1. Introduction
The concerns related to the global warming, attributed in large part to the increasing concentration of CO
2 in the atmosphere as a result of the fossil fuels use, push to a de-fossilization of our society. Although the development of full electric mobility technologies or electrolytic hydrogen-based technologies will likely have a main role in reducing emissions of fossil-derived CO
2, it is evident that the use of biomass for producing energy, fuels, and chemicals will be more largely applied in the near future [
1].
Among organic renewable natural resources, lignin is the most abundant class of compounds having an aromatic character [
2]. Lignin represents around 18-40 % of wood biomass, where it is present together with cellulose and hemicellulose as the largely predominant materials, to which it forms molecular complexes [
3]. It is present even in larger concentration in waste biomasses such as, e.g., olive husk and walnut shell [
4] and could also be recovered from algae [
5]. Currently, technical lignins are byproducts of some industrial processes, among which the manufacture of ligneo-cellulosic bioethanol and of paper. Technical lignins are produced at a rate of around 100 million tons per year, primarily coming from the pulp and paper industry [
6]. Most of them are burned to provide heat and electricity. The rest is sold as a byproduct for fuel or as a mixture or binder in animal feed, or used to produce adhesives, as an additive in cement, fertilizer, paper coatings, etc. [
7],[
8],[
9],[
10].
Among technologies allowing useful application of lignins, pyrolysis represents one of the most promising ways to exploit at least part of its potential. In particular, slow pyrolysis may allow the production of significant amounts of biochar, a carbon-rich material that can represent an important solid fuel for heating and energy production, as well as a reductant for metallurgy (i.e. iron and steelmaking, but maybe also silicon manufacturing), a filler for rubber and a raw material for producing adsorbents and catalysts or catalyst supports. Together with biochar, significant amounts of bio-oils can be produced. Such liquids, when produced by slow pyrolysis at moderate temperatures, are rich in phenol-type compounds some of which are commercial chemical products today, being manufactured mostly by petrochemical routes. Gases are also produced, mainly constituted by carbon oxides, light hydrocarbons, and hydrogen, whose combustion may provide the heat needed for pyrolysis. In the present review, we will summarize data to underline the potential of technologies based on slow pyrolysis of lignins.
4. Product Separation from Slow Pyrolysis Bio-Oils
As mentioned above, slow pyrolysis of lignin can be realized at moderate temperatures and relatively long residence times, to coproduce significant amounts of carbon-rich biochar to be used as a solid fuel or reducing agent in metallurgy, and, together, significant amounts of an organic oil rich in valuable compounds, such as guaiacols and other alkyl-alkoxy phenols (see below). This is evident in the data reported in
Table 1. The process could be nearly autothermal by using the coproduced gas to fuel the pyrolysis reaction.
The exact composition of lignin pyrolysis oils is strongly dependent on the original biomass, the lignin separation process, reaction conditions, aging time, etc. The separation of individual components from extracted lignin pyrolysis bio-oils is really not an easy matter, and few data are reported in the literature about it [
56],[
57]. Taking into account that several organic monomeric units obtained by pyrolysis are prone to rapid repolymerization [
58] it is evident that rapid separation is convenient. On the other hand, according to the different compositions of the produced bio-oils, different separation strategies are also needed.
The liquid product is sometimes monophasic, containing inorganic matter together with water and organics, other times biphasic with a denser organic fraction and a water-rich supernatant [48,50,[
59]. The water-rich phase may contain light oxygenated compounds, at least partially derived from residual cellulose, together with methanol derived from lignin cracking. However, phenols and guaiacols are also a partially soluble in water and may be present both in the aqueous and in the organic phase.
To extract all molecules which are highly soluble in water (e.g. acetic acid, methanol) from bio-oil, a previous water extraction step can be used [
60]. To separate partially water-soluble oxygenated compounds from water, such as guaiacols, eugenols, syringols, etc., non-polar or slightly polar organic solvents can be used [
61] such as methyl isobutyl ketone, methyl tert-butyl ether, toluene, benzene, hexane, cyclohexane, isopropanol, dichloroethane, chloroform, isopropyl acetate [
62], and methylene dichloride. In particular, CH
2Cl
2 is an efficient solvent for extracting bio-oil and can be quite easily removed later by distillation (T
boil 39.6 °C) [
63]. The use of ionic liquids [
64] and deep eutectic solvents [
65] has also been considered. Thus, extraction with the above solvents allows to obtain an almostdried organic fraction rich in oxygenated monomers.
On the other hand, the direct distillation of the organic phase can also be considered, and has been investigated, e.g. in the case of walnut shell pyrolysis bio-oil [
66]. It was found that phenol and guaiacol compounds can produce azeotropic mixtures with increased boiling points. In contrast, phenols and alkylphenols can be separated by fractional distillation with the exception of meta- and para-cresols, whose boiling point is nearly identical (around 202 °C), and can be partially separated by crystallization [
67],[
68]. 2,6-xylenol also boils at a very close temperature (201 °C). In any case, the concentration of phenol and its congeners can be greatly increased by distillation of bio-oils at 260–300 °C, while that of guaiacol and its congeners is increased in the 300–320 °C temperature distillation range [
66]. In a study concerning rice husk bio-oil distillation, guaiacols can be distilled in the range 250-300 °C [
69]. Similarly, from a loblolly pine biocrude, guaiacols and eugenols were enriched up to > 80 % by a four step distillation at 220-280 °C [
70].
It can be remarked that, depending on the pyrolysis conditions, hydrocarbon products amount can vary with respect to oxygenated compounds. If hydrocarbons are present in significant amounts, phenols can be extracted from them using basic water solutions (caustic soda) producing sodium phenolates, and, after acidification (e.g. with CO
2), re-extracted with polar solvents, such as ethers, similar the extraction of phenols from carbolic oil obtained from coal tar distillation [
71].
In a recent study, the solubility of different substituted phenols on soda and potash solutions were investigated, showing important differences in relation to acidity and steric hindrance differences [
72]. The different solubilities allow the separation of relatively similar compounds such as propyl guaiacol and propyl syringol, which can be further purified by crystallization as alkali salts [
72].
After isolation and separation of fractions rich in the desired compounds, the separation of the individual molecules is currently realized by column chromatography [
70]. For example, high selectivity and performance have been obtained in the separation of lignin “monomers” by flash chromatography using silica as the stationary phase and diethyl-ether, dichloromethane, toluene, ethyl-acetate and 4-methyl furan as mobile phases [
73]. Several more complex liquid chromatography methods have been found to be effective for the separation of individual components from bio-oils [70,[
74].
Table 2 summarizes some of the separation methods used to obtain compounds of interest reported in the literature.
6. Application of Lignin Pyrolysis Oil Fraction as a Whole
The bio-oil obtained from lignin pyrolysis can also find various applications depending on the subsequent treatments, as described below.
Bio-oil as a fuel. Bio-oils from lignin and biomass pyrolysis are usually considered to be too oxygen-rich and instable to be used as liquid fuels as such. In fact, their heating value is usually quite low in agreement with their high oxygen content and the two values are correlated inversely [
115]. This is in particular true for slow pyrolysis oils produced at moderate or low temperatures, which are actually rich in oxygenated compounds and poor in hydrocarbons. However, taking into account that they can be considered as byproducts of paper (or bioethanol) and biochar production, they can be used as low-value but cheap and renewable fractions to be mixed with mineral gasoils or heavy oils, e.g. in bunker oils for shipping.
Catalytic hydrodeoxygenation of lignin pyrolysis oils to hydrocarbon rich-fractions. Upgrading of lignin pyrolysis oils may be realized by catalytic cracking and catalytic hydrodeoxygenaton [
116]. Catalytic cracking is mostly realized with medium or large pore acid zeolite catalysts such as H-ZSM-5, H-Beta and H-Faujasite. These microporous materials give rise to shape selective catalysis, catalyzing the cracking of aliphatic chains but also of the methoxy-groups finally producing mainly toluene, xylenes and also naphthalene. Using catalytic hydrodeoxygenation [
117],[
118] performed at 250-400 °C under hydrogen 1-20 Mpa in the presence of metal catalysts, usually Pt, Pd, Rh, Ru or Ni supported on oxide carriers such as alumina, silica, titania and zirconia, or on acid zeolites such as H-ZSM5, H-beta and HY. As an alternative, hydrotreating sulphide catalysts, such as Co-Mo sulphides, can also be used. Bio-oil upgrading catalysts also tend to deactivate by coking, thus regeneration steps are needed [
119]. On the other hand, coking is mainly related to the presence of heavy molecules in the bio-oil [
120]. Thus, prevous distillation or extraction steps to produce fractions pure from heavy molecules can be helpful to produce biofuel by hydrodeoxygenation. Hydrotreatments of lignin bio-oil fractions can also be focused on the production of particular classes of compounds such as e.g. cyclohexanols [
121] useful, e.g. for renewable nylon 6,6 production.
Steam reforming of lignin pyrolysis oils. Steam reforming processes to produce hydrogen can applied to several biomass-derived substances [
122]including biomass-pyrolysis oil [
123],[
124]. Renewable hydrogen-rich syngas can be obtained using Ni-based catalysts in particular if CO
2 is captured on basic oxides [
125].
Application as anti-knocking agent in gasoline blends. Individual compounds or full guiacols fractions could be applied as renewable anti-knocking additives in gasolines [
75].
7. Conclusions
The data summarized and discussed above show that technical lignin slow pyrolysis processes could represent useful technologies to convert waste and hardly treatable biomass to useful products. In fact, it seems likely that the production of cellulose-based plastic materials and paper itself will be increased in the near future to provide biodegradable materials to substitute for non-biodegradable petrochemical plastics. It is also likely that the production of bioethanol, both as a fuel and as a platform chemical for the production of a large number of industrial products will also increase considerably. These technologies may led to the coproduction of technical lignins in higher amounts. The lignin slow pyrolysis process can be a good choice to valorise such a byproduct producing very useful materials.
Figure 4.
Possible flowsheet of a slow lignin pyrolysis process. 1 – Pyrolysis reactor; 2- Burner; 3- Phase separation drum; 4 – Pyrolysis gas desulphurization by adsorption on activated carbons; 5 – Solvent extraction of organics from water fraction; 6 – solvent extraction of oxygenated organics from crude bio-oil; 7 – distillation; 8- column chromatography.
Figure 4.
Possible flowsheet of a slow lignin pyrolysis process. 1 – Pyrolysis reactor; 2- Burner; 3- Phase separation drum; 4 – Pyrolysis gas desulphurization by adsorption on activated carbons; 5 – Solvent extraction of organics from water fraction; 6 – solvent extraction of oxygenated organics from crude bio-oil; 7 – distillation; 8- column chromatography.
In fact, the production and use of plant-derived carbon materials (biochar) can represent an optimal way to replace coal-derived carbon materials, such as coke as a solid fuel as well as a reducing agent in metallurgy, thus obtaining de-fossilization of technologies with reduction of fossil-derived carbon oxides emissions, as well as to produce filler for rubbers and catalytic and adsorption materials. Additionally, the coproduction of complex organic molecules such as pharmaceuticals, which today are produced from oil-derived chemical intermediates, starting from vegetable matter, is also becoming more and more appealing.
Pyrolysis of technical lignin, coproducts of cellulose-based materials, may become a common technology to produce useful products. A tentative flowsheet for the process is reported in
Figure 4. At moderately high temperature, the solid product from lignin pyrolysis is a carbon-rich material (biochar) with high heating value, potentially useful as a solid fuel and as a reductant in metallurgy and steelmaking. Simultaneously, significant amounts of bio-oils rich in guaiacols and similar compounds are produced, that have a market in different fields such as pharmacology, polymer industry, food chemistry, etc.,. Technologies for recovery and purification of single molecules from bio-oils are under development. The endothermicity of the process can be provided by burning the evolved gases. It seems that a slow pyrolysis process can actually represent a useful process to convert lignin to several valuable products, to be integrated together with cellulose-based chemicals manufacturing processes (bioethanol, bioplastics) into biomass-based biorefinery processes.