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KSE, INC.

Address

665 AMHERST RD
SUNDERLAND, MA, 01375-5911
USA

UEI: XSP4KY3W1KA5

Number of Employees: 6

HUBZone Owned: No

Woman Owned: No

Socially and Economically Disadvantaged: No

SBIR/STTR Involvement

Year of first award: 1983

Phase I Awards

Phase II Awards

44%

Conversion Rate

$4,200,777

Phase I Dollars

$11,109,920

Phase II Dollars

$15,310,697

Total Awarded

Awards

Up to 10 of the most recent awards are being displayed. To view all of this company's awards, visit the Award Data search page.

Manufacture of 2,5-Furandicarboxylic Acid from Furfural Produced from a Lignocellulosic Waste Stream

Amount: $650,000 Topic: 8.1

The goal of this Phase II SBIR program is to evaluate optimize and demonstrate noveltechnology to convert lignocellulose waste streams into a value-added building-block chemicalspecifically 25-Furandicarboxylic acid (FDCA) at pilot-scale.FDCA is targeted to replacepetroleum-based chemicals used extensively in the textiles polyesters and plastics industries.As adrop-in replacement for petroleum-based terephthalic acid for example the global market isestimated at 84M metric tons in 2022 growing at 3.3% CAGR and valued over $100B.Common sources of lignocellulose include renewable woody substrates agri-residuesdedicated energy crops and municipal solid wastes.This program will demonstrate viability frommultiple woody sources including timber residue such as sawdust/wood chips hydrolysate frompulp & paper processing for example and directly from furfural.Project tasks include pretreatment of lignocellulose biomass to create pentose-rich hydrolysatescaling of reactive distillation techniques to produce furfural catalytically oxidize and subsequentlyconsume CO2 to transform the 5-carbon pentose molecules into the 6-carbon FDCA form.Theprocess will be demonstrated at 5L scale with efficient closed-loop catalyst and solvent recycle.Experimental operating conditions and results will be utilized to develop a techno-economic modelof the process as well as to transition to toll manufacturing scale for commercialization.Societal benefits of utilizing FDCA from this novel process include health benefits associatedwith replacing endocrine disrupting petroleum phthalate-based plastics improved barrier/thermo- mechanical properties for consumer plastics originating from renewable non-food woodyresources with process technology demonstrating a sustainable low carbon footprint serving globalnet-zero emissions aspirations.By the end of our Phase II program we anticipate manufacturing capacity of 25k lbs/yr of FDCAwith projected cumulative sales revenue approaching $10M in the next 5 years.

SBIR

Phase II

2023

USDA

Manufacture of 2,5-Furandicarboxylic Acid from Furfural Produced from a Lignocellulosic Waste Stream

Amount: $175,000 Topic: 8.1

The overall goal of this Phase I SBIR program is to evaluate optimize and economically scalenovel technology to convert a lignocellulose waste stream into a value-added intermediatechemical specifically 25-Furandicarboxylic acid (FDCA) at high selectivity and without pre- purification of the biomass compounds.FDCA is targeted to replace petroleum-based acids usedextensively in the textiles polyesters and plastics industries.The global market as a drop-inreplacement for terephthalic acid (PTA) is estimated at 79Mmetric tons in 2020 with a CAGRof 3.3%.Common sources of lignocellulose include renewable woody substrates agri-residues dedicatedenergy crops and municipal solid wastes.One identified feedstock from forest relatedresources being a hydrolysate stream from pulp & paper processing.Project tasks include improving reactive distillation & catalytic conversion of pentosecarbohydrates to furfural converting batch scale to continuous oxidation of furfural to furoicacid review alternative alkali metal catalyst combinations to economically maximize FDCAyield implement a closed-loop catalyst regeneration process to control costs and develop aneconomic model based on the R&D program to demonstrate overall economic value proposition.A subsequent Phase II program would further enhance optimize and scale up these technologiesto develop an integrated and highy intensified process targeting a pulp mill hydrolysate wastestream for production of a value-added FDCA product.Societal benefits of utilizing FDCA from this novel process include health improvementsassociated with replacing endocrine disrupting phthalate-based plastics improvedbarrier/thermo-mechanical properties of consumer plastics originating from renewableresources with process technology demonstrating a more sustainable carbon footprint.

SBIR

Phase I

2022

USDA

Evaluation of Technologies for the Pre-Treatment and Enzymatic Breakdown of Lignocellulosic Feedstocks for the Manufacture of 2,5 Furandicarboxylic Acid

Amount: $250,000 Topic: C53-30a

Lignocellulosic biomass is a unique, renewable resource suitable for large-scale, sustainable production of low-cost liquid fuels and chemical products capable of replacing much of the fossil fuel industry in the coming decade. This lignocellulose has a complex internal structure and has a natural and inherit recalcitrance, making it very difficult to separate into its different components and releasing the valuable sugars important to this chemical and fuel production. Various pre-treatment methods have been carefully studied to separate the lignocellulose into cellulose, hemicellulose and lignin components. This pretreatment allows for effective enzymatic deconstruction for the separation of various sugars at high yields, allowing for biofuel and bioproduct development. This pre-treatment and enzymatic hydrolysishas been expensive and has historically involved the use of toxic solvents and chemicals. This Phase I research has been designed to evaluate various pre-treatment and enzymatic hydrolysis methods to optimize process conditions and allow for the economical generation of fermentable sugars for the production of biofuels and xylose sugars for the production of biobased chemicals. This project will allow for the generation of an affordable feedstock for the production of 2,5 furandicarboxylic acid, a highly valued chemical building block for the drop-in replacement of terephthalic acid in the production of polyethylenefuranoate, a non-fossil-fuel based plastic. This would allow for the high-volume production of “plant based” bottles and plastics. The generation of additional value-added products from existing biorefineries allows for the rapid advancement of biomass-based fuel development by off-setting the costs associated with enzymatic hydrolysis and pre-treatment options. The DOE Billion-Ton Report projects that the U.S. has the potential to produce 1 billion tons of non-food biomass annually by the year 2040. This represents a tremendous source of increased biofuel and bioproducts production, replacing a significant volume of fuels and chemicals currently produced from petroleum. This shift to biofuels and bioproduct development can create overall cost efficiencies to the biorefinery model. The development of this affordable technologies would provide higher energy security, lower greenhouse gas emissions, mitigate climate impacts, produce less toxic chemicals and biproducts, create an influx of jobs into more rural areas and improve the overall U.S. trade balance.

SBIR

Phase I

2022

DOE

Manufacture of 2,5-Furandicarboxylic Acid from Furfural Produced from a Wet Waste Stream

Amount: $1,010,000 Topic: 14c

The proposed program provides a new biomass conversion technology to produce FDCA, 2,5- furandicarboxylic acid, to replace hydrocarbon chemicals for production of plasticizers and polyester polymers. FDCA is currently produced from hexose carbohydrates, such as sucrose or high fructose corn syrup. Recent trends in petroleum pricing have reduced biomass raw material cost advantages for replacement of hydrocarbon chemicals, a key driving force for sustainable FDCA commercialization. The proposed technology will provide an alternative pathway to FDCA using low cost biomass obtained from a wet waste pulp mill hydrolysate stream. The new technology will use a slip stream of hydrolysate from a hardwood pulp mill currently being disposed of as a wet organic waste through a waste heat boiler. The production of high value chemicals, such as FDCA, from waste pulp hydrolysate will provide new technologies and products from pulp and paper manufacture to enhance industry profitability, employment and competiveness. The Phase I program successfully demonstrated the technical and economic feasibility of the new catalytic reactive distillation technology for FDCA from pulp waste hydrolysate. The Phase I program successfully demonstrated the production of FDCA by the CO2 carboxylation of furoic acid at greater than 90% selectivity, and a commercially scalable reaction system for performing the carboxylation reaction. The Phase I program also established the feasibility of producing the furoic acid intermediate from furfural derived from pulp mill waste hydrolysate. The new technology, based on a waste stream currently burned for fuel value, will provide a low cost manufacturing process to accelerate the commercialization of FDCA. In the Phase II program, research and development will be completed to support immediate commercialization of the new technology for FDCA production. The overall manufacturing process will be optimized to provide low cost, high quality FDCA product. Performance of FDCA-based non- phthalate plasticizers will be confirmed to meet commercial requirements. The program includes a subcontract to the Department of Chemical Engineering at the University of Massachusetts. Commercial Applications and Other Benefits:FDCA produced by the new technology will find immediate application for production of non- phthalate bio-plasticizers for PVC, and for the production of large volume polyester polymers for fibers, beverage bottles, and other products. The proposed technology will provide a new low cost raw material base for FDCA production, as well as utilizing carbon dioxide greenhouse gas for commodity chemical manufacture. The new technology will benefit the U.S. pulp and paper industry by providing new products from pulp and paper manufacture, to enhance industry profitability, and employment.

SBIR

Phase II

2018

DOE

Manufacture of 2,5-Furandicarboxylic Acid from Furfural Produced from a Wet Waste Stream

Amount: $155,000 Topic: 14c

The proposed program provides a new biomass conversion technology to produce FDCA, 2,5- furandicarboxylic acid, to replace hydrocarbon chemicals for production of plasticizers and polyester polymers. FDCA is currently produced from hexose carbohydrates, such as sucrose or high fructose corn syrup. Recent trends in global petroleum pricing have greatly reduced biomass raw material cost advantages for replacement of hydrocarbon chemicals by FDCA, a key driving force for sustainable FDCA commercialization. The proposed technology will provide an alternative pathway to FDCA using low cost biomass obtained from a wet waste pulp mill hydrolysate stream. The new technology will use a slip stream of hydrolysate from a hardwood pulp mill currently being disposed of as a wet organic waste through a waste heat boiler. The production of high value chemicals, such as FDCA, from waste pulp hydrolysate will provide new technologies and products from pulp and paper manufacture to enhance industry profitability, employment and competiveness. The overall goal of this SBIR project is to commercialize an innovative, highly intensified catalytic technology to convert biomass components in pulp mill hydrolysate to FDCA. The Phase I project will establish the technical and economic feasibility of a novel carbon dioxide carboxylation reaction to produce FDCA from furfural/furoic acid using reactive distillation of the pulp hydrolysate. The Phase I program includes: (1) the development of new catalytic compositions for the carboxylation of furoic acid with carbon dioxide to produce to FDCA, (2) demonstration of the catalytic activity and selectivity of the carboxylation reaction, and (3) demonstration of technical and economic feasibility of the overall process by process design and life cycle cost studies. The proposed technology will; (1) establish a new low cost raw material base for FDCA production, (2) provide utilization of carbon dioxide greenhouse gas in the production of high value chemicals, and (3) provide new technologies and products from pulp and paper manufacture to enhance industry profitability, employment and competiveness in world markets. Commercial Applications and Other Benefits: FDCA produced by the new technology will find immediate application for production of non-phthalate bio-plasticizers, and large volume polyester polymers for fibers, beverage bottles, and other products. The proposed technology will provide a new low cost raw material base for FDCA production, as well as utilizing carbon dioxide greenhouse gas for commodity chemical manufacture. The new technology will benefit the U.S. pulp and paper industry by providing new products from pulp and paper manufacture, to enhance industry profitability, and employment.

SBIR

Phase I

2017

DOE

Process Intensification for the Production of Furandicarboxylic Acid Topic 10 Subtopic b

Amount: $1,000,000 Topic: 10b

The proposed program provides a new biomass conversion technology to produce FDCA, 2,5- furandicarboxylic acid, to replace hydrocarbon chemicals for production of commodity plasticizers and polyester polymers. Using current prices, FDCA can economically replace phthalic anhydride and terephthalic acid, commodity chemicals used for production of large volume phthalate plasticizers and polyester polymers. FDCA is derived from hexose sugars, with 5-hydroxymethylfurfural (HMF) as a key intermediate. Commercial production of FDCA is currently hindered by poor selectivity for the catalytic dehydration of fructose using current catalysts and reaction pathways. The overall goal of the Phase IIA project is to accelerate completion of the commercialization of an innovative technology, Intensified Catalytic and Reactive Distillation, for highly selective production of FDCA from sucrose sugar. Improved process intensification is achieved by: (1) utilization of reactive distillation to remove water generated by the reaction, thereby suppressing degradation reactions and increasing selectivity; (2) development of novel catalysts for use in reactive distillation for hexose dehydration with high selectivity; and (3) catalytic oxidation of HMF to FDCA at very high yield. The ongoing Phase II program is successfully completing the research and development required to commercialize the novel technology for FDCA production at high selectivity. The project has developed new catalysts, and a novel reaction system, which has successfully demonstrated fructose conversion to FDCA with greater than 90% selectivity. The novel technology for FDCA production provides exceptionally attractive economics, with an estimated payout time for a commercial plant investment of less than one year. In the Phase IIA program, research, development, scale up, and commercial validation studies will be completed to accelerate immediate commercialization of the new technology for FDCA production. The catalysts, reaction system, and overall manufacturing process will be optimized to provide low cost, high quality FDCA product. A pilot plant will be constructed and operated to validate the technology, provide design and scale up information for commercial production, and support market development activities. FDCA produced by the new technology will find immediate application for production of non-phthalate bio-plasticizers for polyvinyl chloride, and the production of large volume polyester polymers for fibers, beverage bottles, and other products. This will allow conversion of over 10 billion pounds per year of commodity chemical production from hydrocarbon to a biomass base, resulting in reduced greenhouse gases from consumption from the alternative hydrocarbon use and improving long term U.S. competitiveness in global markets.

SBIR

Phase II

2015

DOE

Manufacture of Acrylic Acid from Biomass Derived Intermediates

Amount: $150,000 Topic: 13a

Statement of Problem Acrylic acid is a global commodity chemical used in acrylic paints, coatings, adhesives, detergents, and hygienic products. The current method to manufacture acrylic acid is a complex, energy intensive process, based on hydrocarbon feedstocks. This proposal will provide a novel selective catalytic reactive distillation technology for the manufacture of acrylic acid from biomass. This proposal will provide technology for producing acrylic acid from crude glycerol, a byproduct of biodiesel manufacture. Crude glycerol is currently in substantial over-supply in the market place, is economically burdensome to biodiesel producers, and is available at extremely low cost. The acrylic acid product of this proposed program is identical to that now derived from petroleum sources, and is a direct substitute in the market. The Solution The overall goal of this Small Business Innovation Research project is to commercialize an innovative, integrated catalytic reactive distillation/oxidation technology to convert crude glycerol into acrylic acid, for use in paints, coatings and adhesives. The Phase I project will establish the technical and economic feasibility of the innovative technology, based on novel catalyst compositions, to manufacture acrylic acid from the crude glycerol byproduct resulting from biodiesel manufacture. Application of the proposed technology will achieve a biobased route to acrylic acid manufacture, while offsetting biodiesel production costs by increasing the value of the crude glycerol byproduct credits, by (1) the use of process intensification techniques, specifically catalytic reactive distillation, to remove acrolein as it is generated by the reaction, thereby suppressing degradation reactions; (2) the development of novel catalysts, specifically designed for use in a catalytic reactive distillation environment, for the dehydration of glycerol with very high selectivity; and (3) the demonstration of the catalytic oxidation of the acrolein to acrylic acid at exceptionally high yield. Commercial Applications and Other Benefits: The use of the integrated catalytic reactive distillation/oxidation technology should find immediate application for the production of acrylic acid from inexpensive crude glycerol byproduct of biodiesel production, thereby supporting the growth of biorefineries, and improving long term U.S. employment and competitiveness in global markets. The novel technology is potentially applicable to production of other products from renewable biomass based resources. Keywords: Acrylic acid, crude glycerol, biodiesel, hydrocarbon feedstocks, selectivity, reactive distillation, employment Summary for Members of Congress: Acrylic acid is used in acrylic paints, disposable diapers, detergents, and other products. A novel technology is proposed that produces acrylic acid from waste glycerol byproduct of biodiesel production. The new KSE technology for acrylic acid manufacture from this low cost waste biomass will produce acrylic acid at manufacturing costs well below current costs of manufacture. Successful commercialization of this technology would reduce cost of biodiesel production, enable U.S. producers to become global low-cost leaders in chemical manufacturing, reduce imports and dependencies on crude oil markets, increase U.S. employment, and reduce greenhouse gas emissions.

SBIR

Phase I

2015

DOE

Process Intensification for the Production of Furandicarboxylic Acid

Amount: $1,000,000 Topic: 10b

The proposed program provides a new biomass conversion technology to produce FDCA, 2,5-furandicarboxylic acid, to replace hydrocarbon chemicals for production of commodity plasticizers and polyester polymers. Using todays prices, FDCA can economically replace phthalic anhydride and terephthalic acid, commodity chemicals used for production of large volume phthalate plasticizers and polyester polymers. FDCA is derived from fructose, with 5-acetoxymethylfurfural (AcHMF) as a key intermediate. Commercial production of FDCA is currently hindered by poor selectivity for the catalytic dehydration of fructose using current catalysts and reaction pathways. The overall goal of the Phase II project is to commercialize an innovative technology, Intensified Catalytic and Reactive Distillation (iCARD), for highly selective production of FDCA from high fructose corn syrup. Improved selectivity will be achieved by: (1) utilization of reactive distillation to remove water generated by the reaction, thereby suppressing degradation reactions and increasing selectivity; (2) development of novel catalysts, for use in reactive distillation for fructose dehydration with high selectivity; (3) use of an alternative reaction pathway, through AcHMF, that further suppresses byproduct formation; and (4) catalytic oxidation of AcHMF to FDCA at exceptionally high yield. The Phase I program successfully demonstrated the technical and economic feasibility of the iCARD technology for FDCA production at high selectivity. The project developed new catalysts, and a novel reaction system, which successfully demonstrated fructose dehydration to FDCA with greater than 90% selectivity. The iCARD technology for FDCA production provides exceptionally attractive economics, with an estimated payout time for a commercial plant investment of less than one year. In the Phase II program, research and development will be completed to support immediate commercialization of the iCARD technology for FDCA production. The iCARD catalysts, reaction system, and overall manufacturing process will be optimized to provide low cost, high quality FDCA product. Performance of FDCA-based non-phthalate plasticizers will be confirmed to meet commercial requirements. The program includes a subcontract to the Department of Chemical Engineering at the University of Massachusetts. Commercial Applications and Other Benefits: FDCA produced by the iCARD technology will find immediate application for production of non-phthalate bio-plasticizers for PVC, and for the production of large volume polyester polymers for fibers, beverage bottles, and other products. This will allow conversion of over 10 billion pounds per year of commodity chemical production from hydrocarbon to biomass base, resulting in reduced consumption of scarce hydrocarbon resources and improving long term U.S. competitiveness in global markets.

SBIR

Phase II

2013

DOE

Improved Method for the Production of Tetrahydrofuran from Biomass

Amount: $150,000 Topic: 10 a

Tetrahydrofuran (THF) is a large volume commodity chemical used in the production of polytetramethylene ether glycol (PTMEG), a component of polyurethane stretch fibers (Spandex) and as an industrial solvent with applications in polyvinyl chloride (PVC) cements, pharmaceuticals and coatings. THF is currently produced from hydrocarbon feedstocks by complex, energy-intensiveprocesses. THF, as derived from biomass furfural, may be used as a drop-in substitute for THF produced from petroleum, as it is an exact molecular replacement. The technology also can convert 1,4 butanediol to THF. The overall goal of this Small Business Innovation Research is to commercialize a new technology to convert dilute aqueous furfural solutions into THF, at high selectivity and without pre-purification of the furfural. Specifically, the Phase I SBIR project is to establish the technical and economic feasibility of an innovative catalytic decarbonylation hydrogenation technology using reactive distillation to produce THF from a dilute aqueous solution containing furfural. Dilute solutions of furfural are commonly produced from acid hydrolysis of biomass. This process is commonly used in the paper industry and is an element of the production of cellulosic ethanol as it releases fermentable sugars in addition to furfural. Improved selectivity to THF will be achieved by the development of novel bifunctional catalysts, specifically designed for the decarbonylation and hydrogenation of furfural to THF with exceptionally high activity and selectivity. The program will assess the technical and economic feasibility of the application of novel catalysts to manufacture THF by reactive distillation at high selectivity. Commercial Applications and Other Benefits: Selective catalytic decarbonylation and hydrogenation of furfural will allow commercial production of THF from renewable hemicellulosic biomass feedstocks for the production of elastomer fibers, and industrial solvents. The technology can exist solely for THF manufacture or be integrated with cellulosic fermentation technology to capture the value of the furfural byproduct liberated through hydrolysis of biomass. This type of integration would support efforts to develop biorefineries, where biomass feedstocks such as wood chips, corn cobs, and stalks are processed to produce an array of fuels and chemicals. Development of commercially competitive biomass based technologies will reduce consumption of scarce hydrocarbon resources, and improve long term U.S. competitiveness in global markets.

SBIR

Phase I

2013

DOE

Process Intensification for the Production of Furandicarboxylic Acid

Amount: $150,000 Topic: 10 b

Terephthalic acid is large volume global commodity chemical used in the production of polyester polymers for applications such as polyester fibers, beverage bottles, and specialty polymers and resins. Terephthalic acid (PTA) is currently produced from hydrocarbon feedstocks by a complex, inefficient, energy intensive process, resulting in poor utilization of hydrocarbon resources, high energy consumption, and substantial greenhouse gas emissions. FDCA, 2,5-furandicarboxylic acid, a furan analog of terephthalic acid, may be utilized in place of terephthalic acid for the production of commodity polyester polymers. FDCA is derived from biomass carbohydrates, specifically fructose, with 5-hydroxymethylfurfural (HMF) as a key intermediate. The synthesis of the key HMF intermediate by conventional technology for the catalytic dehydration of fructose exhibits unacceptably poor selectivity. Commercial production of FDCA, and commodity polyester polymers based on FDCA, is currently hindered by poor selectivity for the catalytic dehydration of fructose to form the key HMF intermediate. The overall goal of this Small Business Innovation Research Phase I project is to establish the technical and economic feasibility of an innovative application of process intensification techniques to manufacture 2,5-furan dicarboxylic acid (FDCA) from fructose. The novel technology is based on renewable lignocellulosic biomass feedstock, and will result in substantial reduction in consumption of scarce hydrocarbon resources, reduction in greenhouse gas emissions, and support for the growth, productivity, and profitability of biorefineries. The key HMF intermediate for the synthesis of FDCA is produced by the catalytic dehydration of fructose. Substantial amounts of water are produced as a byproduct of the dehydration reaction. The presence of water in the dehydration reaction provokes numerous side reactions, resulting in the poor HMF selectivity. Improved selectivity to FDCA will be achieved by: (1) the utilization of process intensification techniques, specifically reactive distillation, to remove the byproduct water as it is generated by the reaction, thereby suppressing water-driven degradation reactions and increasing the rate of dehydration; (2) the development of novel catalysts, specifically designed for use in a reactive distillation environment, for the dehydration of fructose to an HMF ester with very high selectivity; (3) the utilization of an alternative reaction pathway, through an HMF ester, that further suppresses byproduct formation; and (4) the demonstration of the catalytic oxidation of HMF esters to FDCA at exceptionally high yield. The Phase I program will demonstrate the technical and economic feasibility of the novel reactive distillation technology through demonstration of the performance of the reactive distillation system, the evolution of new catalyst compositions designed specifically for use in reactive distillation, and will provide process design, energy usage, and life cycle cost comparisons to existing technologies. This program will be conducted with a subcontract to the Department of Chemical Engineering at the University of Massachusetts. Commercial Applications and Other Benefits: Selective catalytic dehydration of fructose by reactive distillation will allow commercial production of 2,5-furandicarboxylic acid (FDCA) from renewable lignocellulosic biomass feedstocks for the production of large volume commodity products, such polyester fibers, beverage bottles, and other products, resulting in reduced consumption of scarce hydrocarbon resources, supporting the growth of biorefineries, and improving long term U.S. competitiveness in global markets. Reactive distillation represents a new integrated process technology that can potentially be applied to the conversion of a wide range of commodity chemical products and intermediates to biomass based feedstocks.

SBIR

Phase I

2012

DOE