Conversion of kraft lignin to hydrocarbons using an integrated molten salt pyrolysis/catalytic hydrotreatment approach

Thermochemical conversion of underutilized lignocellulosic streams such as kraft lignin from the pulp and paper industry has the potential to produce sustainable chemicals and biofuels. We here report a process to continuously convert softwood-based lignoboost lignin to hydrocarbons using a three-step approach: i) liquefaction/dispersion of the lignin in a suitable molten salt, ii) pyrolysis of the liquefied/dispersed lignin in a molten salt mixture (ZnCl₂, KCl, and NaCl), to obtain a crude lignin oil and iii) upgrading of the lignin oil using a catalytic hydrotreatment to yield hydrocarbons. Step 1 and 2 were integrated using a twin screw extruder with different heating sections at a scale of 20 g/h lignin input. Besides char, a lignin oil, mainly composed of monomeric phenolics, and propylene were the major products. The highest yield of the latter two products was around 32 wt% (23 wt% crude lignin oil and 9 wt% propylene). The lignin oil was subsequently converted to hydrocarbons using a two-step catalytic hydrotreatment approach (stabilization step using CoMo/Al₂O₃ catalyst and a further deep hydrotreatment over a NiMo/Al₂O₃ catalyst). The final liquid product contained less than 0.5 wt% of oxygen and was shown to be rich in (cyclo)alkanes and aromatic hydrocarbons. The carbon yield for the overall conversion of lignin to hydrocarbons was 23 %.