bio-chemicals (furfural and high purity lignin). After biomass fractionation, (1) 5-nonanone is produced with high yield of 89% using cellulose-derived γ-valerolactone (GVL), which can potentially serve as a platform molecule for the production of liquid hydrocarbon fuels for the transportation sector; (2) furfural, a valuable platform chemical, is produced using hemicellulose; and (3) production of high-purity lignin, which can be used to produce carbon foams or battery anodes. Separation subsystems are designed to effectively recover the solvents for reuse in the conversion processes, which ultimately improves the economic feasibility of the integrated process, resulting in achieving lower minimum selling price (MSP) of $5.47 GGE-1 for 5-nonanone compared to market price. Heat pump is introduced to perform heat integration, which reduces utility requirements more than 85%. Finally, a wide range of techno-economic analysis is performed to highlight the major cost and technological drivers of the integrated process.

Integrating anaerobic digestion and pyrolysis for treating digestates derived from sewage sludge and fat wastes

The coupling of biological and thermal technologies allows for the complete conversion of wastes into energy and biochar eliminating the problem of sludge disposal. The valorisation of fatty residues as co-substrate in a mesophilic digester of a wastewater treatment plant was studied considering an integrated approach of co-digestion and pyrolysis. Four digested samples obtained from co-digestion of sewage sludge and butcher's fat waste were studied by thermogravimetric analysis. The activation energy corresponding to the sludge pyrolysis was calculated by a non-isothermal kinetic. Arrhenius activation energy was lower for the pyrolysis of a digested grease sample (92 kJ mol^-1 obtained by OFW and 86 kJ mol^-1 obtained by Vyazovkin) than for the pyrolysis of sewage sludge and its blends (164-190 kJ mol^-1 obtained by OFW and 162-190 kJ mol^-1 obtained by Vyazovkin). The analysis of the integrated approach of anaerobic co-digestion and pyrolysis of digestates demonstrated that the addition of 3% (w/v) of fat to the feeding sludge results in a 25% increase in the electricity obtained from biogas (if a combined heat and power unit is considered for biogas valorisation) and increasing the fat content to 15% allows for covering all thermal needs for drying of digestate and more than doubles (2.4 times) the electricity production when the scenario of digestion and pyrolysis is contemplated.

Intensification of microalgae drying and oil extraction process by vapor recompression and heat integration

Reducing energy penalty caused by drying and oil extraction is the most critical challenge in microalgae biodiesel production. In this study, vapor recompression and heat integration are utilized to optimize the performance of wet microalgae drying and oil extraction. In the microalgae drying stage, the hot exhaust stream is recompressed and coupled with wet microalgae to recover the condensate heat. In the oil extraction stage, the exergy rate of recovered solvent is also elevated by compressor and then exchanged heat with feed and bottom stream in the distillation column. Energy and mass balance of the intensified process is investigated and compared with the conventional microalgae drying-extraction process. The simulation results indicated that the total energy consumption of the intensified process can be saved by 52.4% of the conventional route.

A lignocellulosic ethanol strategy via nonenzymatic sugar production: process synthesis and analysis

The work develops a strategy for the production of ethanol from lignocellulosic biomass. In this strategy, the cellulose and hemicellulose fractions are simultaneously converted to sugars using a γ-valerolactone (GVL) solvent containing a dilute acid catalyst. To effectively recover GVL for reuse as solvent and biomass-derived lignin for heat and power generation, separation subsystems, including a novel CO2-based extraction for the separation of sugars from GVL, lignin and humins have been designed. The sugars are co-fermented by yeast to produce ethanol. Furthermore, heat integration to reduce utility requirements is performed. It is shown that this strategy leads to high ethanol yields and the total energy requirements could be satisfied by burning the lignin. The integrated strategy using corn stover feedstock leads to a minimum selling price of $5 per gallon of gasoline equivalent, which suggests that it is a promising alternative to current biofuels production approaches.

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

In this work, the conceptual designs of the established Organosolv process and a novel biphasic, so-called Organocat process are developed and analyzed. Solvent recycling and energy integration are emphasized to properly assess economic viability. Both processes show a similar energy consumption (approximately 5 MJ/kg(dry biomass)). However, they still show a lack of economic attractiveness even at larger scale. The Organocat process is more favorable due to more efficient lignin separation. The analysis uncovers the remaining challenges toward an economically viable design. They largely originate from by-products formation, product isolation, and solvent recycling. Necessary improvements in process chemistry, equipment design, energy efficiency and process design are discussed to establish economically attractive Organosolv-like processes of moderate capacity as a building block of a future biorefinery.