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.

Suppression of CCR impacts metabolite profile and cell wall composition in Pinus radiata tracheary elements.

Suppression of the lignin-related gene cinnamoyl-CoA reductase (CCR) in the Pinus radiata tracheary element (TE) system impacted both the metabolite profile and the cell wall matrix in CCR-RNAi lines. UPLC-MS/MS-based metabolite profiling identified elevated levels of p-coumaroyl hexose, caffeic acid hexoside and ferulic acid hexoside in CCR-RNAi lines, indicating a redirection of metabolite flow within phenylpropanoid metabolism. Dilignols derived from coniferyl alcohol such as G(8-5)G, G(8-O-4)G and isodihydrodehydrodiconiferyl alcohol (IDDDC) were substantially depleted, providing evidence for CCR's involvement in coniferyl alcohol biosynthesis. Severe CCR suppression almost halved lignin content in TEs based on a depletion of both H-type and G-type lignin, providing evidence for CCR's involvement in the biosynthesis of both lignin types. 2D-NMR studies revealed minor changes in the H:G-ratio and consequently a largely unchanged interunit linkage distribution in the lignin polymer. However, unusual cell wall components including ferulate and unsaturated fatty acids were identified in TEs by thioacidolysis, pyrolysis-GC/MS and/or 2D-NMR in CCR-RNAi lines, providing new insights into the consequences of CCR suppression in pine. Interestingly, CCR suppression substantially promoted pyrolytic breakdown of cell wall polysaccharides, a phenotype most likely caused by the incorporation of acidic compounds into the cell wall matrix in CCR-RNAi lines.

A survey of the natural variation in biomechanical and cell wall properties in inflorescence stems reveals new insights into the utility of Arabidopsis as a wood model.

The natural trait variation in Arabidopsis thaliana (L.) Heynh. accessions is an important resource for understanding many biological processes but it is underexploited for wood-related properties. Twelve A. thaliana accessions from diverse geographical locations were examined for variation in secondary growth, biomechanical properties, cell wall glycan content, cellulose microfibril angle (MFA) and flowering time. The effect of daylength was also examined. Secondary growth in rosette and inflorescence stems was observed in all accessions. Organised cellulose microfibrils in inflorescence stems were found in plants grown under long and short days. A substantial range of phenotypic variation was found in biochemical and wood-related biophysical characteristics, particularly for tensile strength, tensile stiffness, MFA and some cell wall components. The four monosaccharides galactose, arabinose, rhamnose and fucose strongly correlated with each other as well as with tensile strength and MFA, consistent with mutations in arabinogalactan protein and fucosyl- and xyloglucan galactosyl-transferase genes that result in decreases in strength. Conversely, these variables showed negative correlations with lignin content. Our data support the notion that large-scale natural variation studies of wood-related biomechanical and biochemical properties of inflorescence stems will be useful for the identification of novel genes important for wood formation and quality, and therefore biomaterial and renewable biofuel production.

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.

CCoAOMT suppression modifies lignin composition in Pinus radiata.

A cDNA clone encoding the lignin-related enzyme caffeoyl CoA 3-O-methyltransferase (CCoAOMT) was isolated from a Pinus radiata cDNA library derived from differentiating xylem. Suppression of PrCCoAOMT expression in P. radiata tracheary element cultures affected lignin content and composition, resulting in a lignin polymer containing p-hydroxyphenyl (H), catechyl (C) and guaiacyl (G) units. Acetyl bromide-soluble lignin assays revealed reductions in lignin content of up to 20% in PrCCoAOMT-deficient transgenic lines. Pyrolysis-GC/MS and 2D-NMR studies demonstrated that these reductions were due to depletion of G-type lignin. Correspondingly, the proportion of H-type lignin in PrCCoAOMT-deficient transgenic lines increased, resulting in up to a 10-fold increase in the H/G ratio relative to untransformed controls. 2D-NMR spectra revealed that PrCCoAOMT suppression resulted in formation of benzodioxanes in the lignin polymer. This suggested that phenylpropanoids with an ortho-diphenyl structure such as caffeyl alcohol are involved in lignin polymerization. To test this hypothesis, synthetic lignins containing methyl caffeate or caffeyl alcohol were generated and analyzed by 2D-NMR. Comparison of the 2D-NMR spectra from PrCCoAOMT-RNAi lines and synthetic lignins identified caffeyl alcohol as the new lignin constituent in PrCCoAOMT-deficient lines. The incorporation of caffeyl alcohol into lignin created a polymer containing catechyl units, a lignin type that has not been previously identified in recombinant lignin studies. This finding is consistent with the theory that lignin polymerization is based on a radical coupling process that is determined solely by chemical processes.

Exploring the ultrastructural localization and biosynthesis of beta(1,4)-galactan in Pinus radiata compression wood.

Softwood species such as pines react to gravitropic stimuli by producing compression wood, which unlike normal wood contains significant amounts of beta(1,4)-galactan. Currently, little is known regarding the biosynthesis or physiological function of this polymer or the regulation of its deposition. The subcellular location of beta(1,4)-galactan in developing tracheids was investigated in Pinus radiata D. Don using anti-beta(1,4)-galactan antibodies to gain insight into its possible physiological role in compression wood. beta(1,4)-Galactan was prominent and evenly distributed throughout the S2 layer of developing tracheid cell walls in P. radiata compression wood. In contrast, beta(1,4)-galactan was not detected in normal wood. Greatly reduced antibody labeling was observed in fully lignified compression wood tracheids, implying that lignification results in masking of the epitope. To begin to understand the biosynthesis of galactan and its regulation, an assay was developed to monitor the enzyme that elongates the beta(1,4)-galactan backbone in pine. A beta(1,4)-galactosyltransferase (GalT) activity capable of extending 2-aminopyridine-labeled galacto-oligosaccharides was found to be associated with microsomes. Digestion of the enzymatic products using a beta(1,4)-specific endogalactanase confirmed the production of beta(1,4)-galactan by this enzyme. This GalT activity was substantially higher in compression wood relative to normal wood. Characterization of the identified pine GalT enzyme activity revealed pH and temperature optima of 7.0 and 20 degrees C, respectively. The beta(1,4)-galactan produced by the pine GalT had a higher degree of polymerization than most pectic galactans found in angiosperms. This observation is consistent with the high degree of polymerization of the naturally occurring beta(1,4)-galactan in pine.

Suppression of 4-coumarate-CoA ligase in the coniferous gymnosperm Pinus radiata.

Severe suppression of 4-coumarate-coenzyme A ligase (4CL) in the coniferous gymnosperm Pinus radiata substantially affected plant phenotype and resulted in dwarfed plants with a "bonsai tree-like" appearance. Microscopic analyses of stem sections from 2-year-old plants revealed substantial morphological changes in both wood and bark tissues. This included the formation of weakly lignified tracheids that displayed signs of collapse and the development of circumferential bands of axial parenchyma. Acetyl bromide-soluble lignin assays and proton nuclear magnetic resonance studies revealed lignin reductions of 36% to 50% in the most severely affected transgenic plants. Two-dimensional nuclear magnetic resonance and pyrolysis-gas chromatography-mass spectrometry studies indicated that lignin reductions were mainly due to depletion of guaiacyl but not p-hydroxyphenyl lignin. 4CL silencing also caused modifications in the lignin interunit linkage distribution, including elevated beta-aryl ether (beta-O-4 unit) and spirodienone (beta-1) levels, accompanied by lower phenylcoumaran (beta-5), resinol (beta-beta), and dibenzodioxocin (5-5/beta-O-4) levels. A sharp depletion in the level of saturated (dihydroconiferyl alcohol) end groups was also observed. Severe suppression of 4CL also affected carbohydrate metabolism. Most obvious was an up to approximately 2-fold increase in galactose content in wood from transgenic plants due to increased compression wood formation. The molecular, anatomical, and analytical data verified that the isolated 4CL clone is associated with lignin biosynthesis and illustrated that 4CL silencing leads to complex, often surprising, physiological and morphological changes in P. radiata.

Exploring lignification in conifers by silencing hydroxycinnamoyl-CoA:shikimate hydroxycinnamoyltransferase in Pinus radiata.

The enzyme hydroxycinnamoyl-CoA:shikimate hydroxycinnamoyltransferase (HCT) is involved in the production of methoxylated monolignols that are precursors to guaiacyl and syringyl lignin in angiosperm species. We identified and cloned a putative HCT gene from Pinus radiata, a coniferous gymnosperm that does not produce syringyl lignin. This gene was up-regulated during tracheary element (TE) formation in P. radiata cell cultures and showed 72.6% identity to the amino acid sequence of the Nicotiana tabacum HCT isolated earlier. RNAi-mediated silencing of the putative HCT gene had a strong impact on lignin content, monolignol composition, and interunit linkage distribution. AcBr assays revealed an up to 42% reduction in lignin content in TEs. Pyrolysis-GC/MS, thioacidolysis, and NMR detected substantial changes in lignin composition. Most notable was the rise of p-hydroxyphenyl units released by thioacidolysis, which increased from trace amounts in WT controls to up to 31% in transgenics. Two-dimensional 13C-1H correlative NMR confirmed the increase in p-hydroxyphenyl units in the transgenics and revealed structural differences, including an increase in resinols, a reduction in dibenzodioxocins, and the presence of glycerol end groups. The observed modifications in silenced transgenics validate the targeted gene as being associated with lignin biosynthesis in P. radiata and thus likely to encode HCT. This enzyme therefore represents the metabolic entry point leading to the biosynthesis of methoxylated phenylpropanoids in angiosperm species and coniferous gymnosperms such as P. radiata.