Production and Optimisation of Oxygenated Biofuel Blend Components via the Ethanolysis of Lignocellulosic Biomass: A Response Surface Methodology

In this study, a response surface methodology (RSM) using a central composite design (CCD) was implemented to investigate the influence of process variables on ethyl levulinate (EL) production from the ethanolysis of waste corn cob samples, using sulphuric acid as a catalyst. The effects of four independent variables, namely, the temperature (A), the corn cob content (B), corn cob/H2SO4 mass ratio (C) and the reaction time (D) on the yields of EL (Y1), diethyl ether (DEE) (Y2) and solid residue (Y3) were explored. Using multiple regression analysis, the experimental results were fitted to quadratic polynomial models. The predicted yields based on the fitted models were well within the experimental uncertainties. Optimum conditions for maximising the EL yield were found to be 176 ◦C, 14.6 wt. %, 21:1 and 6.75 h for A to D, respectively. A moderate-to-high EL yield (29.2%) from corn cob was achieved in optimised conditions, a result comparable to those obtained from model C6 carbohydrate compounds. Side products were also produced, including diethyl ether, furfural, levulinic acid, 5-hydroxymethyl furfural, ethyl acetate, ethyl formate and water. Total unknown losses of only 5.69% were reported after material balancing. The results suggest that lignocellulosic waste such as corn cob can be used as a potential feedstock for the production of ethyl levulinate by direct acid-catalysed ethanolysis, but that the treatment of side products will need to be considered.