Chemical engineering role in the use of renewable energy and alternative carbon sources in chemical production

Chemoselective derivatisation and ultrahigh resolution mass spectrometry for the determination of hydroxyl functional groups within complex bio-oils

Bio-oils are a renewable alternative resource for the production of fine chemicals and fuels. Bio-oils are characterised by a high content of oxygenated compounds with a diverse array of different chemical functionalities. Here, we performed a chemical reaction to transform the hydroxyl group of the various components in a bio-oil prior to characterisation with ultrahigh resolution mass spectrometry (UHRMS). The derivatisations were first evaluated using twenty lignin-representative standards with different structural features. Our results indicate a highly chemoselective transformation of the hydroxyl group despite the presence of other functional groups. Mono- and di-acetate products were observed in acetone-acetic anhydride (acetone-Ac₂O) mixtures for non-sterically hindered phenols, catechols and benzene diols. Dimethyl sulfoxide-Ac₂O (DMSO-Ac₂O) reactions favoured the oxidation of primary and secondary alcohols and the formation of methylthiomethyl (MTM) products of phenols. The derivatisations were then performed in a complex bio-oil sample to gain insights into the hydroxyl group profile of the bio-oil. Our results indicate that the bio-oil before derivatisation is composed of 4500 elemental compositions containing 1-12 oxygen atoms. After the derivatisation in DMSO-Ac₂O mixtures, the total number of compositions increased approximately five-fold. The reaction was indicative of the variety of hydroxyl group profiles within the sample in particular the presence of phenols that were ortho and para substituted, non-hindered phenols (about 34%), aromatic alcohols (including benzylic and other non-phenolic alcohols) (25%), and aliphatic alcohols (6.3%) could be inferred. Phenolic compositions are known as coke precursors in catalytic pyrolysis and upgrading processes. Thus, the combination of chemoselective derivatisations in conjunction with UHRMS can be a valuable resource to outline the hydroxyl group profile in elemental chemical compositions in complex mixtures.

Advanced (photo)electrocatalytic approaches to substitute the use of fossil fuels in chemical production

Electrification of the chemical industry for carbon-neutral production requires innovative (photo)electrocatalysis. This study highlights the contribution and discusses recent research projects in this area, which are relevant case examples to explore new directions but characterised by a little background research effort. It is organised into two main sections, where selected examples of innovative directions for electrocatalysis and photoelectrocatalysis are presented. The areas discussed include (i) new approaches to green energy or H2 vectors, (ii) the production of fertilisers directly from the air, (iii) the decoupling of the anodic and cathodic reactions in electrocatalytic or photoelectrocatalytic devices, (iv) the possibilities given by tandem/paired reactions in electrocatalytic devices, including the possibility to form the same product on both cathodic and anodic sides to "double" the efficiency, and (v) exploiting electrocatalytic cells to produce green H2 from biomass. The examples offer hits to expand current areas in electrocatalysis to accelerate the transformation to fossil-free chemical production.

Segregationally stabilised plasmids improve production of commodity chemicals in glucose-limited continuous fermentation

Background

The production of chemicals via bio-based routes is held back by limited easy-to-use stabilisation systems. A wide range of plasmid stabilisation mechanisms can be found in the literature, however, how these mechanisms effect genetic stability and how host strains still revert to non-productive variants is poorly understood at the single-cell level. This phenomenon can generate difficulties in production-scale bioreactors as different populations of productive and non-productive cells can arise. To understand how to prevent non-productive strains from arising, it is vital to understand strain behaviour at a single-cell level.

The persistence of genes located on plasmid vectors is dependent on numerous factors but can be broadly separated into structural stability and segregational stability. While structural stability refers to the capability of a cell to resist genetic mutations that bring about a loss of gene function in a production pathway, segregational stability refers to the capability of a cell to correctly distribute plasmids into daughter cells to maintain copy number. A lack of segregational stability can rapidly generate plasmid-free variants during replication, which compromises productivity.

Results

Citramalate synthase expression was linked in an operon to the expression of a fluorescent reporter to enable rapid screening of the retention of a model chemical synthesis pathway in a continuous fermentation of E. coli. Cells without additional plasmid stabilisation started to lose productivity immediately after entering the continuous phase. Inclusion of a multimer resolution site, cer, enabled a steady-state production period of 58 h before a drop in productivity was detected. Single-cell fluorescence measurements showed that plasmid-free variants arose rapidly without cer stabilisation and that this was likely due to unequal distribution of plasmid into daughter cells during cell division. The addition of cer increased total chemical yield by more than 50%.

Conclusions

This study shows the potential remains high for plasmids to be used as pathway vectors in industrial bio-based chemicals production, providing they are correctly stabilised. We demonstrate the need for accessible bacterial ‘toolkits’ to enable rapid production of known, stabilised bacterial production strains to enable continuous fermentation at scale for the chemicals industry.

Supplementary Information

The online version contains supplementary material available at 10.1186/s12934-022-01958-3.

Assessment of hydrogen production from municipal solid wastes as competitive route to produce low-carbon H2

An economic and CO₂ emission impact assessment of the production of H₂ from municipal solid waste in the two configurations of retrofitting an existing waste to energy plant with an electrolysis unit (WtE + El) and of hydrogen production via waste gasification (WtH₂) is made with respect to reference cases of H₂ production by steam reforming of methane (SMR) or of water electrolysis (El). The results are analyzed with reference to two scenarios depending on whether the fate of waste disposal emissions for SMR and El is accounted. The costs of H₂ production as a function of waste gate fee and CO₂ taxation as well as the CO₂ emissions for both scenarios and the four cases of H₂ production analyzed are reported. The results show that produce H₂ from a WtE plant hybridized with an electrolyzer could be economic only when the plant is free from depreciation costs and no CO₂ taxation exists. Conversely, WtH₂ solution results preferable when CO₂ taxation will be applied to the non-biogenic fraction of waste. Conditions when WtH₂ may results competitive to SMR are defined, in terms of both cost of production and CO₂ emissions. With respect to El case, WtH₂ results more competitive under the assumption made in terms of combined costs and CO₂ emissions.

Seeking Genuine Vocations through Sustainability in Chemical Engineering

Sustainability in education is essential in raising awareness among pupils regarding the interconnected global challenges that we are facing and, at the same time, cultivating and transforming their mindsets to embrace and adopt sustainable lifestyles. In particular, college students who might briefly encounter sustainability issues during their courses of study would bring their values and attitudes regarding sustainability into their future workplace and beyond. In this article, we focus on sustainability in engineering education at the tertiary level, particularly in chemical engineering, and reveal how these potential engineers could seek genuine vocations when choosing their careers without compromising sustainability. The article begins with a description of what constitutes chemical engineering and its branches in plain language. It then outlines what to expect when one enrolls in a chemical engineering program as an undergraduate or graduate student. This includes the core subjects to obtain, skill sets to master, and other essential expertise that could be useful in the workplace. Since chemical engineering is one of the disciplines where the paradox of improving and impairing is conspicuous, it is also essential to delve deeper into the sustainability facet of the field, specifically in higher education. The discussion continues with career options for enthusiastic chemical engineers and how these young and early-career graduates could discover their reason for well-being and life purpose as aspiring chemical engineers, while at the same time maintaining and enhancing the sustainability in their vocations.

Catalysis for e-Chemistry: Need and Gaps for a Future De-Fossilized Chemical Production, with Focus on the Role of Complex (Direct) Syntheses by Electrocatalysis

The prospects, needs and limits in current approaches in catalysis to accelerate the transition to e-chemistry, where this term indicates a fossil fuel-free chemical production, are discussed. It is suggested that e-chemistry is a necessary element of the transformation to meet the targets of net zero emissions by year 2050 and that this conversion from the current petrochemistry is feasible. However, the acceleration of the development of catalytic technologies based on the use of renewable energy sources (indicated as reactive catalysis) is necessary, evidencing that these are part of a system of changes and thus should be assessed from this perspective. However, it is perceived that the current studies in the area are not properly addressing the needs to develop the catalytic technologies required for e-chemistry, presenting a series of relevant aspects and directions in which research should be focused to develop the framework system transformation necessary to implement e-chemistry.

Environmental management of industrial decarbonization with focus on chemical sectors: A review

A considerable portion of fossil CO₂ emissions comes from the energy sector for production of heat and electricity. The industrial sector has the second order in emission in which the main parts are released from energy-intensive industries, namely metallurgy, building materials, chemicals, and manufacturing. The decarbonization of industrial wastes contemplates the classic decarbonization through optimization of conventional processes as well as utilization of renewable energy and resources. The upgrading of existing processes and integration of the methodologies with a focus on efficiency improvement and reduction of energy consumption and the environment is the main focus of this review. The implementation of renewable energy and feedstocks, green electrification, energy conversion methodologies, carbon capture, and utilization, and storage are also covered. The main objectives of this review are towards chemical industries by introducing the potential technology enhancement at different subsectors. For this purpose, state-of-the-art roadmaps and pathways from the literature findings are presented. Both common and innovative renewable attempts are needed to reach out both short- and long-term deep decarbonization targets. Even though all of the innovative solutions are not economically viable at the industrial scale, they play a crucial role during and after the energy transition interval.

Reuse of CO2 in energy intensive process industries

Closing the carbon cycle and enabling a carbon circular economy in energy intensive industries (iron and steel, cement, refineries, petrochemistry and fertilizers) are topics of increasing interest to meet the demanding target of defossilizing the production. The focus of this perspective contribution is on CO₂ reuse technologies in this context. While this is a topic with abundant literature, the analysis of applying CO₂ reuse technologies evidences the need to go beyond those receiving most of the attention today, such as conversion of CO₂ to methanol. Depending on the specific context, different scenarios are expected. Some examples illustrating the search for novel solutions are provided, such as those starting from the efficient conversion of CO₂ to CO. Once CO is produced from CO₂ many bio-chemical and catalytic conversion routes open up next to direct uses of CO in the steel and chemical sector.

Towards Sustainable Oxalic Acid from CO2 and Biomass

To quickly and drastically reduce CO2 emissions and meet our ambitions of a circular future, we need to develop carbon capture and storage (CCS) and carbon capture and utilization (CCU) to deal with the CO2 that we produce. While we have many alternatives to replace fossil feedstocks for energy generation, for materials such as plastics we need carbon. The ultimate circular carbon feedstock would be CO2 . A promising route is the electrochemical reduction of CO2 to formic acid derivatives that can subsequently be converted into oxalic acid. Oxalic acid is a potential new platform chemical for material production as useful monomers such as glycolic acid can be derived from it. This work is part of the European Horizon 2020 project "Ocean" in which all these steps are developed. This Review aims to highlight new developments in oxalic acid production processes with a focus on CO2 -based routes. All available processes are critically assessed and compared on criteria including overall process efficiency and triple bottom line sustainability.

Fiber‐Shaped Electronic Devices

Textile electronics embedded in clothing represent an exciting new frontier for modern healthcare and communication systems. Fundamental to the development of these textile electronics is the development of the fibers forming the cloths into electronic devices. An electronic fiber must undergo diverse scrutiny for its selection for a multifunctional textile, viz., from the material selection to the device architecture, from the wearability to mechanical stresses, and from the environmental compatibility to the end‐use management. Herein, the performance requirements of fiber‐shaped electronics are reviewed considering the characteristics of single electronic fibers and their assemblies in smart clothing. Broadly, this article includes i) processing strategies of electronic fibers with required properties from precursor to material, ii) the state‐of‐art of current fiber‐shaped electronics emphasizing light‐emitting devices, solar cells, sensors, nanogenerators, supercapacitors storage, and chromatic devices, iii) mechanisms involved in the operation of the above devices, iv) limitations of the current materials and device manufacturing techniques to achieve the target performance, and v) the knowledge gap that must be minimized prior to their deployment. Lessons learned from this review with regard to the challenges and prospects for developing fiber‐shaped electronic components are presented as directions for future research on wearable electronics.

Plasma Generating—Chemical Looping Catalyst Synthesis by Microwave Plasma Shock for Nitrogen Fixation from Air and Hydrogen Production from Water for Agriculture and Energy Technologies in Global Warming Prevention

Simultaneous generation of plasma by microwave irradiation of perovskite or the spinel type of silica supported porous catalyst oxides and their reduction by nitrogen in the presence of oxygen is demonstrated. As a result of plasma generation in air, NOx generation is accompanied by the development of highly heterogeneous regions in terms of chemical and morphological variations within the catalyst. Regions of almost completely reduced catalyst are dispersed within the catalyst oxide, across micron-scale domains. The quantification of the catalyst heterogeneity and evaluation of catalyst structure are studied using Scanning Electron Microscopy, Energy Dispersive X-ray Spectroscopy and XRD. Plasma generating supported spinel catalysts are synthesized using the technique developed by the author (Catalysts; 2016; 6; 80) and BaTiO3 is used to exemplify perovskites. Silica supported catalyst systems are represented as M/Si = X (single catalysts) or as M(1)/M(2)/Si = X/Y/Z (binary catalysts) where M; M(1) M(2) = Cr; Mn; Fe; Co; Cu and X, Y, Z are the molar ratio of the catalysts and SiO2 support. Composite porous catalysts are synthesized using a mixture of Co and BaTiO3. In all the catalysts, structural heterogeneity manifests itself through defects, phase separation and increased porosity resulting in the creation of the high activity sites. The chemical heterogeneity results in reduced and oxidized domains and in very large changes in catalyst/support ratio. High electrical potential activity within BaTiO3 particles is observed through the formation of electrical treeing. Plasma generation starts as soon as the supported catalyst is synthesized. Two conditions for plasma generation are observed: Metal/Silica molar ratio should be > 1/2 and the resulting oxide should be spinel type; represented as MaOb (a = 3; b = 4 for single catalyst). Composite catalysts are represented as {M/Si = X}/BaTiO3 and obtained from the catalyst/silica precursor fluid with BaTiO3 particles which undergo fragmentation during microwave irradiation. Further irradiation causes plasma generation, NOx formation and lattice oxygen depletion. Partially reduced spinels are represented as MaOb–c. These reactions occur through a chemical looping process in micron-scale domains on the porous catalyst surface. Therefore; it is possible to scale-up this process to obtain NOx from MaOb for nitric acid production and H2 generation from MaOb–c by catalyst re-oxidized by water. Re-oxidation by CO2 delivers CO as fuel. These findings explain the mechanism of conversion of combustion gases (CO2 + N2) to CO and NOx via a chemical looping process. Mechanism of catalyst generation is proposed and the resulting structural inhomogeneity is characterized. Plasma generating catalysts also represent a new form of Radar Absorbing Material (RAM) for stealth and protection from radiation in which electromagnetic energy is dissipated by plasma generation and catalytic reactions. These catalytic RAMs can be expected to be more efficient in frequency independent microwave absorption.