A new lignin-first biorefinery with a reductive catalytic fractionation process, which targets the valorization of the lignin and the carbohydrate fraction into higher value end-products, is currently being designed. To identify the various R&D drivers for projects with a low technology readiness level (TRL), we developed an integrated techno-economic assessment (TEA) that directly integrates the results of lab studies with economic costs and benefits. Furthermore, different linkages are made to upstream wood availability and downstream demand to understand its fit into existing wood value chains. By making the relations across the wood value chain explicit within the integrated TEA, we find that the scale of the plant, the feedstock-specific output quantities, and output prices highly determine the economic feasibility. Furthermore, this detailed analysis reveals the importance of assessing different types of feedstock. If only virgin wood is available as feedstock, minimum capacity levels between 190 and 234 kilotons per year are needed for the investment to be profitable. Waste wood proves to be the most profitable feedstock with an NPV of MV 59 and an IRR of 26%. Using only waste wood as feedstock makes the investment profitable at a lower capacity level of 80 kilotons per year and economic shocks can be absorbed. Based on these results we show that an integrated and detailed TEA is indispensable to define future development paths for early-stage, innovative technologies.

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The development of biomass pretreatment approaches that, next to (hemi)cellulose valorization, aim at the conversion of lignin to chemicals is essential for the long-term success of a biorefinery. Herein, we discuss a dithionite-assisted organosolv fractionation (DAOF) of lignocellulose in n-butanol and water to produce cellulosic pulp and mono-/oligo-aromatics. The present study frames the technicalities of this biorefinery process and relates them to the features of the obtained product streams. Via the extensive characterization of the solid pulp (by acid hydrolysis-HPLC, ATR-FTIR, XRD, SEM and enzymatic hydrolysis-HPLC), of lignin derivatives (by GPC, GC-MS/FID, 1H-13C HSQC NMR, and ICP-AES) and of carbohydrate derivatives (by HPLC) we comprehensively identify and quantify the different products of interest. These results were used for inspecting the economic feasibility of DAOF. The adoption of a dithionite loading of 16.7% w/wbiomass and of an equivolumetric mixture of n-butanol and water, which led to a high yield of monophenolics (~20%, based on acid insoluble lignin, for the treatment of birch sawdust), was identified as the most profitable process configuration. Furthermore, the treatment of various lignocellulosic feedstocks was explored, which showed that DAOF is particularly effective for processing hardwood and herbaceous biomass. Overall, this study provides a comprehensive view of the development of an effective dithionite-assisted organosolv fractionation method for the sustainable upgrading of lignocellulosic biomass.