The thermochemical decomposition of woody biomass has
been widely
identified as a promising route to produce renewable biofuels. More
recently, the use of molten salts in combination with pyrolysis has
gathered increased interest. The molten salts may act as a solvent,
a heat transfer medium, and possibly also a catalyst. In this study,
we report experimental studies on a process to convert woody biomass
to a liquid hydrocarbon product with a very low oxygen content using
molten salt pyrolysis (350–450 °C and atmospheric pressure)
followed by subsequent catalytic conversions of the liquids obtained
by pyrolysis. Pyrolysis of woody biomass in molten salt (ZnCl
2
/NaCl/KCl with a molar composition of 60:20:20) resulted in
a liquid yield of 46 wt % at a temperature of 450 °C and a molten
salt/biomass ratio of 10:1 (mass). The liquids are highly enriched
in furfural (13 wt %) and acetic acid (14 wt %). To reduce complexity
and experimental issues related to the production of sufficient amounts
of pyrolysis oils for further catalytic upgrading, model studies were
performed to convert both compounds to hydrocarbons using a three-step
catalytic approach, viz., (i) ketonization of acetic acid to acetone,
(ii) cross-aldol condensation between acetone and furfural to C
8
–C
13
products, followed by (iii) a two-stage
catalytic hydrotreatment of the latter to liquid hydrocarbons. Ketonization
of acetic acid to acetone was studied in a continuous setup over a
ceria–zirconia-based catalyst at 250 °C. The catalyst
showed no signs of deactivation over a period of 230 h while also
achieving high selectivity toward acetone. Furfural was shown to have
a negative effect on the catalyst performance, and as such, a separation
step is required after pyrolysis to obtain an acetic-acid-enriched
fraction. The cross-aldol condensation reaction between acetone and
furfural was studied in a batch using a commercial Mg/Al hydrotalcite
as the catalyst. Furfural was quantitatively converted with over 90%
molar selectivity toward condensed products with a carbon number between
C
8
and C
13
. The two-stage hydrotreatment of
the condensed product consisted of a stabilization step using a Ni-based
Picula catalyst and a further deep hydrotreatment over a NiMo catalyst,
in both batch setups. The final product with a residual 1.5 wt % O
is rich in (cyclo)alkanes and aromatic hydrocarbons. The overall carbon
yield for the four-step approach, from pinewood biomass to middle
distillates, is 21%, assuming that separation of furfural and acetic
acid after the pyrolysis step can be performed without losses.