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Every twig and splinter used

Plant-based production of commodity chemicals faces steep competition from fossil resources, which are often cheaper and easier to partition. Sustainable use of renewable resources requires strategies for converting complex and recalcitrant biomolecules into streams of chemicals with extraordinary efficiency. Liao et al. developed a biorefinery concept in which wood is eventually fully converted into useful chemicals: phenol, propylene, pulp amenable to ethanol production, and phenolic oligomers that can be incorporated into ink production (see the Perspective by Zhang). A life-cycle assessment and techno-economic analysis highlight the efficiency of the process and reveal the potential for such biorefinery strategies to contribute to sustainable chemicals markets.
Science, this issue p. 1385; see also p. 1305

Abstract

The profitability and sustainability of future biorefineries are dependent on efficient feedstock use. Therefore, it is essential to valorize lignin when using wood. We have developed an integrated biorefinery that converts 78 weight % (wt %) of birch into xylochemicals. Reductive catalytic fractionation of the wood produces a carbohydrate pulp amenable to bioethanol production and a lignin oil. After extraction of the lignin oil, the crude, unseparated mixture of phenolic monomers is catalytically funneled into 20 wt % of phenol and 9 wt % of propylene (on the basis of lignin weight) by gas-phase hydroprocessing and dealkylation; the residual phenolic oligomers (30 wt %) are used in printing ink as replacements for controversial para-nonylphenol. A techno-economic analysis predicts an economically competitive production process, and a life-cycle assessment estimates a lower carbon dioxide footprint relative to that of fossil-based production.
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Supplementary Material

Summary

Materials and Methods
Supplementary Text
Figs. S1 to S53
Tables S1 to S14
References (2682)

Resources

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References and Notes

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Volume 367 | Issue 6484
20 March 2020

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Received: 21 May 2018
Accepted: 4 February 2020
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Acknowledgments

We thank W. Vermandel for his assistance in producing lignin oil and R. Ooms and J. Maes for technical assistance during the catalytic testing. Funding: Y.L., G.V.d.B., D.V., J.V.A., and B.L. acknowledge funding from the China Scholarship Council (201404910467), Catalisti-ICON project MAIA (Flemish government), Fonds Wetenschappelijk Onderzoek – Vlaanderen (FWO) (postdoc), Flanders Innovation & Entrepreneurship (innovation mandate - postdoc), and the Industrial Research Fund KU Leuven (IOF fellow), respectively. S.-F.K. acknowledges Catalisti cSBO ARBOREF and BIO-HArT (Interreg VA Vlaanderen-Nederland) funding from the Flemish government. K.V.Ae. acknowledges funding from FWO-SBO project Biowood (S003518N). T.R. acknowledges KU Leuven internal research funds for a postdoctoral mandate (PDM). S.V.d.B. acknowledges funding from KU Leuven internal research funds for a PDM, the Flemish government for the FWO-SBO project Biowood, and Flanders Innovation & Entrepreneurship (innovation mandate - postdoc). T.N. and J.M.T. acknowledge ARBOREF. Funding by BIOFACT (FNRS – FWO EOS project G0H0918N), supporting lignin conversion, is also acknowledged. Author contributions: Y.L. and B.F.S. conceived the idea and designed the experiments. Y.L. carried out the experimental work of the main catalysis research, and catalyst characterization and interpretation was assisted by D.V. S.-F.K. performed the liquid-liquid extraction separation work. G.V.d.B. and T.R. performed and interpreted the wood composition analysis and the processing experiments, according to the lignin-first concept, and the preparation and analysis of a large batch of isolated lignin-first phenolic monomers. J.V.A., S.V.d.B., and B.L. composed and focused on the TEA with the kind assistance of Exyte. K.N. and K.V.Ac. performed the LCA. T.N. and J.M.T. performed the fermentation of the lignin-first carbohydrate pulp to bioethanol. K.V.Ae. conducted the characterization and analysis of phenolic oligomers. M.M. and H.M. performed the production and characterization of the renewable resin and ink varnish. The text was initially composed by B.F.S., Y.L., S.-F.K., and G.V.d.B., and all authors further contributed to the discussion of the experimental work and the final version of the manuscript. Competing interests: Y.L., B.F.S., J.V.A., and S.V.d.B. are inventors on a patent application [attorney docket number 292-P15233US (ZL919134)], held and submitted by KU Leuven, that covers lignocellulose refinery. Data and materials availability: All data needed to support the conclusions of this manuscript are included in the main text or supplementary materials.

Authors

Affiliations

Center for Sustainable Catalysis and Engineering, KU Leuven, Celestijnenlaan 200F, 3001 Heverlee, Belgium.
Center for Sustainable Catalysis and Engineering, KU Leuven, Celestijnenlaan 200F, 3001 Heverlee, Belgium.
Gil Van den Bossche
Center for Sustainable Catalysis and Engineering, KU Leuven, Celestijnenlaan 200F, 3001 Heverlee, Belgium.
Joost Van Aelst
Center for Sustainable Catalysis and Engineering, KU Leuven, Celestijnenlaan 200F, 3001 Heverlee, Belgium.
Center for Sustainable Catalysis and Engineering, KU Leuven, Celestijnenlaan 200F, 3001 Heverlee, Belgium.
Tom Renders
Center for Sustainable Catalysis and Engineering, KU Leuven, Celestijnenlaan 200F, 3001 Heverlee, Belgium.
Department of Materials Engineering, KU Leuven, Kasteelpark Arenberg 44, 3001 Leuven, Belgium.
Thomas Nicolaï
Laboratory of Molecular Cell Biology, KU Leuven, and Center for Microbiology, VIB, Kasteelpark Arenberg 31, 3001 Heverlee, Belgium.
Korneel Van Aelst
Center for Sustainable Catalysis and Engineering, KU Leuven, Celestijnenlaan 200F, 3001 Heverlee, Belgium.
Lawter bvba, Ketenislaan 1C, Haven 1520, 9130 Kallo, Belgium.
Hironori Matsushima
Lawter bvba, Ketenislaan 1C, Haven 1520, 9130 Kallo, Belgium.
Laboratory of Molecular Cell Biology, KU Leuven, and Center for Microbiology, VIB, Kasteelpark Arenberg 31, 3001 Heverlee, Belgium.
Department of Materials Engineering, KU Leuven, Kasteelpark Arenberg 44, 3001 Leuven, Belgium.
Center for Economics and Corporate Sustainability, KU Leuven, Warmoesberg 26, 1000 Brussels, Belgium.
Center for Sustainable Catalysis and Engineering, KU Leuven, Celestijnenlaan 200F, 3001 Heverlee, Belgium.
Danny Verboekend
Center for Sustainable Catalysis and Engineering, KU Leuven, Celestijnenlaan 200F, 3001 Heverlee, Belgium.
Present address: Zeopore Technologies NV, Lelielaan 4, 3061 Bertem, Belgium.
Center for Sustainable Catalysis and Engineering, KU Leuven, Celestijnenlaan 200F, 3001 Heverlee, Belgium.

Notes

*Corresponding author. Email: [email protected] (B.F.S); [email protected] or [email protected] (Y.L.)

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