Preparation of Biobased Nonisocyanate Polyurethane/Epoxy Thermoset Materials Using Depolymerized Native Lignin.

Polyurethane polymers are found in a wide range of material applications. However, the toxic nature of isocyanates used in their formulation is a major concern; hence, more environmentally friendly alternatives are of high interest in the search for new sustainable polymer materials. In this work, we present the preparation of isocyanate-free polyurethane/epoxy hybrid thermosets with a high biobased content (85-90 wt %). The isocyanate-free polyurethanes were based on polyhydroxyurethanes (PHUs) prepared from depolymerized native lignin, which we refer to as lignin hydrogenolysis oil (LHO). The LHO was functionalized with epichlorohydrin to yield the epoxidized structure (LHO-GE), which was in turn reacted with CO2 to form the cyclocarbonated species (LHO-CC). Blends of the LHO-CC and glycerol diglycidyl ether (GDGE) were cured to produce hybrid PHU/epoxy (LHO-CC/GDGE) thermosets. Thermosetting materials with flexural moduli of 4.5 GPa and flexural strengths of 160 MPa were produced by optimizing the mass ratio of the two main components and the triamine hardener. These novel biobased hybrid materials outperformed the corresponding epoxy-only thermosets and comparable hybrid PHU/epoxy materials produced from petrochemicals.

Toward Bio-Based Epoxy Thermoset Polymers from Depolymerized Native Lignins Produced at the Pilot Scale.

Producing the next generation of thermoset polymers from renewable sources is an important sustainability goal. Hydrogenolysis of pinewood lignin was scaled up for the first time from lab scale to a 50 L pilot-scale reactor, producing a range of depolymerized lignin oils under different conditions. These lignin hydrogenolysis oils were glycidylated, blended with bisphenol A diglycidyl ether, and cured to give epoxy thermoset polymers. The thermal and mechanical properties of the epoxy polymers were assessed by differential scanning calorimetry, thermogravimetric analysis, flexural testing, and dynamic mechanical thermal analysis. Replacing up to 67% of the bisphenol A epoxy with the lignin oil epoxies resulted in cured epoxy polymers with improvements of up to 25% in flexural stiffness and strength. Considerable scope exists in simplifying and scaling up the hydrogenolysis process to produce depolymerized lignins that can substitute established petrochemicals in the quest for renewable high-performance thermoset polymers.

Biobased Epoxy Thermoset Polymers from Depolymerized Native Hardwood Lignin.

Biobased epoxy thermoset polymers were prepared from lignin hydrogenolysis oils produced from native hardwood lignin. Native lignin in Eucalyptus nitens and Eucalyptus saligna wood was reacted in situ under Pd-catalyzed mild hydrogenolysis conditions to give depolymerized lignin oils in yields up to 98 wt %. Reacting these lignin oils with epichlorohydrin produced biobased epoxy resins. Blending these resins with nonrenewable bisphenol A diglycidyl ether (BADGE) in different proportions, and curing with diethylenetriamine, produced a series of epoxy thermoset polymers with varying biobased content. Up to 67% of the BADGE could be replaced with hardwood lignin-derived epoxy resins while achieving superior or equivalent mechanical properties to the BADGE control polymer. Comparing the performance of lignin-based epoxy polymers from eucalyptus and pine wood provided insights into the advantages and disadvantages of using hardwood versus softwood native lignins in the quest for high performance biobased thermoset polymers.

Thermosetting Polymers from Lignin Model Compounds and Depolymerized Lignins.

Lignin is the most abundant source of renewable ready-made aromatic chemicals for making sustainable polymers. However, the structural heterogeneity, high polydispersity, limited chemical functionality and solubility of most technical lignins makes them challenging to use in developing new bio-based polymers. Recently, greater focus has been given to developing polymers from low molecular weight lignin-based building blocks such as lignin monomers or lignin-derived bio-oils that can be obtained by chemical depolymerization of lignins. Lignin monomers or bio-oils have additional hydroxyl functionality, are more homogeneous and can lead to higher levels of lignin substitution for non-renewables in polymer formulations. These potential polymer feed stocks, however, present their own challenges in terms of production (i.e., yields and separation), pre-polymerization reactions and processability. This review provides an overview of recent developments on polymeric materials produced from lignin-based model compounds and depolymerized lignin bio-oils with a focus on thermosetting materials. Particular emphasis is given to epoxy resins, polyurethanes and phenol-formaldehyde resins as this is where the research shows the greatest overlap between the model compounds and bio-oils. The common goal of the research is the development of new economically viable strategies for using lignin as a replacement for petroleum-derived chemicals in aromatic-based polymers.

Biobased Epoxy Resins from Deconstructed Native Softwood Lignin.

The synthesis of novel epoxy resins from lignin hydrogenolysis products is reported. Native lignin in pine wood was depolymerized by mild hydrogenolysis to give an oil product that was reacted with epichlorohydrin to give epoxy prepolymers. These were blended with bisphenol A diglycidyl ether or glycerol diglycidyl ether and cured with diethylenetriamine or isophorone diamine. The key novelty of this work lies in using the inherent properties of the native lignin in preparing new biobased epoxy resins. The lignin-derived epoxy prepolymers could be used to replace 25-75% of the bisphenol A diglycidyl ether equivalent, leading to increases of up to 52% in the flexural modulus and up to 38% in the flexural strength. Improvements in the flexural strength were attributed to the oligomeric products present in the lignin hydrogenolysis oil. These results indicate lignin hydrogenolysis products have potential as sustainable biobased polyols in the synthesis of high performance epoxy resins.

A mild thermomechanical process for the enzymatic conversion of radiata pine into fermentable sugars and lignin.

BACKGROUND: Conversion of softwoods into sustainable fuels and chemicals is important for parts of the world where softwoods are the dominant forest species. While they have high theoretical sugar yields, softwoods are amongst the most recalcitrant feedstocks for enzymatic processes, typically requiring both more severe pretreatment conditions and higher enzyme doses than needed for other lignocellulosic feedstocks. Although a number of processes have been proposed for converting softwoods into sugars suitable for fuel and chemical production, there is still a need for a high-yielding, industrially scalable and cost-effective conversion route. RESULTS: We summarise work leading to the development of an efficient process for the enzymatic conversion of radiata pine (Pinus radiata) into wood sugars. The process involves initial pressurised steaming of wood chips under relatively mild conditions (173 °C for 3-72 min) without added acid catalyst. The steamed chips then pass through a compression screw to squeeze out a pressate rich in solubilised hemicelluloses. The pressed chips are disc-refined and wet ball-milled to produce a substrate which is rapidly saccharified using commercially available enzyme cocktails. Adding 0.1% polyethylene glycol during saccharification was found to be particularly effective with these substrates, reducing enzyme usage to acceptable levels, e.g. 5 FPU/g OD substrate. The pressate is separately hydrolysed using acid, providing additional hemicellulose-derived sugars, for an overall sugar yield of 535 kg/ODT chips (76% of theoretical). The total pretreatment energy input is comparable to other processes, with the additional energy for attrition being balanced by a lower thermal energy requirement. This pretreatment strategy produces substrates with low levels of fermentation inhibitors, so the glucose-rich mainline and pressate syrups can be fermented to ethanol without detoxification. The lignin from the process remains comparatively unmodified, as evident from the level of retained ß-ether interunit linkages, providing an opportunity for conversion into saleable co-products. CONCLUSIONS: This process is an efficient route for the enzymatic conversion of radiata pine, and potentially other softwoods, into a sugar syrup suitable for conversion into fuels and chemicals. Furthermore, the process uses standard equipment that is largely proven at commercial scale, de-risking process scale-up.

Structural features affecting the enzymatic digestibility of pine wood pretreated with ionic liquids.

Pretreating lignocellulosic biomass with certain ionic liquids results in structural and chemical changes that make the biomass more digestible by enzymes. In this study, pine wood was pretreated with 1-ethyl-3-methylimidazolium chloride/acetate ([C2 mim]Cl and [C2 mim][OAc]) at different temperatures to investigate the relative importance of substrate features, such as accessible surface area, cellulose crystallinity, and lignin content, on enzymatic digestibility. The ionic liquid pretreatments resulted in glucan conversions ranging from 23% to 84% on saccharification of the substrates, with [C2 mim][OAc] being more effective than [C2 mim]Cl. The pretreatments resulted in no delignification of the wood, some loss of cellulose crystallinity under certain conditions, and varying levels of increased surface area. Enzymatic digestibility closely correlated with accessible surface area and porosity measurements obtained using Simons' staining and thermoporosimetry techniques. Increased accessible surface area was identified as the principal structural feature responsible for the improved enzymatic digestibility.

Mild hydrogenolysis of in-situ and isolated Pinus radiata lignins.

The Pd/C-catalysed hydrogenolysis of in-situ and isolated lignins from Pinus radiata wood was investigated to gain a more complete understanding of the factors affecting yield and composition of the hydrogenolysis products. Such hydrogenolysis products could potentially be refined into aromatic feedstock chemicals providing sustainable alternatives to petroleum-derived phenols. Lignins were converted into solvent-soluble oils composed of monomeric, dimeric and oligomeric products in high yields, up to 89% of the original lignin. The main monomer products were dihydroconiferyl alcohol and 4-n-propyl guaiacol. Dimeric and oligomeric compounds constituted 75% of the hydrogenolysis oils and were mainly composed of dihydroconiferyl alcohol and 4-n-propyl guaiacol units linked by ß-5, 5-5, 4-O-5 and ß-1 linkages. Hydrogenolysis of steam exploded wood gave lower yields of lignin hydrogenolysis products compared to unmodified wood due to fewer reactive aryl-ether linkages in the lignin.