Optimizing Catalytic Depolymerization of Lignin in Ethanol with a Day-Clustered Box-Behnken Design

Lignin is a potential resource for biobased aromatics with applications in the field of fuel additives, resins, and bioplastics. Via a catalytic depolymerization process using supercritical ethanol and a mixed metal oxide catalyst (CuMgAlOx), lignin can be converted into a lignin oil, containing phenolic monomers that are intermediates to the mentioned applications. Herein, we evaluated the viability of this lignin conversion technology through a stage-gate scale-up methodology. Optimization was done with a day-clustered Box-Behnken design to accommodate the large number of experimental runs in which five input factors (temperature, lignin-to-ethanol ratio, catalyst particle size, catalyst concentration, and reaction time) and three output product streams (monomer yield, yield of THF-soluble fragments, and yield of THF-insoluble fragments and char) were considered. Qualitative relationships between the studied process parameters and the product streams were determined based on mass balances and product analyses. Linear mixed models with random intercept were employed to study quantitative relationships between the input factors and the outcomes through maximum likelihood estimation. The response surface methodology study reveals that the selected input factors, together with higher order interactions, are highly significant for the determination of the three response surfaces. The good agreement between the predicted and experimental yield of the three output streams is a validation of the response surface methodology analysis discussed in this contribution.