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Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - LigniOx (Lignin oxidation technology for versatile lignin dispersants)

Teaser

Summary

Lignin is the most important by-product from lignocellulosic biorefineries, and valuable renewable resource for bio-based industries. Annually over 60 million tons of lignin is extracted from wood as a by-product of the pulping industry. Substantial amount of lignin is also expected to originate from the 2nd generation bioethanol production. These lignocellulosic biorefineries are currently actively looking for opportunities to valorise the lignin by-products in high-value products instead of direct energy production. Furthermore, lignin offers a renewable low-cost raw material for chemical industry, improving resource sufficiency and promoting replacement of fossil based chemicals and materials. However, to fully exploit these raw material streams, there is an urgent need to commercialise economically and sustainably viable lignin upgrading process technologies that are adaptable to lignin side-streams originating from different processes and raw materials.

The aim of the LigniOx Innovation Action is to demonstrate the techno-economic viability of alkali-O2 oxidation technology (LigniOx) for the conversion of variable lignin-rich side-streams into versatile dispersants, and especially high-performance concrete and mortar plasticizers. Both the oxidation technology and the end-product performance will be demonstrated at operation conditions at biorefineries and by field tests, enabling industrial process installations and entry of novel lignin products into the markets after the project. The valorisation of lignin side-streams will significantly improve the cost-competitiveness and resource efficiency of lignocellulosic biorefineries, and will create low-cost, sustainable raw materials for the chemical industry. The versatile LigniOx technology can be integrated into lignocellulosic biorefineries, or be operated as a stand-alone unit by chemical industry, as demonstrated in the project.

Work performed

During the LigniOx project, optimal oxidation and post treatment concepts were developed for lignin by-products (softwood kraft lignin, softwood hydrolysis lignin, and wheat straw organosolv lignin) originating from variable industrial processes and feedstock. In all cases, the optimization was done in order to obtain high-performing lignin derived concrete plasticizer, while simultaneously also considering the feasible and safe operation of the oxidation process. For kraft lignin, a techno-economically feasible process concept was developed that can be integrated into the kraft pulp mill. Optimal oxidation conditions were also defined for the hydrolysis and organosolv lignins. Based on oxidation protocols developed, a mobile pilot unit for the scale-up and process demonstrations was designed, and construction can be started. Scale-up of the post-treatments was also started.

The performance of all the produced LigniOx lignins was tested in mortar with different cement qualities compared to several commercial reference admixtures, and the development of product formulations was started. Especially oxidised kraft and organosolv lignins showed good plasticization performance. Those provided clearly better plasticization performance compared to the tested lignosulphonates, and could also compete with several polycarboxylate and sulphonated naphtaleine condensate based commercial admixtures. Oxidised hydrolysis lignin samples also showed rather good performance. Their plasticization performance was better than with lignosulphonates, and in best cases comparable with the tested sulphonated naphthalene based commercial product.

Process simulations were performed to evaluate the integration effects at kraft pulp mill together with the techno-economic and life cycle assessment (LCA). Preliminary cost calculations and mass balances on possible oxidation concepts for the hydrolysis lignin were also performed. Process simulation work supported that the integration into kraft pulp mill can be performed without interference of the main process. Also from the economical point of view, the developed process concepts seem promising. The preliminary environmental accessment of kraft lignin based LigniOx product showed at least 50% lower impacts in most of the categories evaluated compared to the commercial products.

Review of relevant regulations, and socio-economic assessment has been started together with the preliminary market study and business plans. The LigniOx technology and the performance of LigniOx products as concrete plasticizers has mainly been disseminated through project web page and press releases, as well as in conferences and other events.

Final results

All the work carried out in the LigniOx project leads the way towards commercially viable process that can be integrated into the biorefineries, or to be operated in stand-alone unit. Techno-economically promising process concepts were developed for lignins originating from variable processes (kraft, organosolv, bioethanol production) and feedstocks (softwood, wheat straw). For kraft lignin, the process is nearly ready for scale-up using the mobile pilot unit designed in the project. The LigniOx lignins produced in well optimized oxidation conditions show plasticizing performance that can compete even with some commercial fossil based concrete admixtures. Substantial reduction of environmental impacts compared to the current synthetic products were also shown in preliminary LCA assessment. As a result of LigniOx project, lignin upgrading technology for production of lignin based dispersants will be ready for the industrial installation right after the project, and a new lignin based high-performance concrete plasticizer will enter the markets within 1-3 years after the project, creating new business opportunities for lignocellulosic biorefineries and chemical industry. In addition to the first target product (concrete plasticizer), the LigniOx technology will enable several additional application possibilities in products where anionic surface active agents currently are used, contributing to the establishment of a more sustainable and low carbon industry