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Development of Selective Fractionation Methods for the Integrated Upgrade of Corn Cobs in the Biorefinery Framework

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Development of Selective Fractionation Methods for the Integrated Upgrade of Corn Cobs in the Biorefinery Framework Development of selective fractionation methods for the integrated upgrade of corn cobs in the biorefinery framework João Nuno Dourado Fialho Thesis to obtain the Master of Science Degree in Biological Engineering Supervisors: Prof. Frederico Castelo Alves Ferreira Dr. Florbela de Oliveira Carvalheiro Esteves Amaro Examination Committee Chairperson: Professor Jorge Humberto Gomes Leitão Supervisor: Doctor Florbela de Oliveira Carvalheiro Esteves Amaro Member of the committee: Professor Maria Manuela Regalo da Fonseca June 2015 ii Acknowledgments I would like to express my gratitude to all those who make this work possible. To Dr. Francisco Gírio, Director at Bioenergy Unit, place where the work was developed, for the opportunity granted. To Dr. Florbela Carvalheiro, for all the help and friendship since the day one, for all the guidance and the critics but mainly for all the knowledge shared. To Prof. Frederico Ferreira, for all the availability and for accepting me as thesis student. To Dr. Luis Duarte, for all the help, the enthusiasm and for all the proposed challenges with high goals. To Céu Penedo, for all the help with the experimental work. To Patricia and Ana, for teaching me a lot of what I know, being always ready to help with experiments, doubts, results, “whys” and “whats” during the last months, and, of course, for all the friendship. To Pedro Branco and Pedro Martins, for all the help and knowledge shared. To all my K2 colleagues, for the help and gaiety during the development of this work, especially to Marlene, Júnia and Cláudia. To Vasco and Catarina, the companions in the IST long trip since the beginning, for all the help, the friendship and the support, always. To my parents and my sister, thank you a lot for believing in me! To Joana, for all the support, love and patience, in all moments. To my friends. Thank you for the friendship along this way! iii iv Resumo O carolo de milho é um resíduo agrícola abundante a nível mundial, mas cuja valorização é ainda pouco estudada. O fracionamento seletivo dos seus componentes estruturais (hemicelulose, celulose e lenhina) poderá, todavia, permitir a obtenção de produtos de valor acrescentado bem como responder ao problema dos resíduos. Neste trabalho, desenvolveu-se uma estratégia de fracionamento integrada, tendo por base o estudo da deslenhificação deste material. Assim, foi otimizado um processo organosolv (etanol:água, 50:50, m/m). Como método comparativo foi também estudada a deslenhificação alcalina (NaOH, 1-2%). O processo organosolv permitiu uma deslenhificação significativa do material (rendimento de 79%), contendo a corrente líquida uma concentração apreciável (14,6 g/L) de xilo-oligossacáridos (XOS). A fração sólida resultante, rica em celulose, apresentou uma digestibilidade enzimática de 90%. O processo alcalino permitiu um rendimento de deslenhificação de 94% obtendo-se uma fração sólida com uma digestibilidade enzimática da celulose de 83%. Os processos anteriores foram ainda utilizados numa estratégia combinada de processamento hidrotérmico (auto-hidrólise) seguido de deslenhificação. O primeiro permitiu a hidrólise seletiva da hemicelulose, produzindo hidrolisados ricos em XOS (26,8 g/L, rendimento de 67,3 g/100 g xilano inicial). Os processos de deslenhificação seguintes, organosolv ou alcalino, conduziram a rendimentos de deslenhificação globais de 76 e 93%, respetivamente. Os resíduos sólidos enriquecidos em glucano (acima de 75% para ambos os processos combinados) apresentaram também rendimentos de sacarificação enzimática elevados, 89% e 90%, respetivamente. As estratégias de fracionamento propostas e os resultados obtidos são muito promissores e possibilitam a integração deste material num enquadramento de biorrefinaria. Palavras-chave: organosolv; pré-tratamento hidrotérmico; lenhina; hemiceluloses; pré- tratamento alcalino; resíduos agrícolas. v vi Abstract Corn cob is an abundant agricultural residue worldwide, which valorisation still needs to be studied. The selective fractionation of its structural components (hemicellulose, cellulose and lignin) may, however, allow obtaining value-added products and also solve the waste problem. In this work, an integrated fractionation strategy mainly based on the study of corn cob delignification was developed. Thus, an organosolv process (using ethanol:water, 50:50, w/w) was optimized. As a comparative method, alkaline delignification (using NaOH, 1-2%) was also studied. The organosolv process allowed a significant delignification of the material (79% delignification yield) and, at the same time, to obtain a liquid phase containing an appreciable concentration (14.6 g/L) of xylo- oligosaccharides (XOS). The resulting solid fraction, rich in cellulose, showed an enzymatic digestibility of 90%. The alkaline process allowed a delignification yield of 94%, producing a solid fraction with a cellulose enzymatic digestibility of 83%. The above processes were also used in a combined strategy consisting in a hydrothermal processing (autohydrolysis) followed by delignification. The first, allowed the selective hydrolysis of hemicellulose to produce XOS-rich hydrolysates (26.8 g/L, 67.3 g/100 g initial xylan). The further delignification processes, alkaline or organosolv, led to global delignification yields of 76% and 93%, respectively. The solid residue, enriched in glucan (above 75% for both combined processes), also presented high enzymatic saccharification yields, 89% and 90%, respectively. The fractionation strategies proposed as well as the results obtained are very promising enabling the integrated upgrading of this material into a biorefinery framework. Keywords: organosolv; hydrothermal treatment; lignin; hemicellulose; alkaline treatment; agricultural residues. vii viii Contents Acknowledgments ...................................................................................................... iii Resumo ....................................................................................................................... v Abstract ..................................................................................................................... vii List of tables ............................................................................................................. xiii List of figures ............................................................................................................. xv Notation .................................................................................................................... xix 1 Introduction ........................................................................................................... 1 1.1 Context and motivation ................................................................................................ 1 1.2 Objectives .................................................................................................................... 2 1.3 Structure ...................................................................................................................... 3 2 State of the art ...................................................................................................... 4 2.1 The biorefinery ............................................................................................................. 4 2.1.1 The biorefinery concept ........................................................................................... 4 2.1.2 Classification of biorefineries ................................................................................... 5 2.2 The lignocellulosic materials ........................................................................................ 6 2.2.1 Diversity ................................................................................................................... 6 2.2.2 Composition of lignocellulosic materials ................................................................. 6 2.2.2.1 Cellulose ........................................................................................................... 8 2.2.2.2 Hemicelluloses .................................................................................................. 9 2.2.2.3 Lignin ................................................................................................................ 9 2.2.2.4 Other components .......................................................................................... 11 2.3 Agricultural and forestry residues .............................................................................. 11 2.3.1 Most relevant crops and residues ......................................................................... 12 2.3.2 Corn cultivation ...................................................................................................... 14 2.3.2.1 Availability and geographic dispersion ........................................................... 15 2.3.2.2 Corn residues ................................................................................................. 17 2.3.2.3 Use of corn residues ....................................................................................... 18 2.4 Pretreatments for fractionation of lignocellulosic materials ....................................... 20 2.4.1 Acid hydrolysis....................................................................................................... 20 ix 2.4.1.1 Concentrated acid ........................................................................................... 21 2.4.1.2 Dilute acid ......................................................................................................
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