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Rosales‑Calderon and Arantes Biotechnol Biofuels (2019) 12:240 Biotechnology for Biofuels https://doi.org/10.1186/s13068‑019‑1529‑1 REVIEW Open Access A review on commercial‑scale high‑value products that can be produced alongside cellulosic ethanol Oscar Rosales‑Calderon and Valdeir Arantes* Abstract The demand for fossil derivate fuels and chemicals has increased, augmenting concerns on climate change, global economic stability, and sustainability on fossil resources. Therefore, the production of fuels and chemicals from alter‑ native and renewable resources has attracted considerable and growing attention. Ethanol is a promising biofuel that can reduce the consumption of gasoline in the transportation sector and related greenhouse gas (GHG) emissions. Lignocellulosic biomass is a promising feedstock to produce bioethanol (cellulosic ethanol) because of its abundance and low cost. Since the conversion of lignocellulose to ethanol is complex and expensive, the cellulosic ethanol price cannot compete with those of the fossil derivate fuels. A promising strategy to lower the production cost of cellulosic ethanol is developing a biorefnery which produces ethanol and other high‑value chemicals from lignocellulose. The selection of such chemicals is difcult because there are hundreds of products that can be produced from lignocel‑ lulose. Multiple reviews and reports have described a small group of lignocellulose derivate compounds that have the potential to be commercialized. Some of these products are in the bench scale and require extensive research and time before they can be industrially produced. This review examines chemicals and materials with a Technology Readiness Level (TRL) of at least 8, which have reached a commercial scale and could be shortly or immediately inte‑ grated into a cellulosic ethanol process. Keywords: Cellulosic ethanol, Bioproducts, Commercial production, Biorefnery, Biofuel, Lignocellulose, Bio‑based chemicals Background on alternative energy sources to decay [1, 2]. In addition Over six decades ago, petroleum was the indisputable to subsequent oil crises, the increasing evidence of the source of energy that kept the world working and grow- links between climate change and greenhouse gas (GHG) ing. Nonetheless, at the beginning of the 1970s, the emissions has renewed the interest in alternative energy members of the Organization of Arab Petroleum Export- sources [3]. Tus, the emphasis today is to develop ing Countries (OPEC) proclaimed an oil embargo aimed renewable energy sources that reduce our oil dependency to control the production and, therefore, the price of and GHG emissions. petroleum [1]. In response, oil prices increased dramati- Te transportation sector, which consumed 31.8% of cally causing an “energy crisis” that awaked the interest the produced oil in 2017 [4], was responsible for 41.5% of in alternative fuels. Due to a serious surplus of crude the global CO2 emissions in 2016 [5]. Tus, a promising oil caused by price controls and gasoline rationing, way of reducing our environmental impact and depend- energy prices declined, causing the interest and support ency on petroleum is through the substitution of gasoline and diesel with environmentally friendly fuels [6]. Etha- *Correspondence: [email protected] nol produced from biomass, named bioethanol, is by far Department of Biotechnology, Lorena School of Engineering, University the most widely used biofuel in the transportation sec- of Sao Paulo, Estrada Municipal do Campinho, Lorena, SP CEP 12602‑810, tor worldwide. As a result, the number of countries with Brazil © The Author(s) 2019. This article is distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creat iveco mmons .org/licen ses/by/4.0/), which permits unrestricted use, distribution, and reproduction in any medium, provided you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license, and indicate if changes were made. The Creative Commons Public Domain Dedication waiver (http://creat iveco mmons .org/ publi cdoma in/zero/1.0/) applies to the data made available in this article, unless otherwise stated. Rosales‑Calderon and Arantes Biotechnol Biofuels (2019) 12:240 Page 2 of 58 renewable energy policies in the transportation sector fermented theoretically into 172.0 gallons of bioethanol, increased from 56 in 2012 to 66 by 2015 [7]. Similarly, the and that one ton of arabinan or xylan yields 1.14 tons of annual world production of bioethanol increased from fve-carbon sugars that could be fermented theoretically 13.0 billion gallons in 2007 to about 25.6 billion gallons in into 176.0 gallons of bioethanol, the theoretical global 2015 [7]. Despite these eforts, Brazil and the USA are the production of ethanol from lignocellulosic materials only countries that produce large quantities of bioethanol, (rice straw, corn stover, wheat straw, pulp, etc.) can reach 7.1 and 14.7 billion gallons of ethanol per year, respec- -442 billion liters per year [12]. Due to its complex com- tively [8]. Bioethanol is currently produced from sugar- position (30–60% cellulose, 20–40% hemicellulose and or starch-containing feedstocks. Sugar/starch derivate 15–25% lignin), conversion of cellulosic materials to eth- bioethanol is defned as frst-generation (1G) bioethanol anol is more challenging than for sugar/starch-feedstocks [9]. A general 1G bioethanol process is shown in Fig. 1. [13]. Terefore, even when the cost of lignocellulose is While the 1G bioethanol process is relatively simple, its lower than that of the sugar/starch crops, the produc- main disadvantage is the high price of the sugar/starch tion cost of cellulosic ethanol is too high to be competi- feedstocks, which accounts for 40 to 70% of the total etha- tive [14, 15]. Consequently, eforts to develop efcient nol cost [10]. To achieve competitive costs and increase and cost-efective technologies that reduce bioethanol’s production, the supply of cheap raw materials is required. production cost have been made in the last decades. Cellulosic biomass, or lignocellulose, is considered the After years of research and development, various cellu- most promising feedstock for producing bioethanol, due losic ethanol pilot and demonstration plants have started to its availability, low cost, and the fact that it does not operations [16]. compete with food production as sugar/starch feedstocks In 2012, Beta Renewables started up operations at do. In agreement with the 1G bioethanol defnition, the frst industrial cellulosic ethanol plant in the world. bioethanol produced from lignocellulose is named sec- By 2015, the 40 MMgy plant, located in Crescentino, ond-generation (2G) bioethanol or cellulosic ethanol [11]. Italy, was reported to operate on a daily basis, shipping Considering that one ton of glucan, galactan, or man- cellulosic ethanol to Europe [17]. After this success, nan yields 1.11 tons of six-carbon sugars, which could be Beta Renewables was planning to build more cellulosic • 1,2-butanediol • Lacde • 1,3-propanediol • Lysine • 1,4-butanediol • Polylacc acid • 2,3-butanediol • Polytrimethylene • Acetone-butanol-ethanol terephthalate • Furfural • Propylene Glycol • Furfuryl alcohol • Sorbitol • Glutamic acid • Squalene • Isobutanol • Succinic acid • Itaconic acid • Terpenes • Lacc acid • Xylitol Sugar feedstock Extracon (sugarcane, sugar beets) C6 Glucose Fermentaon • Acetaldehyde • Acec acid • Acec anhydride Starch feedstock • Ethyl acetate Extracon Hydrolysis (corn, wheat) • Ethyl Lactate • Ethyl tert-butyl ether Separaon Ethanol • Ethylene • Ethylene glycol • Ethylene-propylene-diene monomer Hexose and Lignocellulose C5 & C6 • Polyethylene Pretreatment Hydrolysis Pentose ( sugarcane bagasse) Fermentaon • Polyethylene glycol sugars Burner/boiler Solid residues Electricity Turbogenerator Producon of bioethanol Commercialized bioproducts • Microfibrillated Cellulose Fig. 1 Process diagram to produce bioethanol from sugar and starch feedstocks, and lignocellulose including biochemicals and biomaterials with potential to be produced alongside bioethanol (red lines) Rosales‑Calderon and Arantes Biotechnol Biofuels (2019) 12:240 Page 3 of 58 ethanol plants in India, USA, Brazil, and China. How- boost the investment on cellulosic ethanol, technolo- ever, Beta Renewables was sold in 2018 to pay of debts gies that reduce the production costs must be developed from its bankrupt parent company, Mossi Ghisolf and industrially demonstrated. Te biorefnery concept, Group [18]. DuPont started producing cellulosic ethanol in which biomass is converted to biochemicals and bio- at its 30-MMgy plant in Nevada, USA. With the merge materials, such as benzene, microfbrillated cellulose, of Dow Chemical and DuPont, questions about DuPont’s toluene, xylene, styrene, or cumene [30], is a promising cellulosic ethanol investment raised. While DuPont con- strategy to reduce production costs. Even so, the large tinued building commercial relationships with feedstock number of possible combinations of feedstock, pre- growers and producing cellulosic ethanol [19], in 2017, treatment options, conversion technologies, and down- DowDuPont announced that it intends to sell its cellu- stream processes, makes difcult the evaluation of these losic biofuels business and its frst commercial cellulosic technologies. Various authors have reviewed promis- ethanol plant in Nevada, USA. Te company found a ing chemicals that can be produced from lignocellulose. buyer for
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