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Catalytic fast pyrolysis (CFP) has been identified as a promising pathway for the production of renewable fuels and co-products. However, continued technology development is needed to increase proc...

Co-processing bio-oils with petroleum-derived feeds in the existing multitrillion dollar refining and distribution infrastructure is an attractive option for introducing renewable energy into the f...

The impact of upgrading temperature and biomass-to-catalyst mass ratio on upgrading pine pyrolysis vapors over HZSM-5 was studied in a dual fluidized bed reactor system. Increasing the upgrading te...

Catalytic fast pyrolysis using the zeolite ZSM-5 is an attractive process for converting lignocellulosic biomass into fuels and chemicals. Ga-modified ZSM-5 has demonstrated improved hydrocarbon yields compared to ZSM-5 due to additional functionality imparted by Ga; however, there is little knowledge of the active Ga species and its role in the catalytic mechanisms. Here, we employ micropyrolyzer – GC-MS experiments and theoretical calculations to demonstrate that a hydrogen-pretreated Ga species (Ga*/ZSM-5) and a reductive environment are critical towards upgrading pine pyrolysis vapors into high yields of alkenes and aromatic hydrocarbons at near atmospheric pressure. The total carbon yield (g C in product per g C in pine) in alkenes and aromatic hydrocarbons under these conditions was 37% compared to 25% for the parent ZSM-5 catalyst. The corresponding carbon yield was only 19% for Ga*/ZSM-5 under inert conditions indicating that both the hydrogen-pretreated Ga* species and reducing atmosphere are required to obtain high hydrocarbon yields. The ratio of carbon in alkenes to carbon in aromatic hydrocarbons increased to 2.5 with Ga*/ZSM-5 under a reductive environment vs. 0.4 for ZSM-5. The carbon yield of alkenes increased with Ga loading; in contrast, increasing catalyst acidity promoted aromatic hydrocarbon production. Experiments conducted with isopropanol demonstrated high selectivity to propene over Ga*/ZSM-5 under reductive environments, indicating enhancement of dehydration reactions. A computational mechanism study was conducted to identify the active Ga species ([GaH2]+, [GaO]+, [Ga(OH)2]+ or [GaH(OH)]+) using the dehydration of isopropanol as a model reaction. Theoretical calculations suggested that [Ga(OH)2]+ and [GaH(OH)]+ are the most likely species responsible for dehydration with 39.7 and 38.8 kcal mol−1 activation energy barriers, respectively, and based on thermodynamic analysis, their ratio in the catalyst is dictated by H2 partial pressure and temperature. The model compound studies and computational results provide mechanistic support for the observed biomass experiments showing increased alkene selectivity.

Comprehensive analysis of the molecular weight distribution of raw and catalytic fast pyrolysis oils derived from biomass remains a key technical hurdle to understanding oil quality as it relates to downstream use and multiple methods may be necessary to accurately represent all components present. Here, we report the molecular weight distribution metrics of fast pyrolysis (FP) and catalytic fast pyrolysis (CFP) oils as determined by gel permeation chromatography (GPC) combined with UV-diode array (UV), differential refractive index (RI), and multi-angle laser light scattering (MALS) detection. The measured molar mass distributions revealed that FP oil consisted of a higher proportion of larger products relative to the low molecular weight products contained in the CFP oil. GPC/RI and UV methods showed FP oil to have higher weight-average molecular weight (Mw) and number-average molecular weight (Mn) than CFP oil based on elution time. However, GPC/MALS, determined the two oils to have similar overall molecular weight distribution metrics (Mw and Mn) and yielded values significantly higher than those determined by RI and UV detectors relative to external standards. Overall, the use of a multiple detection GPC method could enable a more accurate comparison and determination of true molecular weight metrics of bio-oils.

Inverse bimetallic catalysts (IBCs), synthesized by sequential deposition of noble and oxophilic metals, offer potential reactivity enhancements to various reactions, including the reduction of car...

This work addresses the effect of the support on the performance of Pd-based catalysts for hydrodeoxygenation of different model molecules (phenol, m-cresol, anisole, guaiacol) in the vapor phase at 573 K. The activity and the selectivity to deoxygenated products strongly depended on the support, regardless the model molecule. For HDO of phenol and m-cresol, benzene and toluene were the dominant products on niobia supported catalysts, whereas cyclohexanone and methylcyclohexanone were the main compounds formed on Pd/SiO2. For HDO of anisole, demethoxylation reaction producing benzene is favored over Pd/Nb2O5 catalyst, while demethylation is the preferred route over Pd/SiO2. Phenol and methanol were the main products observed for HDO of guaiacol over all catalysts but significant formation of benzene was detected over Pd/Nb2O5. The improved deoxygenation performance over the niobia supported catalysts is explained in terms of the oxophilic sites represented by Nb4+/Nb5+ cations. These catalysts were also tested for HDO of pine pyrolysis vapors. All three catalysts were effective for reducing the total yield of oxygenated products. The extent of deoxygenation was highest over the Pd/Nb2O5 and Pd/NbOPO4 catalysts. The effectiveness of Pd/Nb2O5 and Pd/NbOPO4 for deoxygenation of real feeds is in good agreement with the model compound results and suggests that these catalysts are promising materials for the upgrading of pyrolysis vapors to produce hydrocarbon fuels.

Noble metal catalysts may be attractive for hydrotreating of catalytic fast pyrolysis (CFP) oils. Model mixtures of raw noncatalytic fast pyrolysis and CFP oils representative of upgrading over HZSM-5 were hydrotreated in a batch reactor at 250–360 °C with palladium/carbon catalyst and 100 bar (cold) of hydrogen. The CFP oils gave high carbon yields of >95%, consumed less hydrogen per gram of oil produced, and had lower final oxygen concentrations than the raw oils did. GC/MS results were consistent with hydrogenation of alkenes and some oxygen-functionalized aromatic rings (e.g., phenolics) followed by hydrodeoxygenation at 360 °C. Complete deoxygenation was not obtained, and higher temperatures are recommended. The model oils’ chemical transformations, carbon yields, and deoxygenation were similar to those of oils produced in a bench-scale reactor with HZSM-5 catalyst.

Catalytic fast pyrolysis (CFP) has emerged as an attractive process for the conversion of lignocellulosic biomass into renewable fuels and products. Considerable research and development has focused on using circulating-bed reactors with zeolite catalysts (e.g., HZSM-5) for CFP because of their propensity to form gasoline-range aromatic hydrocarbons. However, the high selectivity for aromatics comes at the expense of low carbon yield, a key economic driver for this process. In this contribution, we evaluate non-zeolite catalysts in a fixed-bed reactor configuration for an integrated CFP process to produce fuel blendstocks from lignocellulosic biomass. These experimental efforts are coupled with technoeconomic analysis (TEA) to benchmark the process and guide research and development activities to minimize costs. The results indicate that CFP bio-oil can be produced from pine with improved yield by using a bifunctional metal-acid 2 wt% Pt/TiO2 catalyst in a fixed-bed reactor operated with co-fed H2 at near atmospheric pressure, as compared to H-ZSM5 in a circulating-bed reactor. The Pt/TiO2 catalyst exhibited good stability over 13 reaction-regeneration cycles with no evidence of irreversible deactivation. The CFP bio-oil was continuously hydrotreated for 140 h time-on-stream using a single-stage system with 84 wt% of the hydrotreated product having a boiling point in the gasoline and distillate range. This integrated biomass-to-blendstock process was determined to exhibit an energy efficiency of 50% and a carbon efficiency of 38%, based on the experimental results and process modelling. TEA of the integrated process revealed a modelled minimum fuel selling price (MFSP) of $4.34 per gasoline gallon equivalent (GGE), which represents a cost reduction of $0.85 GGE−1 compared to values reported for CFP with a zeolite catalyst. TEA also indicated that catalyst cost was a significant factor influencing the MFSP, which informed additional CFP experiments in which lower-cost Mo2C and high-dispersion 0.5 wt% Pt/TiO2 catalysts were synthesized and evaluated. These materials demonstrated CFP carbon yield and oil oxygen content similar to those of the 2 wt% Pt/TiO2 catalyst, offering proof-of-concept that the lower-cost catalysts can be effective for CFP and providing a route to reduce the modelled MFSP to $3.86–3.91 GGE−1. This report links foundational science and applied engineering to demonstrate the potential of fixed-bed CFP and highlights the impact of coupled TEA to guide research activities towards cost reductions.

Catalytic fast pyrolysis (CFP) of biomass produces a liquid product consisting of organic and aqueous streams. The organic stream is typically slated for hydrotreating to produce hydrocarbon biofuels, while the aqueous stream is considered a waste stream, resulting in the loss of residual biogenic carbon. Here, we report the detailed characterization and catalytic conversion of a CFP wastewater stream with the ultimate aim to improve overall biomass utilization within a thermochemical biorefinery. An aqueous stream derived from CFP of beech wood was comprehensively characterized, quantifying 53 organic compounds to a total of 17% organics. The most abundant classes of compounds are acids, aldehydes, and alcohols. The most abundant components identified in the aqueous stream were C1-C2 organics, comprising 6.40% acetic acid, 2.16% methanol, and 1.84% formaldehyde on wet basis. The CFP aqueous stream was catalytically upgraded to olefins and aromatic hydrocarbons using a Ga/HZSM-5 catalyst at 500°C. When th...

Catalytic fast pyrolysis (CFP) bio-oils with different organic oxygen contents (4–18 wt%) were prepared in a bench-scale dual fluidized bed reactor system by ex situ CFP of southern pine over HZSM-5, and the oils were subsequently hydrotreated over a sulfided CoMo catalyst at 170 bar. The goal was to determine the impact of the CFP oil oxygen content on hydrotreating requirements. The CFP oils with higher oxygen contents included a variety of oxygenates (phenols, methoxyphenols, carbonyls, anhydrosugars) whereas oxygenates in the 4 wt% oxygen oil were almost exclusively phenols. Phenols were the most recalcitrant oxygenates during hydrotreating as well, and the hydrotreated oils consisted mainly of aromatic and partially saturated ring hydrocarbons. The temperature required to produce oil with

Metal-impregnated (Ni or Ga) ZSM-5 catalysts were studied for biomass pyrolysis vapor upgrading to produce hydrocarbons using three reactors constituting a 100 000× change in the amount of catalyst used in experiments. Catalysts were screened for pyrolysis vapor phase upgrading activity in two small-scale reactors: (i) a Pyroprobe with a 10 mg catalyst in a fixed bed and (ii) a fixed-bed reactor with 500 mg of catalyst. The best performing catalysts were then validated with a larger scale fluidized-bed reactor (using ∼1 kg of catalyst) that produced measurable quantities of bio-oil for analysis and evaluation of mass balances. Despite some inherent differences across the reactor systems (such as residence time, reactor type, analytical techniques, mode of catalyst and biomass feed) there was good agreement of reaction results for production of aromatic hydrocarbons, light gases, and coke deposition. Relative to ZSM-5, Ni or Ga addition to ZSM-5 increased production of fully deoxygenated aromatic hydrocarb...

In situ and ex situ catalytic pyrolysis were compared in a system with two 2-in. bubbling fluidized bed reactors. Pine was pyrolyzed in the system with a catalyst, HZSM-5 with a silica-to-alumina ratio of 30, placed either in the first (pyrolysis) reactor or the second (upgrading) reactor. Both the pyrolysis and upgrading temperatures were 500 °C, and the weight hourly space velocity was 1.1 h–1. Five catalytic cycles were completed in each experiment. The catalytic cycles were continued until oxygenates in the vapors became dominant. The catalyst was then oxidized, after which a new catalytic cycle was begun. The in situ configuration gave slightly higher oil yield but also higher oxygen content than the ex situ configuration, which indicates that the catalyst deactivated faster in the in situ configuration than the ex situ configuration. Analysis of the spent catalysts confirmed higher accumulation of metals in the in situ experiment. In all experiments, the organic oil mass yields varied between 14 and...

Three HZSM-5 catalysts with different binders (alumina, silica, and clay) were evaluated for upgrading of pine pyrolysis vapors. All catalysts were based on the same HZSM-5 with silica to alumina molar ratio of 30. Experiments in micro-scale analytical Py-GCMS/FID showed that fresh catalysts with silica and clay produced predominantly aromatic hydrocarbons at similar carbon yields. The catalyst with alumina gave lower vapor yields and produced both hydrocarbons and partially deoxygenated products, in particular furans. The catalyst with alumina also gave higher coke yields and exhibited faster deactivation than the catalysts with clay and silica binders. The low hydrocarbon yields and coke formation were attributed to the acidic sites provided by alumina and blocking of the zeolite sites. The catalysts with silica and clay as binders were further tested in a 2-inch fluidized bed system for ex situ catalytic pyrolysis of pine. Similar oils were produced over both catalysts with carbon yields of approximately 23 % and oxygen contents of 20–21 %.

Biomass fast pyrolysis vapors contain a significant quantity of persistent aerosols, which can impact downstream processing by e.g. fouling of surfaces and deposition on downstream catalysts. In this study, aerosol concentrations and size distributions were measured by an impactor in two pyrolysis systems, a bench-scale fluidized-bed pyrolyzer and a pilot-scale cyclone pyrolyzer. In both units, the mass-based mode aerosol diameter was approximately 1 μm before aerosol collection devices in cooled vapors of 300–370 K but the number-based median was 1 μm deposited during cooling of pyrolysis vapors from 620 to 370 K in the fluidized-bed pyrolysis system. The oil fraction collected from the aerosols constituted approximately 40 wt% of the total oils collected in both systems. Compared to the total collected oil, the oil fraction from the aerosols was enriched in lignin-derived components and anhydrosugars and had lower concentrations of low molecular weight cellulose derived oxygenates, such as hydroxyketones.