Ni-Based Hydrotalcite (HT)-Derived Cu Catalysts for Catalytic Conversion of Bioethanol to Butanol

Catalytic conversion of biomass-derived ethanol into n-butanol through Guerbet coupling reaction has become one of the key reactions in biomass valorization, thus attracting significant attention recently. Herein, a series of supported Cu catalysts derived from Ni-based hydrotalcite (HT) were prepared and performed in the continuous catalytic conversion of ethanol into butanol. Among the prepared catalysts, Cu/NiAlOx shows the best performance in terms of butanol selectivity and catalyst stability, with a sustained ethanol conversion of ~35% and butanol selectivity of 25% in a time-on-stream (TOS) of 110 h at 280 °C. While for the Cu/NiFeOx and Cu/NiCoOx, obvious catalyst deactivation and/or low butanol selectivity were obtained. Extensive characterization studies of the fresh and spent catalysts, i.e., X-ray diffraction (XRD), Transmission electron microscopy (TEM), X-ray photoelectron spectroscopy (XPS) and Hydrogen temperature-programmed reduction (H2-TPR), reveal that the catalysts' deactivation is mainly caused by the support deconstruction during catalysis, which is highly dependent on the reducibility. Additionally, an appropriate acid-base property is pivotal for enhancing the product selectivity, which is beneficial for the key process of aldol-condensation to produce butanol.

Effect of Strontium Modification in Mg-Al Mixed Oxide Catalysts on Product Distribution toward Catalytic Reaction of Ethanol

The aim of this research was to examine the effect of strontium content in the MgAlO catalyst for the catalytic ethanol reaction on the product distribution. The structure of the catalysts and the actual amount of strontium on the catalysts were verified using XRD and ICP techniques, respectively. The acid and basic strength characteristics of catalysts were examined using NH3-TPD and CO2-TPD techniques, respectively. The strontium content was found to influence the textural properties and the acidic and basic characteristics of the catalysts, leading to differences in product selectivity and ethanol conversion. The MgAlO catalyst with 1.9 wt % strontium provided the maximum ethylene and butanol selectivity, probably due to the presence of appropriate medium acidic and strong basic sites. All catalysts can efficiently produce ethylene by a dehydration reaction and acetaldehyde by a dehydrogenation reaction. Acetaldehyde selectivity was dominant with increased strontium loading.

Highly Selective and Stable Cu Catalysts Based on Ni-Al Catalytic Systems for Bioethanol Upgrading to n-Butanol

The catalytic upgrading of ethanol into butanol through the Guerbet coupling reaction has received increasing attention recently due to the sufficient supply of bioethanol and the versatile applications of butanol. In this work, four different supported Cu catalysts, i.e., Cu/Al2O3, Cu/NiO, Cu/Ni3AlOx, and Cu/Ni1AlOx (Ni2+/Al3+ molar ratios of 3 and 1), were applied to investigate the catalytic performances for ethanol conversion. From the results, Ni-containing catalysts exhibit better reactivity; Al-containing catalysts exhibit better stability; but in terms of ethanol conversion, butanol selectivity, and catalyst stability, a corporative effect between Ni-Al catalytic systems can be clearly observed. Combined characterizations such as XRD, TEM, XPS, H2-TPR, and CO2/NH3-TPD were applied to analyze the properties of different catalysts. Based on the results, Cu species provide the active sites for ethanol dehydrogenation/hydrogenation, and the support derived from Ni-Al-LDH supplies appropriate acid-base sites for the aldol condensation, contributing to the high butanol selectivity. In addition, catalysts with strong reducibility (i.e., Cu/NiO) may be easily deconstructed during catalysis, leading to fast deactivation of the catalysts in the Guerbet coupling process.

Ethanol Coupling Reactions over MgO-Al2O3 Mixed Oxide-Based Catalysts for Producing Biofuel Additives

Catalytic conversion of ethanol to 1-butanol was studied over MgO-Al₂O₃ mixed oxide-based catalysts. Relationships between acid-base and catalytic properties and the effect of active metal on the hydrogen transfer reaction steps were investigated. The acid-base properties were studied by temperature-programmed desorption of CO₂ and NH₃ and by the FT-IR spectroscopic examination of adsorbed pyridine. Dispersion of the metal promoter (Pd, Pt, Ru, Ni) was determined by CO pulse chemisorption. The ethanol coupling reaction was studied using a flow-through microreactor system, He or H₂ carrier gas, WHSV = 1 gEtOH·gcat.-1·h-1, at 21 bar, and 200-350 °C. Formation and transformation of surface species under catalytic conditions were studied by DRIFT spectroscopy. The highest butanol selectivity and yield was observed when the MgO-Al₂O₃ catalyst contained a relatively high amount of strong-base and medium-strong Lewis acid sites. The presence of metal improved the activity both in He and H₂; however, the butanol selectivity significantly decreased at temperatures ≥ 300 °C due to acceleration of undesired side reactions. DRIFT spectroscopic results showed that the active metal promoted H-transfer from H₂ over the narrow temperature range of 200-250 °C, where the equilibrium allowed significant concentrations of both dehydrogenated and hydrogenated products.

Potentials of bio-butanol conversion to valuable products

In the last decade, there was observed a growing demand for both n-butanol as a potential fuel or fuel additive, and propylene as the only raw material for production of alcohol and other more bulky propylene chemical derivatives with faster growing outputs (polymers, propylene oxide, and acrylic acid). The predictable oilfield depletion and the European Green Deal adoption stimulated interest in alternative processes for n-butanol production, especially those involving bio-based materials. Their commercialization will promote additional market penetration of n-butanol for its application as a basic chemical. We analyze briefly the current status of two most advanced bio-based processes, i.e. ethanol–to-n-butanol and acetone–butanol–ethanol (ABE) fermentation. In the second part of the review, studies of n-butanol and ABE conversion to valuable products are considered with an emphasis on the most perspective catalytic systems and variants of the future processes realization.

Optimal Conditions for Butanol Production from Ethanol over MgAlO Catalyst Derived from Mg-Al Layer Double Hydroxides

The MgAlO catalyst was obtained from thermal decomposition of the MgAl-LDH catalyst having Mg/Al molar ratio of 5. The catalytic Guerbet reaction of ethanol was investigated to determine the effect of WHSV and nitrogen flow rate on butanol production and product distribution. It was performed in a fixed-bed microreactor under continuous flow of vaporized ethanol mixed with N₂. The MgAlO catalyst had high total basic sites and high total acid sites that were crucial for ethanol Guerbet reaction. The MgAlO catalyst showed the highest butanol selectivity at 300℃ under WHSV = 3.10 h^-1 and nitrogen flow rate = 3,600 mL/h, and the highest butanol yield at 400℃ under WHSV = 3.10 h^-1 and nitrogen flow rate = 900 mL/h. It can be summarized that in order to enhance the butanol yield, the low WHSV is preferred to increase the contact time of ethanol and catalyst under moderate temperature.

Renewable Butanol Production via Catalytic Routes

Fluctuating crude oil price and global environmental problems such as global warming and climate change lead to growing demand for the production of renewable chemicals as petrochemical substitutes. Butanol is a nonpolar alcohol that is used in a large variety of consumer products and as an important industrial intermediate. Thus, the production of butanol from renewable resources (e.g., biomass and organic waste) has gained a great deal of attention from researchers. Although typical renewable butanol is produced via a fermentative route (i.e., acetone-butanol-ethanol (ABE) fermentation of biomass-derived sugars), the fermentative butanol production has disadvantages such as a low yield of butanol and the formation of byproducts, such as acetone and ethanol. To avoid the drawbacks, the production of renewable butanol via non-fermentative catalytic routes has been recently proposed. This review is aimed at providing an overview on three different emerging and promising catalytic routes from biomass/organic waste-derived chemicals to butanol. The first route involves the conversion of ethanol into butanol over metal and oxide catalysts. Volatile fatty acid can be a raw chemical for the production of butanol using porous materials and metal catalysts. In addition, biomass-derived syngas can be transformed to butanol on non-noble metal catalysts promoted by alkali metals. The prospect of catalytic renewable butanol production is also discussed.

Interfacial Sites in Ag Supported Layered Double Oxide for Dehydrogenation Coupling of Ethanol to n-Butanol

Upgrading of ethanol to n-butanol through dehydrogenation coupling has received increasing attention due to the wide application of n-butanol. But the enhancement of ethanol dehydrogenation and followed coupling to produce high selectivity to n-butanol is still highly desired. Our previous work has reported an acid-base-Ag synergistic catalysis, with Ag particles supported on Mg and Al-containing layered double oxides (Ag/MgAl-LDO). Here, Ag-LDO interfaces have been manipulated for dehydrogenation coupling of ethanol to n-butanol by tailoring the size of Ag particles and the interactions between Ag and LDO. It has been revealed that increasing the population of surface Ag sites at Ag-LDO interfaces promotes not only the dehydrogenation of ethanol to acetaldehyde but also the subsequent aldol condensation of generated acetaldehyde. A selectivity of up to 76 % to n-butanol with an ethanol conversion of 44 % has been achieved on Ag/LDO with abundant interfacial Ag sites, much superior to the state-of-the-art catalysts.

Bio-DEE Synthesis and Dehydrogenation Coupling of Bio-Ethanol to Bio-Butanol over Multicomponent Mixed Metal Oxide Catalysts

Within the Waste2Fuel project, innovative, high-performance, and cost-effective fuel production methods from municipal solid wastes (MSWs) are sought for application as energy carriers or direct drop-in fuels/chemicals in the near-future low-carbon power generation systems and internal combustion engines. Among the studied energy vectors, C1-C2 alcohols and ethers are mainly addressed. This study presents a potential bio-derived ethanol oxidative coupling in the gas phase in multicomponent systems derived from hydrotalcite-containing precursors. The reaction of alcohol coupling to ethers has great importance due to their uses in different fields. The samples have been synthesized by the co-precipitation method via layered double hydroxide (LDH) material synthesis, with a controlled pH, where the M(II)/M(III) ≈ 0.35. The chemical composition and topology of the sample surface play essential roles in catalyst activity and product distribution. The multiple redox couples Ni2+/Ni3+, Cr2+/Cr3+, Mn2+/Mn3+, and the oxygen-vacant sites were considered as the main active sites. The introduction of Cr (Cr3+/Cr4+) and Mn (Mn3+/Mn4+) into the crystal lattice could enhance the number of oxygen vacancies and affect the acid/base properties of derived mixed oxides, which are considered as crucial parameters for process selectivity towards bio-DEE and bio-butanol, preventing long CH chain formation and coke deposition at the same time.

Butanol Synthesis Routes for Biofuel Production: Trends and Perspectives

Butanol has similar characteristics to gasoline, and could provide an alternative oxygenate to ethanol in blended fuels. Butanol can be produced either via the biotechnological route, using microorganisms such as clostridia, or by the chemical route, using petroleum. Recently, interest has grown in the possibility of catalytic coupling of bioethanol into butanol over various heterogenic systems. This reaction has great potential, and could be a step towards overcoming the disadvantages of bioethanol as a sustainable transportation fuel. This paper summarizes the latest research on butanol synthesis for the production of biofuels in different biotechnological and chemical ways; it also compares potentialities and limitations of these strategies.

Efficient conversion of ethanol to 1-butanol and C5–C9 alcohols over calcium carbide

Production of 1-butanol or alcohols with 4–9 carbon atoms (C₄–C₉ alcohols) from widely available bio-ethanol has attracted much interest in recent years in academia and industry of renewable chemicals and liquid fuels. This work discloses for the first time that calcium carbide (CaC₂) has a superior catalytic activity in condensation of ethanol to C₄–C₉ alcohols at 275–300 °C. The 1-butanol yield reached up to 24.5% with ethanol conversion of 62.4% at the optimized conditions. The by-products are mainly alcohols with 5–9 carbons besides 2-butanol, and the total yield of all the alcohols reached up to 56.3%. The reaction route was investigated through controlled experiments and quantitative analysis of the products. Results indicated that two reaction routes, aldol-condensation and self-condensation, took place simultaneously. The aldol-condensation route involves coupling of ethanol with acetaldehyde (formed from ethanol dehydrogenation) to form 2-butenol, which is subsequently hydrogenated to 1-butanol. The alkynyl moiety in CaC₂ plays an important role in the catalytic pathways of both routes and affords the good activity of CaC₂. CaC₂ is converted to acetylene [C₂H₂] and calcium hydroxide [Ca(OH)₂] simultaneously by the H₂O that was generated from the condensation of alcohols.

Efficient synthesis of 1-butanol and C₅–C₉ alcohols from widely available bio-ethanol over CaC₂ and reaction mechanism were investigated in this work.

Continuous Gas-Phase Condensation of Bioethanol to 1-Butanol over Bifunctional Pd/Mg and Pd/Mg-Carbon Catalysts

The condensation of ethanol to 1-butanol in the presence of different catalyst systems based on a Pd dehydrogenating/hydrogenating component and magnesium hydroxide-derived materials as basic ingredient was studied in a fixed-bed reactor. The metal was incorporated by wetness impregnation, and the resulting material was then reduced in situ with hydrogen at 573 K for 1 h before reaction. The bifunctional catalysts were tested in a fixed-bed reactor operated in the gas phase at 503 K and 50 bar with a stream of helium and ethanol. A bifunctional catalyst supported on a synthetic composite based on Mg and high surface area graphite (HSAG) was also studied. Improved catalytic performance in terms of selectivity towards 1-butanol and stability was shown by the Pd catalyst supported on the Mg-HSAG composite after thermal treatment in helium at 723 K, presumably due to the compromise between two parameters: adequate size of the Pd nanoparticles and the concentration of strongly basic sites. The results indicate that the optimal density of strongly basic sites is a key aspect in designing superior bifunctional heterogeneous catalyst systems for the condensation of ethanol to 1-butanol.

Catalytic Upgrading of Ethanol to n-Butanol: Progress in Catalyst Development

Because n-butanol as a fuel additive has more advantageous physicochemical properties than those of ethanol, ethanol valorization to n-butanol through homo- or heterogeneous catalysis has received much attention in recent decades in both scientific and industrial fields. Recent progress in catalyst development for upgrading ethanol to n-butanol, which involves homogeneous catalysts, such as iridium and ruthenium complexes, and heterogeneous catalysts, including metal oxides, hydroxyapatite (HAP), and, in particular, supported metal catalysts, is reviewed herein. The structure-activity relationships of catalysts and underlying reaction mechanisms are critically examined, and future research directions on the design and improvement of catalysts are also proposed.

Hydrogen transfer reactions relevant to Guerbet coupling of alcohols over hydroxyapatite and magnesium oxide catalysts

The rates of double bond hydrogenation, deuterium exchange, and benzyl alcohol dehydrogenation were compared to those of ethanol coupling.

Continuous catalytic upgrading of ethanol to n-butanol over Cu–CeO2/AC catalysts

Cu–CeO₂/AC catalysts exhibited the highest n-butanol yields (21.6% and nearly 20%) under mild reaction conditions in batch and fixed-bed reactors, respectively, which could be ascribed to the synergy of Cu, CeO₂ and the activated carbon support.

A New Process for Maleic Anhydride Synthesis from a Renewable Building Block: The Gas-Phase Oxidehydration of Bio-1-butanol

We investigated the synthesis of maleic anhydride by oxidehydration of a bio-alcohol, 1-butanol, as a possible alternative to the classical process of n-butane oxidation. A vanadyl pyrophosphate catalyst was used to explore the one-pot reaction, which involved two sequential steps: 1) 1-butanol dehydration to 1-butene, catalysed by acid sites, and 2) the oxidation of butenes to maleic anhydride, catalysed by redox sites. A non-negligible amount of phthalic anhydride was also formed. The effect of different experimental parameters was investigated with chemically sourced 1-butanol, and the results were then confirmed by using genuinely bio-sourced 1-butanol. In the case of bio-1-butanol, however, the purity of the product remarkably affected the yield of maleic anhydride. It was found that the reaction mechanism includes the oxidation of butenes to crotonaldehyde and the oxidation of the latter to either furan or maleic acid, both of which are transformed to produce maleic anhydride.

On the chemistry of ethanol on basic oxides: revising mechanisms and intermediates in the Lebedev and Guerbet reactions

A common way to convert ethanol into chemicals is by upgrading it over oxide catalysts with basic features; this method makes it possible to obtain important chemicals such as 1-butanol (Guerbet reaction) and 1,3-butadiene (Lebedev reaction). Despite their long history in chemistry, the details of the close inter-relationship of these reactions have yet to be discussed properly. Our present study focuses on reactivity tests, in situ diffuse reflectance infrared Fourier transform spectroscopy, MS analysis, and theoretical modeling. We used MgO as a reference catalyst with pure basic features to explore ethanol conversion from its very early stages. Based on the obtained results, we formulate a new mechanistic theory able to explain not only our results but also most of the scientific literature on Lebedev and Guerbet chemistry. This provides a rational description of the intermediates shared by the two reaction pathways as well as an innovative perspective on the catalyst requirements to direct the reaction pathway toward 1-butanol or butadiene.

Review of catalytic systems and thermodynamics for the Guerbet condensation reaction and challenges for biomass valorization

This review deals with homogeneous and heterogeneous catalytic processes for the Guerbet condensation, as well as discusses biomass sources, thermodynamics and technological considerations.

Vitamin B1-catalyzed acetoin formation from acetaldehyde: a key step for upgrading bioethanol to bulk C₄ chemicals

The production of bulk chemicals and fuels from renewable biobased feedstocks is of significant importance for the sustainability of human society. The production of ethanol from biomass has dramatically increased and bioethanol also holds considerable potential as a versatile building block for the chemical industry. Herein, we report a highly selective process for the conversion of ethanol to C4 bulk chemicals, such as 2,3-butanediol and butene, via a vitamin B1 (thiamine)-derived N-heterocyclic carbene (NHC)-catalyzed acetoin condensation as the key step to assemble two C2 acetaldehydes into a C4 product. The environmentally benign and cheap natural catalyst vitamin B1 demonstrates high selectivity (99%), high efficiency (97% yield), and high tolerance toward ethanol and water impurities in the acetoin reaction. The results enable a novel and efficient process for ethanol upgrading.

Chemocatalytic conversion of ethanol into butadiene and other bulk chemicals

The development of new and improved processes for the synthesis of bio-based chemicals is one of the scientific challenges of our time. These new discoveries are not only important from an environmental point of view, but also represent an important economic opportunity, provided that the developed processes are selective and efficient. Bioethanol is currently produced from renewable resources in large amounts and, in addition to its use as biofuel, holds considerable promise as a building block for the chemical industry. Indeed, further improvements in production, both in terms of efficiency and feedstock selection, will guarantee availability at competitive prices. The conversion of bioethanol into commodity chemicals, in particular direct 'drop-in' replacements is, therefore, becoming increasingly attractive, provided that the appropriate (catalytic) technology is in place. The production of green and renewable 1,3-butadiene is a clear example of this approach. The Lebedev process for the one-step catalytic conversion of ethanol to butadiene has been known since the 1930s and has been applied on an industrial scale to produce synthetic rubber. Later, the availability of low-cost oil made it more convenient to obtain butadiene from petrochemical sources. The desire to produce bulk chemicals in a sustainable way and the availability of low-cost bioethanol in large volumes has, however, resulted in a renaissance of this old butadiene production process. This paper reviews the catalytic aspects associated with the synthesis of butadiene via the Lebedev process, as well as the production of other, mechanistically related bulk chemicals that can be obtained from (bio)ethanol.

The Challenge of Efficient Synthesis of Biofuels from Lignocellulose for Future Renewable Transportation Fuels

Dehydration of sugars to 5-hydroxymethylfurfural (HMF) has recently been under intensive study by a multitude of research groups. On the other hand, when lignocellulosic biomass is applied as the starting material, very few studies can be found in the open literature. The direct synthesis of HMF, in line with the idea of “one-pot” synthesis strategy from lignocellulose, is demanding since the overall process should encompass dissolution, hydrolysis, and dehydration steps in a single processing unit. Ionic liquid-assisted methods to produce hydroxymethyl-furfural directly from lignocellulosic biomass are reported here together with a short overview of the most important biofuels. In reality, HMF is not suitable to be used as a single-component fuel as such, and, consequently, methods to produce HMF derivatives suitable as liquid fuels are reported.