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The negative impact of crude oil on the environment has led to a necessary transition toward alternative, renewable, and sustainable resources. In this regard, lignocellulosic biomass (LCB) is a promising renewable and sustainable alternative to crude oil for the production of fine chemicals and fuels in a so-called biorefinery process. LCB is composed of polysaccharides (cellulose and hemicellulose), as well as aromatics (lignin). The development of a sustainable and economically advantageous biorefinery depends on the complete and efficient valorization of all components. Therefore, in the new generation of biorefinery, the so-called biorefinery of type III, the LCB feedstocks are selectively deconstructed and catalytically transformed into platform chemicals. For this purpose, the development of highly stable and efficient catalysts is crucial for progress toward viability in biorefinery. Furthermore, a modern and integrated biorefinery relies on process and reactor design, toward more efficient and cost-effective methodologies that minimize waste. In this context, the usage of continuous flow systems has the potential to provide safe, sustainable, and innovative transformations with simple process integration and scalability for biorefinery schemes.
This thesis addresses three main challenges for future biorefinery: catalyst synthesis, waste feedstock valorization, and usage of continuous flow technology. Firstly, a cheap, scalable, and sustainable approach is presented for the synthesis of an efficient and stable 35 wt.-% Ni catalyst on highly porous nitrogen-doped carbon support (35Ni/NDC) in pellet shape. Initially, the performance of this catalyst was evaluated for the aqueous phase hydrogenation of LCB-derived compounds such as glucose, xylose, and vanillin in continuous flow systems. The 35Ni/NDC catalyst exhibited high catalytic performances in three tested hydrogenation reactions, i.e., sorbitol, xylitol, and 2-methoxy-4-methylphenol with yields of 82 mol%, 62 mol%, and 100 mol% respectively. In addition, the 35Ni/NDC catalyst exhibited remarkable stability over a long time on stream in continuous flow (40 h). Furthermore, the 35Ni/NDC catalyst was combined with commercially available Beta zeolite in a dual–column integrated process for isosorbide production from glucose (yield 83 mol%).
Finally, 35Ni/NDC was applied for the valorization of industrial waste products, namely sodium lignosulfonate (LS) and beech wood sawdust (BWS) in continuous flow systems. The LS depolymerization was conducted combining solvothermal fragmentation of water/alcohol mixtures (i.e.,methanol/water and ethanol/water) with catalytic hydrogenolysis/hydrogenation (SHF). The depolymerization was found to occur thermally in absence of catalyst with a tunable molecular weight according to temperature. Furthermore, the SHF generated an optimized cumulative yield of lignin-derived phenolic monomers of 42 mg gLS-1. Similarly, a solvothermal and reductive catalytic fragmentation (SF-RCF) of BWS was conducted using MeOH and MeTHF as a solvent. In this case, the optimized total lignin-derived phenolic monomers yield was found of 247 mg gKL-1.
The valorization of carbohydrates is one of the most promising fields in green chemistry, as it enables to produce bulk chemicals and fuels out of renewable and abundant resources, instead of further exploiting fossil feedstocks. The focus in this thesis is the conversion of fructose, using dehydration and hydrodeoxygenation reactions. The main goal is to find an easy continuous process, including the solubility of the sugar in a green solvent, the conversion over a solid acid as well as over a metal@tungsten carbide catalyst.
At the beginning of this thesis, solid acid catalysts are synthesized by using carbohydrate material like glucose and starch at high temperatures (up to 600 °C). Additionally a third carbon is synthesized, using an activation method based on Ca(OH)2. After carbonization and further sulfonation, using fuming sulfuric acid, the three resulting catalysts are characterized together with sulfonated carbon black and Amberlyst 15 as references. In order to test all solid acid catalysts in reaction, a 250 mm x 4.6 mm stainless steel column is used as a fixed-bed continuous reactor. The temperature (110 °C to 250 °C) and residence time (2 to 30 minutes) is varied, and a direct relationship between contact time and selectivity is determined. The reaction mechanism, as well as the product distribution is showing a dehydration step of fructose towards 5-hydroxymethylfurfural (HMF). These furan-ring molecules are considered as “sleeping giants”, due to the possibility of using them as fuel, but also for upgrading them to chemicals like terephthalic acid or p-xylene. Consecutive reactions are producing levulinic acid, as well as condensation products with ethanol and formic acid. The activated carbon is additionally showing a 2 % yield of 2,5-Dimethylfuran (DMF) production, pointing towards the extraordinary properties of this catalyst. Without a metal catalyst present, what is normally necessary for hydrogenation reactions, a transferhydrogenation (with formic acid) is observed. The active catalyst was therefore carbon itself, what activated the hydrogen on its surface. This phenomenon was just very rarely observed so far. Expensive noble metals are the material of choice, when it comes to hydrogenation reactions nowadays and cheaper alternatives are necessary.
By postulating a similar electronic structure of tungsten carbide (WC) to platinum by Lewy and Boudart, research is focusing on the replacement of Pt. The production of nano-sized tungsten carbide particles (7.5 ± 2.5 nm, 70 m2 g-1) is enabled by the so called “urea glass route” and its catalytic performances are compared to commercial material. It is shown, that the activity is strongly dependent on the size of the particles as well as the surface area. Nano-sized tungsten carbide is showing activity for hydrogenation reactions under mild conditions (maximum 150 °C, 30 bar). This material therefore opens up new possibilities for replacing the rare and expensive platinum with tungsten carbide based catalysts.
Additionally different metal nanoparticles of palladium, copper and nickel are deposited on top of WC to further promote its reactivity. The nickel nanoparticles are strongly connected to WC and showed the best activity as well as selectivity for upgrading HMF with hydrodeoxygenation. The Ni@WC is not leaching and is showing very good hydrodeoxygenation properties with DMF yields up to 90 percent. Copper@WC is not showing good activity and palladium@WC enables undesired consecutive reactions, hydrogenating the furan ring system.
In order to enable the upgrade of fructose to DMF directly in a continuous system, the current H CUBE Pro TM hydrogenation system is customized with a second reaction column. A 250 mm x 4.6 mm stainless steel reactor column is connected ahead of the hydrogen insertion, enabling the dehydration of fructose to HMF derivatives, before pumping these products into the second column for hydrogenation. The overall residence time in the two column reactor system is 14 minutes. The overall results are an almost full conversion with a yield of 38.5 % DMF and 47 % yield of EL. The main disadvantage is the formation of higher mass products, so called humins, which start depositing on top of the catalysts, blocking their active sites.
In general it can be stated, that a two column system goes along with a higher investment as well as more maintenance costs, compared to a one column catalytic approach. To develop a catalyst, which is on the one hand able to dehydrate as well as hydrodeoxygenate the reactants, is aimed for at the last part of the thesis. The activated carbon however shows already activity for hydrodeoxygenation without any metal present and offers itself therefore as an alternative to overcome the temperature instability of Amberlyst 15 (max. 120 °C) for a combined DMF production directly from fructose. The activity for the upgrade to DMF is increased from 2 % to 12 % DMF yield in one mixed continuous column.
In order to scale up the entire one column approach, an 800 mm x 28.5 mm inner diameter column was planned and manufactured. The system is scaled up and assembled, whereas this flow reactor system is able to be run with 50 mL min-1 maximum flow rate, to stand a pressure of maximum 100 bar and be heated to around 500 °C. The tubing and connections, as well as the used devices are planned according to be safe and easy in use. The scaled-up approach offers a reaction column 120 times bigger (510 ml) then the first extension of the commercial system. This further extension offers the possibility of ranging between 1 and 1000 mL min-1, making it possible to use the approach in pilot plant applications.
Lignin valorization
(2017)
The topic of this project is the use of lignin as alternative source of aromatic building blocks and oligomers to fossil feedstocks. Lignin is known as the most abundant aromatic polymer in nature and is isolated from the lignocellulosic component of plants by different possible extraction treatments. Both the biomass source and the extraction method affect the structure of the isolated lignin, therefore influencing its further application. Lignin was extracted from beech wood by two different hydrothermal alkaline treatments, which use NaOH and Ba(OH)2 as base and by an acid-catalyzed organosolv process. Moreover, lignin was isolated from bamboo, beech wood and coconut by soda treatment of the biomasses. A comparison of the structural features of such isolated lignins was performed through the use of a wide range of analytical methods. Alkaline lignins resulted in a better candidate as carbon precursor and macromonomers for the synthesis of polymer than organosolv lignin. In fact, alkaline lignins showed higher residual mass after carbonization and higher content of the reactive hydroxy functionalities. In contrast, the lignin source turned out to slightly affect the lignin hydroxyl content.
One of the most common lignin modifications is its deconstruction to obtain aromatic molecules, which can be used as starting materials for the synthesis of fine chemicals. Lignin deconstruction leads to a complex mixture of aromatic molecules. A gas chromatographic analytical method was developed to characterize the mixture of products obtained by lignin deconstruction via heterogeneous catalytic hydrogenolysis. The analytical protocol allowed the quantification of three main groups of molecules by means of calibration curves, internal standard and a preliminary silylation step of the sample. The analytical method was used to study the influence of the hydrogenolysis catalyst, temperature and system (flow and batch reactor) on the yield and selectivity of the aromatic compounds.
Lignin extracted from beech wood by a hydrothermal process using Ba(OH)2 as base, was functionalized by aromatic nitration in order to add nitrogen functionalities. The final goal was the synthesis of a nitrogen doped carbon. Nitrated lignin was reduced to the amino form in order to compare the influence of different nitrogen functionalities on the porosity of the final carbon. The carbons were obtained by ionothermal treatment of the precursors in the presence of the eutectic salt mixture KCl/ZnCl2 Such synthesized carbons showed micro-, macro- and mesoporosity and were tested for their electrocatalytic activity towards the oxygen reduction reaction. Mesoporous carbon derived from nitro lignin displayed the highest electrocatalytic activity.
Lignins isolated from coconut, beech wood and bamboo were used as macromonomers for the synthesis of biobased polyesters. A condensation reaction was performed between lignin and a hyper branched poly(ester-amine), previously obtained by condensation of triethanolamine and adipic acid. The influence of the lignin source and content on the thermochemical and mechanical properties of the final material was investigated. The prepolymer showed adhesive properties towards aluminum and its shear strength was therefore measured. The gluing properties of such synthesized glues turned out to be independent from the lignin source but affected by the amount of lignin in the final material.
This work shows that, although still at a laboratory scale, the valorization of lignin can overcome the critical issues of lignin´s structure variability and complexity.
Reactive eutectic media based on ammonium formate for the valorization of bio-sourced materials
(2023)
In the last several decades eutectic mixtures of different compositions were successfully used as solvents for vast amount of chemical processes, and only relatively recently they were discovered to be widely spread in nature. As such they are discussed as a third liquid media of the living cell, that is composed of common cell metabolites. Such media may also incorporate water as a eutectic component in order to regulate properties such as enzyme activity or viscosity. Taking inspiration form such sophisticated use of eutectic mixtures, this thesis will explore the use of reactive eutectic media (REM) for organic synthesis. Such unconventional media are characterized by the reactivity of their components, which means that mixture may assume the role of the solvent as well as the reactant itself.
The thesis focuses on novel REM based on ammonium formate and investigates their potential for the valorization of bio-sourced materials. The use of REM allows the performance of a number of solvent-free reactions, which entails the benefits of a superior atom and energy economy, higher yields and faster rates compared to reactions in solution. This is evident for the Maillard reaction between ammonium formate and various monosaccharides for the synthesis of substituted pyrazines as well as for a Leuckart type reaction between ammonium formate and levulinic acid for the synthesis of 5-methyl-2-pyrrolidone. Furthermore, reaction of ammonium formate with citric acid for the synthesis of yet undiscovered fluorophores, shows that synthesis in REM can open up unexpected reaction pathways.
Another focus of the thesis is the study of water as a third component in the REM. As a result, the concept of two different dilution regimes (tertiary REM and in REM in solvent) appears useful for understanding the influence of water. It is shown that small amounts of water can be of great benefit for the reaction, by reducing viscosity and at the same time increasing reaction yields.
REM based on ammonium formate and organic acids are employed for lignocellulosic biomass treatment. The thesis thereby introduces an alternative approach towards lignocellulosic biomass fractionation that promises a considerable process intensification by the simultaneous generation of cellulose and lignin as well as the production of value-added chemicals from REM components. The thesis investigates the generated cellulose and the pathway to nanocellulose generation and also includes the structural analysis of extracted lignin.
Finally, the thesis investigates the potential of microwave heating to run chemical reactions in REM and describes the synergy between these two approaches. Microwave heating for chemical reactions and the use of eutectic mixtures as alternative reaction media are two research fields that are often described in the scope of green chemistry. The thesis will therefore also contain a closer inspection of this terminology and its greater goal of sustainability.