Novel Route to Produce Hydrocarbons from Woody Biomass Using Molten Salts

Abstract

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.

Virtual Special Issue of Recent Advances in Biofuel Production via Co-refining Route

“…Bergvall et al studied catalytic slurry hydroprocessing of kraft lignin to liquid products suitable for downstream refining in more conventional reactors and proposed related implementation strategies. Sridharan et al targeted middle distillates (aviation/diesel) and proposed a novel process concept to obtain a hydrocarbon-rich product with a low oxygen content from pinewood biomass involving integration of molten salt pyrolysis with separation and catalytic conversions of isolated furfural and acetic acid. A hydrocarbon-rich final product with an oxygen content of 1.68 wt % was obtained with an overall carbon yield of 21%.…”