Enhanced furfural production from raw corn stover employing a novel heterogeneous acid catalyst

High production of furfural by flash pyrolysis of C6 sugars and lignocellulose by Pd-PdO/ZnSO4 catalyst

Furfural (C5H4O2) is an important platform chemical for the synthesis of next-generation bio-fuels. Herein, we report a novel and reusable heterogeneous catalyst, Pd-PdO/ZnSO4 with 1.1 mol% palladium (Pd), for the production of furfural by flash pyrolysis of lignocelluloses at 400 °C. For both dry and wet C6 cellulose and its monomers, the furfural yields reach 74-82 mol%, relative to 96 mol% from C5 xylan and 23-33 wt% from sugarcane bagasse and corncob. The catalyst has a well-defined structure and bifunctional property, comprising a ZnSO4 support for the dehydration and isomerization of glucose, and a local core-shell configuration for metallic Pd0 encapsulated by an oxide (PdO) layer. The PdO layer is active for the Grob fragmentation of formaldehyde (HCHO) from glucose, which is subsequently in-situ steam reformed into syn-gas (i.e. H2 and CO), whereas the Pd0 core is active in promoting the last dehydration step for the formation of furfural.

An efficient chemoenzymatic cascade strategy for transforming biomass into furfurylamine with lobster shell-based chemocatalyst and mutated ω-transaminase biocatalyst in methyl isobutyl ketone-water

To date, an efficient process for manufacturing valuable furan compounds from available renewable resources has gained great attention via a chemoenzymatic route. In this study, a sulfonated tin-loaded heterogeneous catalyst CLUST-Sn-LS using lobster shell as biobased carrier was prepared to convert corncob (75.0 g/L) into furfural (122.5 mM) at 170 °C for 30 min in methyl isobutyl ketone (MIBK)-H₂O biphasic system (2:1, v/v). To improve furfurylamine yield, a novel recombinant E. coli TFTS harboring robust mutant Aspergillus terreus ω-transaminase [hydrophilic threonine (T) at position 130 was site-directed mutated to hydrophobic phenylalanine (F)] was constructed to transform 300-500 mM furfural into furfurylamine (90.1-93.6 % yield) at 30 °C and pH 7.5 in MIBK-H₂O. Corncob was converted to furfurylamine in MIBK-H₂O with a high productivity of 0.461 g furfurylamine/(g xylan). This constructed chemoenzymatic method coupling bio-based chemocatalyst CLUST-Sn-LS and mutant ω-transaminase biocatalyst in a biphasic system could efficiently convert lignocellulose into furfurylamine.

Towards efficient and greener processes for furfural production from biomass: A review of the recent trends

As mentioned in several recent reviews, biomass-based furfural is attracting increasing interest as a feasible alternative for the synthesis of a wide range of non-petroleum-derived compounds. However, the lack of environmentally friendly, cost-effective, and sustainable industrial procedures is still evident. This review describes the chemical and biological routes for furfural production. The mechanisms proposed for the chemical transformation of xylose to furfural are detailed, as are the current advances in the manufacture of furfural from biomass. The main goal is to overview the different ways of improving the furfural synthesis process. A pretreatment process, particularly chemical and physico-chemical, enhances the digestibility of biomass, leading to the production of >70 % of available sugars for the production of valuable products. The combination of heterogeneous (zeolite and polymeric solid) catalyst and biphasic solvent system (water/GVL and water/CPME) is regarded as an attractive approach, affording >75 % furfural yield for over 80 % of selectivity with the possibility of catalyst reuse. Microwave heating as an activation technique reduces reaction time at least tenfold, making the process more sustainable. The state of the art in industrial processes is also discussed. It shows that, when sulfuric acid is used, the furfural yields do not exceed 55 % for temperatures close to 180 °C. However, the MTC process recently achieved an 83 % yield by continuously removing furfural from the liquid phase. Finally, the CIMV process, using a formic acid/acetic acid mixture, has been developed. The economic aspects of furfural production are then addressed. Future research will be needed to investigate scaling-up and biological techniques that produce acceptable yields and productivities to become commercially viable and competitive in furfural production from biomass.

Enhanced Furfural Production in Deep Eutectic Solvents Comprising Alkali Metal Halides as Additives

The addition of alkali metal halide salts to acidic deep eutectic solvents is here reported as an effective way of boosting xylan conversion into furfural. These salts promote an increase in xylose dehydration due to the cation and anion interactions with the solvent being a promising alternative to the use of harsh operational conditions. Several alkali metal halides were used as additives in the DES composed of cholinium chloride and malic acid ([Ch]Cl:Mal) in a molar ratio of 1:3, with 5 wt.% of water. These mixtures were then used as both solvent and catalyst to produce furfural directly from xylan through microwave-assisted reactions. Preliminary assays were carried out at 150 and 130 °C to gauge the effect of the different salts in furfural yields. A Response Surface Methodology was then applied to optimize the operational conditions. After an optimization of the different operating conditions, a maximum furfural yield of 89.46 ± 0.33% was achieved using 8.19% of lithium bromide in [Ch]Cl:Mal, 1:3; 5 wt.% water, at 157.3 °C and 1.74 min of reaction time. The used deep eutectic solvent and salt were recovered and reused three times, with 79.7% yield in the third cycle, and the furfural and solvent integrity confirmed.

Features correlated to improved enzymatic digestibility of corn stover subjected to alkaline hydrogen peroxide pretreatment

As one of the leading pretreatment approaches, alkaline hydrogen peroxide (AHP) pretreatment can enhance the enzymatic digestibility of lignocellulose significantly. In this study, the glucan conversion of AHP pretreated corn stover (CS) without and with water-wash were 28.4% and 50.0% higher than that of raw material, respectively. In order to systematically understand its mechanism, analyses of the features of AHP pretreated and raw CS, such as specific surface area, crystallinity, zeta potential, water holding capacity and swelling capacity and others were performed. The weight-average molecular weight (Mw) of the sugars in the hydrolysate and the particle size distribution of the hydrolysis residue were also analyzed. These results explained why AHP-CS was more conducive to enzymatic hydrolysis. The deeper reason was that the removal of lignin and the destruction of hydrogen bonds within cellulose and hemicellulose increased the accessibility of cellulose and reduced the non-productive adsorption of cellulase, which significantly improved the enzymatic digestibility.

Recent catalytic routes for the preparation and the upgrading of biomass derived furfural and 5-hydroxymethylfurfural

Furans represent one of the most important classes of intermediates in the conversion of non-edible lignocellulosic biomass into bio-based chemicals and fuels. At present, bio-furan derivatives are generally obtained from cellulose and hemicellulose fractions of biomass via the acid-catalyzed dehydration of their relative C6-C5 sugars and then converted into a wide range of products. Furfural (FUR) and 5-hydroxymethylfurfural (HMF) are surely the most used furan-based feedstocks since their chemical structure allows the preparation of various high-value-added chemicals. Among several well-established catalytic approaches, hydrogenation and oxygenation processes have been efficiently adopted for upgrading furans; however, harsh reaction conditions are generally required. In this review, we aim to discuss the conversion of biomass derived FUR and HMF through unconventional (transfer hydrogenation, photocatalytic and electrocatalytic) catalytic processes promoted by heterogeneous catalytic systems. The reaction conditions adopted, the chemical nature and the physico-chemical properties of the most employed heterogeneous systems in enhancing the catalytic activity and in driving the selectivity to desired products are presented and compared. At the same time, the latest results in the production of FUR and HMF through novel environmental friendly processes starting from lignocellulose as well as from wastes and by-products obtained in the processing of biomass are also overviewed.

Chemoenzymatic conversion of Sorghum durra stalk into furoic acid by a sequential microwave-assisted solid acid conversion and immobilized whole-cells biocatalysis

In this study, chemoenzymatic conversion of Sorghum durra stalk (SDS) into furoic acid was developed by a sequential microwave-assisted solid acid conversion and immobilized whole-cells biocatalysis method. Dry dewaxed SDS (75 g/L) was catalyzed into furfural at 57.8% yield with heterogeneous Sn-argil (2.0 wt% dosage) in n-ethyl butyrate-H₂O (1:1, v:v) biphasic system using a microwave (600 W) for 10 min at 180 °C. In this biphasic media (pH 6.5), SDS-derived furfural (125.0 mM) was biologically oxidized to furoic acid by immobilized Brevibacterium lutescens cells harboring furfural-oxidizing activity at 30 °C, and furfural was wholly transformed to furoic acid within 24 h. Finally, the recovery and reuse of the Sn-argil catalyst and immobilized biocatalysts were conducted for synthesizing furoic acid from SDS in the biphasic system. This chemoenzymatic route can be attractive for furoic acid production.

One-pot conversion of alginic acid into furfural using Amberlyst-15 as a solid acid catalyst in γ-butyrolactone/water co-solvent system

One-pot conversion of alginic acid, which was derived from brown algae, to furfural was investigated using various solid acid catalysts. Among the solid acid catalysts tested, Amberlyst-15 showed the highest activity in furfural production in aqueous media. When the effect of reaction media was examined by applying various organic solvent mixtures, it was found that γ-butyrolactone/water co-solvent system was selected as the most appropriate system for the reaction. Maximum furfural yield of 32.2% was obtained using Amberlyst-15 in the γ-butyrolactone/H₂O at 210 °C for 20 min. Catalyst showed gradual deactivation behavior as the reaction proceeded, although the catalyst recovered its activity upon the simple treatment with sulfuric acid. N₂ adsorption-desorption experiments, Fourier-transform infrared spectroscopy (FT-IR), back titration, and CHNS analysis were applied to investigate the physicochemical property of post-reaction samples, confirming that the leaching of the active sulfonic acid group and decrease in acid density was the major cause of deactivation.

Enhanced Conversion of Xylan into Furfural using Acidic Deep Eutectic Solvents with Dual Solvent and Catalyst Behavior

An efficient process for the production of furfural from xylan by using acidic deep eutectic solvents (DESs), which act both as solvents and catalysts, is developed. DESs composed of cholinium chloride ([Ch]Cl) and malic acid or glycolic acid at different molar ratios, and the effects of water and γ-valerolactone (GVL) contents, solid/liquid (S/L) ratio, and microwave heating are investigated. The best furfural yields are obtained with the DES [Ch]Cl:malic acid (1:3 molar ratio)+5 wt % water, under microwave heating for 2.5 min at 150 °C, a S/L ratio of 0.050, and GVL at a weight ratio of 2:1. Under these conditions, a remarkable furfural yield (75 %) is obtained. Direct distillation of furfural from the DES/GVL solvent and distillation from 2-methyltetrahydrofuran (2-MeTHF) after a back-extraction step enable 89 % furfural recovery from 2-MeTHF. This strategy allows recycling of the DES/GVL for at least three times with only small losses in furfural yield (>69 %). This is the fastest and highest-yielding process reported for furfural production using bio-based DESs as solvents and catalysts, paving the way for scale-up of the process.

High performance of Mo-promoted Ir/SiO2 catalysts combined with HZSM-5 toward the conversion of cellulose to C5/C6 alkanes

In this study, the Mo-promoted Ir/SiO₂ (Ir-MoO_x/SiO₂) catalysts combined with the zeolite HZSM-5 were used for the direct conversion of microcrystalline cellulose (MCC) to liquid fuel (C₅/C₆ alkanes) in n-dodecane/H₂O system. A synergistic effect was formed between the partially reduced MoO_x species and the Ir particles, which effectively promoted the catalytic activity of Ir/SiO₂ catalyst. When the Mo/Ir molar ratio was 0.5, a high yield of C₅/C₆ alkanes (91.7%) was achieved at 210 ℃ for 12 h. In addition, the main component of C₅/C₆ alkanes was n-hexane, which was proven to be obtained by the hydrogenolysis of the key intermediate, sorbitol, formed from the hydrolysis and hydrogenation of MCC.

Production of furfural from xylose catalyzed by a novel calcium gluconate derived carbon solid acid in 1,4-dioxane

A novel carbon-based solid acid catalyst (SC-GCa-800) was prepared by the high-temperature carbonization of calcium gluconate followed by sulfonation with 4-diazoniobenzenesulfonate at room temperature.

Heterogeneous Nickel Catalysts Derived from 2D Metal-Organic Frameworks for Regulating the Selectivity of Furfural Hydrogenation

Hydrolysis of the biomass platform compound furfural can produce a bulk of fine chemicals because of its multiple functional groups. Developing an efficient catalytic system to regulate the process toward some desirable products has always been a hot research area. Herein, the novel Ni-based catalysts (Ni-MFC-X, X = 300, 400...800) synthesized by pyrolysis of the 2D Ni-based metal-organic framework (MOF) in the temperature range 300-800 °C show good performance for selective hydrogenation of furfural (FUR). Interestingly, the calcination temperature of the MOF precursor plays an important role in hydrogenation of furfural with controllable selectivity toward furfuryl alcohol (FOL) and tetrahydro FOL (THFOL). Ni-MFC-500 affords us 92.5% conversion of furfural and 59.5% selectivity of FOL. Ni-MFC-700 can promote hydrogenation of furfural with 91.8% conversion and 51.0% selectivity of THFOL. Furthermore, the stability of as-obtained Ni-MFC-500 and Ni-MFC-700 was also very impressive in this reaction system.

Pretreatment and enzymatic hydrolysis for the efficient production of glucose and furfural from wheat straw, pine and poplar chips

A flexible approach to a two-step Biorefinery for the production of glucose and furfural from three different feedstocks is presented. Pretreatment conditions were selected to drive the production towards the generation of glucose or furfural. Harsh pretreatment conditions produced solids with highly accessible glycan contents for the enzymatic hydrolysis with 100% glucose yields when wheat straw or poplar chips were used as feedstock. Mild conditions afforded xylan-rich hydrolysates that could be efficiently transformed to furfural, either under conventional or microwave heating in biphasic media. Yields for the transformation of xylan from feedstocks ranged between 45% and 90% depending on the feedstock, the thermal pretreatment and the cyclodehydration conditions. Up to 12.6 kg of glucose and materials and 2.5 kg of furfural can be produced starting from 50 kg of biomass. A new analytical methodology based on ¹³C NMR that provided good quality analytical results is also presented.

Transformation of corncob into furfural by a bifunctional solid acid catalyst

A transformation route was developed for the conversion of raw corncob into furfural by a Clbearing solid acid catalyst (HSCSO₃H) prepared by the hydrothermal carbonization and sulfonation of sucralose. The catalytic performances of HSCSO₃H in selected solvents were demonstrated and optimized, where a furfural yield of 90.8 mol% (20.9 wt%) was achieved at 448 K in 30 min in γ-valerolactone/water system. Interestingly, significant furfural yields were also obtained from cellulose. The effect of elevated temperature on furfural yield from high initial feedstock loading was also investigated. HSCSO₃H with COOH, phenolicOH, and Cl as binding sites and SO₃H as the catalytic site on its surface presents a bifunctional catalyst, and synergic effects of these functional groups, reaction solvent property and temperature are made responsible for the good catalytic performances. The catalytic strategy proposed in this study demonstrated an effective transformation of corncob into furfural with a high yield.

Efficient catalytic conversion of corn stalk and xylose into furfural over sulfonated graphene in γ-valerolactone

Sulfonated graphene (SG) was prepared and employed to convert corn stalk and xylose into furfural. Transmission electron microscopy (TEM), scanning electron microscopy (SEM), X-ray photoelectron spectroscopy (XPS) and Fourier transform infrared spectroscopy (FT-IR) were used to characterize SG. The effects of reaction time, temperature, substrate loading, catalyst dosage and solvents on the reaction were researched and optimized. SG exhibited high catalytic activity in the conversion of xylose and corn stalk to furfural. A fairly high furfural yield of 96% was achieved at 150 °C from xylose and a 71.9% furfural yield was obtained when using a 10.7 ratio (mass ratio: xylose to SG) at 140 °C. While a 48% furfural yield was obtained from corn stalk (based on the starting combined moles of xylan and glucan in corn stalk; yield was >100%, if based on only xylan) using a substrate loading (corn stalk to catalyst mass ratio) of 2.14 and a 19% 5-hydroxymethylfurfural (5-HMF) yield was obtained. What's more, a 43.9% yield of furfural was obtained in only 20 min. In addition, the reusability of SG was also investigated and shown to have good stability for xylose dehydration.

Catalytic conversion of corn stalk over sulfonated graphene.

One-pot co-catalysis of corncob with dilute hydrochloric acid and tin-based solid acid for the enhancement of furfural production

A newly synthesized solid acid catalyst SO₄^2-/SnO₂-diatomite was prepared for synthesizing furfural from corncob in the presence of homogeneous Brönsted acid. The relationship between pKa of Brönsted acid and turnover frequency (TOF) of co-catalysis with Brönsted acid plus SO₄^2-/SnO₂-diatomite was explored on the conversion of corncob to furfural. HCl (pKa = -7.0) (0.5 wt%) plus SO₄^2-/SnO₂-diatomite (3.6 wt%) gave the highest furfural yield (40.1%) with TOF value at 2.98 h^-1 in the aqueous media. In the γ-valerolactone-water (6:4, v:v) biphasic media containing 15 g/L ZnCl₂, one-pot conversion of corncob with co-catalysts gave a furfural yield of 68.9% at 170 °C for 30 min. Additionally, an efficient SO₄^2-/SnO₂-diatomite recycling was achieved with a productivity of 15.6 g furfural/(g solid acid·day) after 5 cycles of repeated use. Clearly, this one-pot co-catalysis process has high potential application for furfural production in future.

Efficient transformation of corn stover to furfural using p-hydroxybenzenesulfonic acid-formaldehyde resin solid acid

In this work, p-hydroxybenzenesulfonic acid-formaldehyde resin acid catalyst (MSPFR), was synthesized by a hydrothermal method, and employed for the furfural production from raw corn stover. Scanning electron microscopy (SEM), transmission electron microscopy (TEM), N₂ adsorption-desorption, elemental analysis (EA), thermogravimetric analysis (TGA), and Fourier transform infrared spectroscopy (FT-IR) were used to characterize the MSPFR. The effects of reaction time, temperature, solvents and corn stover loading were investigated. The MSPFR presented high catalytic activity for the formation of furfural from corn stover. When the MSPFR/corn stover mass loading ratio was 0.5, a higher furfural yield of 43.4% could be achieved at 190 °C in 100 min with 30.7% 5-hydroxymethylfurfural (HMF) yield. Additionally, quite importantly, the recyclability of the MSPFR for xylose dehydration is good, and for the conversion of corn stover was reasonable.

Enhanced Furfural Yields from Xylose Dehydration in the γ-Valerolactone/Water Solvent System at Elevated Temperatures

High yields of furfural (>90 %) were achieved from xylose dehydration in a sustainable solvent system composed of γ-valerolactone (GVL), a biomass derived solvent, and water. It is identified that high reaction temperatures (e.g., 498 K) are required to achieve high furfural yield. Additionally, it is shown that the furfural yield at these temperatures is independent of the initial xylose concentration, and high furfural yield is obtained for industrially relevant xylose concentrations (10 wt %). A reaction kinetics model is developed to describe the experimental data obtained with solvent system composed of 80 wt % GVL and 20 wt % water across the range of reaction conditions studied (473-523 K, 1-10 mm acid catalyst, 66-660 mm xylose concentration). The kinetic model demonstrates that furfural loss owing to bimolecular condensation of xylose and furfural is minimized at elevated temperature, whereas carbon loss owing to xylose degradation increases with increasing temperature. Accordingly, the optimal temperature range for xylose dehydration to furfural in the GVL/H₂ O solvent system is identified to be from 480 to 500 K. Under these reaction conditions, furfural yield of 93 % is achieved at 97 % xylan conversion from lignocellulosic biomass (maple wood).

Hydrolysis of Hemicellulose and Derivatives-A Review of Recent Advances in the Production of Furfural

Biobased production of furfural has been known for decades. Nevertheless, bioeconomy and circular economy concepts is much more recent and has motivated a regain of interest of dedicated research to improve production modes and expand potential uses. Accordingly, this review paper aims essentially at outlining recent breakthroughs obtained in the field of furfural production from sugars and polysaccharides feedstocks. The review discusses advances obtained in major production pathways recently explored splitting in the following categories: (i) non-catalytic routes like use of critical solvents or hot water pretreatment, (ii) use of various homogeneous catalysts like mineral or organic acids, metal salts or ionic liquids, (iii) feedstock dehydration making use of various solid acid catalysts; (iv) feedstock dehydration making use of supported catalysts, (v) other heterogeneous catalytic routes. The paper also briefly overviews current understanding of furfural chemical synthesis and its underpinning mechanism as well as safety issues pertaining to the substance. Eventually, some remaining research topics are put in perspective for further optimization of biobased furfural production.

Controlling the cleavage of the inter- and intra-molecular linkages in lignocellulosic biomass for further biorefining: A review

The abundant intermolecular linkages among cellulose, hemicellulose and lignin significantly limit the utilization of the most promising renewable biomass. Process control with solvents, catalysts and temperature is of significant importance providing ways to break the above linkages, and benefiting to the further conversion of the main biomass components to small molecular products. This article discusses the effect of catalyst under hydrothermal and organosolv treatment emphasizing the cleavage of the intermolecular linkage. Acidic catalysts show good performance on cleaving the linkages between carbohydrates and lignin. Basic catalysts promoted the dissolution of lignin component. Hydrogenolysis assisted conversion of lignin can efficiently break the intermolecular linkages to yield lignin-derived bio-oil, especially in co-solvent reaction system. Besides, the effects of single solvent and co-solvent systems, as well as the cleavage of the intramolecular linkages to yield target chemicals are also included. Several further study strategies are proposed.

Camellia oleifera shell as an alternative feedstock for furfural production using a high surface acidity solid acid catalyst

This paper focuses on the high-value transformation of camellia oleifera shell, which is an agricultural waste enriched in hemicellulose. An efficient catalytic route employing sulfonated swelling mesoporous polydivinylbenzene (PDVB-SO₃H) as catalyst in monophasic or biphasic solvents was developed for the conversion of raw camellia oleifera shell into furfural. The reaction parameters were evaluated and optimized for improving the furfural yield. It was found that the solvent greatly influenced the hydrolysis of camellia oleifera shells, and the highest furfural yield of 61.3% was obtained in "γ-butyrolactone + water" system when the feedstock-to-catalyst ratio was 2 for 30 min at 443 K. Camellia oleifera shell exhibited a high potential as feedstock to produce furfural in high yields. The outcome of this study provides an attractive utilization option to camellia oleifera shell, which is currently burned or discarded for producing a bio-based chemical.

Selective yields of furfural and hydroxymethylfurfural from glucose in tetrahydrofuran over Hβ zeolite

Several simple and effective solvents combined with Hβ zeolite were tested to selectively convert glucose into furfural and hydroxymethylfurfural in this work. The physicochemical properties of typically different polar aprotic solvents were compared. Tetrahydrofuran was found to be a suitable solvent in the selective conversion of glucose. The effect of reaction parameters, such as temperature, reaction time, water content, glucose dosage and protonic acid addition, on the product distribution were investigated in detail. Furfural and hydroxymethylfurfural could be selectively produced in this system, and the highest yields of furfural and hydroxymethylfurfural were up to 35.2% and 49.7% respectively. Furfural could be stable in a tetrahydrofuran medium when adding 5 wt% water in the absence of extra protonic acid. However, furfural production was extremely suppressed after addition of an acidic inorganic salt, which increased the yield of hydroxymethylfurfural. This investigation indicates a simple and feasible method to selectively produce furfural and hydroxymethylfurfural from renewable cellulosic carbohydrates.

Several simple and effective solvents combined with Hβ zeolite were tested to selectively convert glucose into furfural and hydroxymethylfurfural in this work.