Periodic Reporting for period 2 - FRACTION (Novel lignocellulose fractionation process for high purity lignin, hemicellulose and cellulose valorisation into added value products)
Reporting period: 2022-12-01 to 2024-05-31
FRACTION has developed, and demonstrated at bench scale, a new process to fractionate lignocellulosic biomass, which can make 2nd generation biorefineries more sustainable and economically viable.
Biorefineries are still limited by the complex structure of lignocellulose. An efficient separation process into its three main components, cellulose, hemicellulose, and lignin, is required to improve yields and economics of the process. Most current methods either imply high energy consumption and costs, or raise environmental concerns. As a result, most 2nd generation biorefineries concentrate only on one component and do not exploit the full potential of the feedstock.
FRACTION has developed a novel integrated biorefinery approach to obtain all three streams simultaneously with high yield and purity. In addition, FRACTION has demonstrated new value chains for hemicellulose and lignin, while maintaining the value of the cellulose.
The main objectives of the project are:
• Optimization of the novel fractionation process, based on the use of the green solvent ɣ-valerolactone (GVL), demonstrating its economic viability and solvent recovery.
• Maximization of the purity and quality of the lignin (>95% purity) and hemicellulose streams (>90% extraction and >75% furfural yield in a continuous process).
• Technoeconomic analysis which indicates that cellulose, lignin and furfural can be produced at competitive costs.
• Demonstration of the suitability of these streams for the production of high added-value products, such as furfural, alkyl lactates and lignin derive products (polyols, polyurethanes and resins).
• Demonstration that the cellulose can be bleached and is a promising feedstock for dissolving pulp production.
The specific strength of FRACTION is the integration of the full supply chain. It starts from different types of European biomass, then moves on to the fractionation, the downstream processing, including separation and purification, and the recovery of the green solvent. Finally, it leads to a variety of end products. The demonstrated value chains (hemicellulose and lignin derived products) are not limited to the FRACTION technology, and other technologies that produce lignin, furfural and/or sugars can also be used as feedstock providers.
Biorefineries are still limited by the complex structure of lignocellulose. An efficient separation process into its three main components, cellulose, hemicellulose, and lignin, is required to improve yields and economics of the process. Most current methods either imply high energy consumption and costs, or raise environmental concerns. As a result, most 2nd generation biorefineries concentrate only on one component and do not exploit the full potential of the feedstock.
FRACTION has developed a novel integrated biorefinery approach to obtain all three streams simultaneously with high yield and purity. In addition, FRACTION has demonstrated new value chains for hemicellulose and lignin, while maintaining the value of the cellulose.
The main objectives of the project are:
• Optimization of the novel fractionation process, based on the use of the green solvent ɣ-valerolactone (GVL), demonstrating its economic viability and solvent recovery.
• Maximization of the purity and quality of the lignin (>95% purity) and hemicellulose streams (>90% extraction and >75% furfural yield in a continuous process).
• Technoeconomic analysis which indicates that cellulose, lignin and furfural can be produced at competitive costs.
• Demonstration of the suitability of these streams for the production of high added-value products, such as furfural, alkyl lactates and lignin derive products (polyols, polyurethanes and resins).
• Demonstration that the cellulose can be bleached and is a promising feedstock for dissolving pulp production.
The specific strength of FRACTION is the integration of the full supply chain. It starts from different types of European biomass, then moves on to the fractionation, the downstream processing, including separation and purification, and the recovery of the green solvent. Finally, it leads to a variety of end products. The demonstrated value chains (hemicellulose and lignin derived products) are not limited to the FRACTION technology, and other technologies that produce lignin, furfural and/or sugars can also be used as feedstock providers.
The work in FRACTION has been structured in 4 main lines that are hierarchically organised:
1. Optimisation of the fractionation process of the biomass.
2. Development of downstream processes of the three lignocellulose fractions and production of intermediate building blocks.
3. Formulation and validation of end products based on these building blocks.
4. Maximisation of project impacts.
For the fractionation process, we have demonstrated that moisture and particle size have no effect on the yields and purity of the streams, so we can use wet wood chips as feedstock. We can also work with mixtures of feedstock with no negative effect. Overall, we have fulfilled the objective of demonstrating that we can extract >90% of the hemicellulose and >90% of the lignin, while >90% of the cellulose remains as solid with >90%. We have reached lignin extraction and cellulose purity of close to 80%. In addition, we have scaled-up the process to a 20 L reactor, producing samples of cellulose, hemicellulose and lignin at kg scale.
The downstream processes have tested lignin and hemicellulose from biomass fractionation. For cellulose, we have demonstrated that it can be bleached following conventional methods, has not been degraded, and is a potential feedstock for dissolving pulp application. Hemicellulose has been converted to furfural with >75% yield for samples rich in C5 sugars. Samples rich in C6 sugars have been processed to purify the sugars, and used to produce alkyl lactates and frutosides. The lignin has been oxidized, converted to products such as vanillin, and hydrogenated to polyols.
The lignin produced in FRACTION has been tested in the production of polyurethanes and resins, where we have demonstrated that up to 20% of phenols can be replaced by lignin. Also, PBS (polybutylensuccinate) and other polyols have been obtained from succinic acid and 1,5 pentanodiol produced in the project.
To make the FRACTION concept attractive for bioindustries, we have studied its sustainability and economic viability. The technoeconomic analysis has demonstrated that cellulose can be produced at 865 €/MT, lignin at 326 €/MT and furfural at 1535 €/MT, all competitive with current market prices. Other products, such as lignin polyols and carbonate, also show potential for commercialization. Furthermore, we have identified bottlenecks and proposed optimisations that reduce the energy requirements by almost 90%, compared to the initial study. The sustainability and LCA analysis has shown that GHG emissions were reduced by more than 50%, compared to preliminary estimations. We have determined the environmental impact of intermediates and main end products. The environmental foot-print of the end-products shows improvement compared with fossil-based reference products. In particular, lignin shows a reduction of 35 % with regard to phenol. Polyols based on succinic acid show a reduction in environmental impacts with regard to conventional non-SAc polyols (up to 50 %).
We have established a dialogue with key players from the European bioeconomy through activities such as the organisation of 6 Roundtables in different European countries, and presentation of FRACTION results at the 2023 CBE Stakeholder Forum, apart from participation in numerous scientific conferences. One patent based on FRACTION results has been filed and another is in preparation. Fraction result have also contributed to another, more general patent, and several other results are kept as confidential know-how with a high potential of future exploitation.
1. Optimisation of the fractionation process of the biomass.
2. Development of downstream processes of the three lignocellulose fractions and production of intermediate building blocks.
3. Formulation and validation of end products based on these building blocks.
4. Maximisation of project impacts.
For the fractionation process, we have demonstrated that moisture and particle size have no effect on the yields and purity of the streams, so we can use wet wood chips as feedstock. We can also work with mixtures of feedstock with no negative effect. Overall, we have fulfilled the objective of demonstrating that we can extract >90% of the hemicellulose and >90% of the lignin, while >90% of the cellulose remains as solid with >90%. We have reached lignin extraction and cellulose purity of close to 80%. In addition, we have scaled-up the process to a 20 L reactor, producing samples of cellulose, hemicellulose and lignin at kg scale.
The downstream processes have tested lignin and hemicellulose from biomass fractionation. For cellulose, we have demonstrated that it can be bleached following conventional methods, has not been degraded, and is a potential feedstock for dissolving pulp application. Hemicellulose has been converted to furfural with >75% yield for samples rich in C5 sugars. Samples rich in C6 sugars have been processed to purify the sugars, and used to produce alkyl lactates and frutosides. The lignin has been oxidized, converted to products such as vanillin, and hydrogenated to polyols.
The lignin produced in FRACTION has been tested in the production of polyurethanes and resins, where we have demonstrated that up to 20% of phenols can be replaced by lignin. Also, PBS (polybutylensuccinate) and other polyols have been obtained from succinic acid and 1,5 pentanodiol produced in the project.
To make the FRACTION concept attractive for bioindustries, we have studied its sustainability and economic viability. The technoeconomic analysis has demonstrated that cellulose can be produced at 865 €/MT, lignin at 326 €/MT and furfural at 1535 €/MT, all competitive with current market prices. Other products, such as lignin polyols and carbonate, also show potential for commercialization. Furthermore, we have identified bottlenecks and proposed optimisations that reduce the energy requirements by almost 90%, compared to the initial study. The sustainability and LCA analysis has shown that GHG emissions were reduced by more than 50%, compared to preliminary estimations. We have determined the environmental impact of intermediates and main end products. The environmental foot-print of the end-products shows improvement compared with fossil-based reference products. In particular, lignin shows a reduction of 35 % with regard to phenol. Polyols based on succinic acid show a reduction in environmental impacts with regard to conventional non-SAc polyols (up to 50 %).
We have established a dialogue with key players from the European bioeconomy through activities such as the organisation of 6 Roundtables in different European countries, and presentation of FRACTION results at the 2023 CBE Stakeholder Forum, apart from participation in numerous scientific conferences. One patent based on FRACTION results has been filed and another is in preparation. Fraction result have also contributed to another, more general patent, and several other results are kept as confidential know-how with a high potential of future exploitation.
The aim of the FRACTION project has been to provide a competitive lignocellulosic biorefinery concept, flexible to both feedstock and products. On a long run, if scaled-up to commercial scale, this project can be a game changer for the bioeconomy.
Environmental impact: The project has demonstrated the potential reduction of greenhouse gas emissions in the value chain through improvements in a range of production methods. Energy requirements compose the main bottleneck for the sustainability of the process. GHG emissions were reduced by more than 50% from preliminary LCA estimations.
Economic impact: FRACTION allows biorefinery operators to leverage the full potential of the biomass instead of discarding part of its valuable contents. This provides an opportunity to bio-based companies to extend their portfolio and open new revenue streams. The project has demonstrated that the total economic value of lignocellulose processing-derived products can reach 546 €/MT of biomass.
Wider societal implications: From a social perspective, the FRACTION project has demonstrated the potential for creating new jobs in rural and coastal areas within the bio-based economy. This could make these less-urban settings easier and more attractive places to live and work. The validation of the process for different types of biomass makes the process applicable in different geographical settings.
Environmental impact: The project has demonstrated the potential reduction of greenhouse gas emissions in the value chain through improvements in a range of production methods. Energy requirements compose the main bottleneck for the sustainability of the process. GHG emissions were reduced by more than 50% from preliminary LCA estimations.
Economic impact: FRACTION allows biorefinery operators to leverage the full potential of the biomass instead of discarding part of its valuable contents. This provides an opportunity to bio-based companies to extend their portfolio and open new revenue streams. The project has demonstrated that the total economic value of lignocellulose processing-derived products can reach 546 €/MT of biomass.
Wider societal implications: From a social perspective, the FRACTION project has demonstrated the potential for creating new jobs in rural and coastal areas within the bio-based economy. This could make these less-urban settings easier and more attractive places to live and work. The validation of the process for different types of biomass makes the process applicable in different geographical settings.