Modified versions of sulfated zirconia as catalysts for the conversion of xylose to furfural

Towards efficient and greener processes for furfural production from biomass: A review of the recent trends

As mentioned in several recent reviews, biomass-based furfural is attracting increasing interest as a feasible alternative for the synthesis of a wide range of non-petroleum-derived compounds. However, the lack of environmentally friendly, cost-effective, and sustainable industrial procedures is still evident. This review describes the chemical and biological routes for furfural production. The mechanisms proposed for the chemical transformation of xylose to furfural are detailed, as are the current advances in the manufacture of furfural from biomass. The main goal is to overview the different ways of improving the furfural synthesis process. A pretreatment process, particularly chemical and physico-chemical, enhances the digestibility of biomass, leading to the production of >70 % of available sugars for the production of valuable products. The combination of heterogeneous (zeolite and polymeric solid) catalyst and biphasic solvent system (water/GVL and water/CPME) is regarded as an attractive approach, affording >75 % furfural yield for over 80 % of selectivity with the possibility of catalyst reuse. Microwave heating as an activation technique reduces reaction time at least tenfold, making the process more sustainable. The state of the art in industrial processes is also discussed. It shows that, when sulfuric acid is used, the furfural yields do not exceed 55 % for temperatures close to 180 °C. However, the MTC process recently achieved an 83 % yield by continuously removing furfural from the liquid phase. Finally, the CIMV process, using a formic acid/acetic acid mixture, has been developed. The economic aspects of furfural production are then addressed. Future research will be needed to investigate scaling-up and biological techniques that produce acceptable yields and productivities to become commercially viable and competitive in furfural production from biomass.

Role of Sulfation of Zirconia Catalysts in Vapor Phase Ketonization of Acetic Acid

The effect of the sulfation of zirconia catalysts on their structure, acidity/basicity, and catalytic activity/selectivity toward the ketonization of organic acids is investigated by a combined experimental and computational method. Here, we show that, upon sulfation, zirconia catalysts exhibit a significant increase in their Brønsted and Lewis acid strength, whereas their Lewis basicity is significantly reduced. Such changes in the interplay between acid-base sites result in an improvement of the selectivity toward the ketonization process, although the measured conversion rates show a significant drop. We report a detailed DFT investigation of the putative surface species on sulfated zirconia, including the possible formation of dimeric pyrosulfate (S₂O₇ ^2-) species. Our results show that the formation of such a dimeric system is an endothermic process, with energy barriers ranging between 60.0 and 70.0 kcal mol^-1, and which is likely to occur only at high SO₄ ^2- coverages (4 S/nm²), high temperatures, and dehydrating conditions. Conversely, the formation of monomeric species is expected at lower SO₄ ^2- coverages, mild temperatures, and in the presence of water, which are the usual conditions experienced during the chemical upgrading of biofuels.

Guerbet Reactions for Biofuel Production from ABE Fermentation Using Bifunctional Ni-MgO-Al2O3 Catalysts

To upgrade biomass-derived alcohol mixtures to biofuels under solvent-free conditions, MgO–Al2O3 mixed metal oxides (MMO) decorated with Ni nanoparticles (Ni–MgO–Al2O3) are synthesized and characterized. Based on the result, Ni nanoparticles are highly dispersed on the surface of MgAl MMO. As the Ni loading content varies from 2 to 10 wt.%, there is a slight increase in the mean Ni particle size from 6.7 to 8.5 nm. The effects of Ni loading amount, reducing temperature, and Mg/Al ratio on the conversion and product distribution are investigated. With the increase in both the Ni loading amount and reducing temperature, dehydrogenation (the first step of the entire reaction network) is accelerated. This results in an increase in the conversion process and a higher selectivity for the dialkylated compounds. Due to the higher strength and density of basic sites under high Mg/Al ratios, double alkylation is preferred and more long-chain hydrocarbons are obtained. A conversion of 89.2% coupled with a total yield of 79.9% for C5–C15 compounds is acquired by the as-prepared catalyst (prepared with Ni loading of 6 wt.%, reducing temperature of 700 °C, and Mg/Al molar ratio of 3. After four runs, the conversion drops by 17.1%, and this loss in the catalytic activity can be attributed to the decrease in the surface area of the catalyst and the increase in the Ni mean particle size.

Catalytic conversion of corncob to furfuryl alcohol in tandem reaction with tin-loaded sulfonated zeolite and NADPH-dependent reductase biocatalyst

In this study, tin-loaded sulfonated zeolite (Sn-zeolite) catalyst was synthesized for catalysis of raw corncob (75.0 g/L) to 103.0 mM furfural at 52.3% yield in water (pH 1.0) at 170 °C. This corncob-derived furfural was subsequently biotransformed with recombinant E. coli CG-19 cells coexpressing NADPH-dependent reductase and glucose dehydrogenase at 35 °C by supplementary of glucose (1.5 mol glucose/mol furfural), sodium dodecyl sulfate (0.50 mM) and NADP⁺ (1.0 μmol NADP⁺/mmol furfural) in the aqueous catalytic media (pH 7.5). Both sodium dodecyl sulfate (0.50 mM) and Sn⁴⁺ (1.0 mM) could promote reductase activity by 1.4-folds. Within 3 h, furfural was wholly catalyzed into furfuryl alcohol. By combining chemical catalysis with Sn-zeolite and biocatalysis with CG-19 cells in one-pot, an effective and sustainable process was established for tandemly catalyzing renewable biomass into furfuryl alcohol under environmentally-friendly way.

One-pot conversion of alginic acid into furfural using Amberlyst-15 as a solid acid catalyst in γ-butyrolactone/water co-solvent system

One-pot conversion of alginic acid, which was derived from brown algae, to furfural was investigated using various solid acid catalysts. Among the solid acid catalysts tested, Amberlyst-15 showed the highest activity in furfural production in aqueous media. When the effect of reaction media was examined by applying various organic solvent mixtures, it was found that γ-butyrolactone/water co-solvent system was selected as the most appropriate system for the reaction. Maximum furfural yield of 32.2% was obtained using Amberlyst-15 in the γ-butyrolactone/H₂O at 210 °C for 20 min. Catalyst showed gradual deactivation behavior as the reaction proceeded, although the catalyst recovered its activity upon the simple treatment with sulfuric acid. N₂ adsorption-desorption experiments, Fourier-transform infrared spectroscopy (FT-IR), back titration, and CHNS analysis were applied to investigate the physicochemical property of post-reaction samples, confirming that the leaching of the active sulfonic acid group and decrease in acid density was the major cause of deactivation.

Bimetallic Pd-Au/SiO2 Catalysts for Reduction of Furfural in Water

Catalytic systems based on bimetallic Pd-Au particles deposited on SiO2 were prepared by ultrasonically assisted water impregnation and used in the hydrogenation of furfural obtained by the acidic hydrolysis of waste biomass (brewery’s spent grain) in aqueous phase. Pd-Au/SiO2 catalysts containing 50 g of Pd and 2–100 g of Au per 1 kg of catalyst were characterized by high activity in the studied process and, depending on the Pd/Au ratio, selectivity to 2-methyloxolan-2-ol. The modification of 5%Pd/SiO2 by Au leads to the formation of dispersed Au-Pd solid solution phases, which was confirmed by XRD, XPS, ToF-SIMS, SEM-EDS, and H2-TPR techniques. The effect of dilution of surface palladium by gold atoms is probably crucial for modification of the reaction mechanism and formation of 2-methyloxolan-2-ol as the main product.

Efficient Synthesis of Furfural from Biomass Using SnCl₄ as Catalyst in Ionic Liquid

Furfural is a versatile platform molecule for the synthesis of various chemicals and fuels, and it can be produced by acid-catalyzed dehydration of xylose derived from renewable biomass resources. A series of metal salts and ionic liquids were investigated to obtain the best combination of catalyst and solvent for the conversion of xylose into furfural. A furfural yield of 71.1% was obtained at high xylose loading (20 wt%) from the single-phasic reaction system whereby SnCl₄ was used as catalyst and ionic liquid 1-ethyl-3-methylimidazolium bromide (EMIMBr) was used as reaction medium. Moreover, the combined catalyst consisting of 5 mol% SnCl₄ and 5 mol% MgCl₂ also produced a high furfural yield (68.8%), which was comparable to the furfural yield obtained with 10 mol% SnCl₄. The water⁻organic solvent biphasic systems could improve the furfural yield compared with the single aqueous phase. Although these organic solvents could form biphasic systems with ionic liquid EMIMBr, the furfural yield decreased remarkably compared with the single EMIMBr phase. Besides, the EMIMBr/SnCl₄ system with appropriate water was also efficient to convert xylan and lignocellulosic biomass corn stalk into furfural, obtaining furfural yields as high as 57.3% and 54.5%, respectively.

Hydrolysis of Hemicellulose and Derivatives-A Review of Recent Advances in the Production of Furfural

Biobased production of furfural has been known for decades. Nevertheless, bioeconomy and circular economy concepts is much more recent and has motivated a regain of interest of dedicated research to improve production modes and expand potential uses. Accordingly, this review paper aims essentially at outlining recent breakthroughs obtained in the field of furfural production from sugars and polysaccharides feedstocks. The review discusses advances obtained in major production pathways recently explored splitting in the following categories: (i) non-catalytic routes like use of critical solvents or hot water pretreatment, (ii) use of various homogeneous catalysts like mineral or organic acids, metal salts or ionic liquids, (iii) feedstock dehydration making use of various solid acid catalysts; (iv) feedstock dehydration making use of supported catalysts, (v) other heterogeneous catalytic routes. The paper also briefly overviews current understanding of furfural chemical synthesis and its underpinning mechanism as well as safety issues pertaining to the substance. Eventually, some remaining research topics are put in perspective for further optimization of biobased furfural production.

Furfural production using ionic liquids: A review

Furfural, a platform chemical with a bright future, is commercially obtained by acidic processing of xylan-containing biomass in aqueous media. Ionic liquids (ILs) can be employed in processed for furfural manufacture as additives, as catalysts and/or as reaction media. Depending on the IL utilized, externally added catalysts (usually, Lewis acids, Brönsted acids and/or solid acid catalysts) can be necessary to achieve high reaction yields. Oppositely, acidic ionic liquids (AILs) can perform as both solvents and catalysts, enabling the direct conversion of suitable substrates (pentoses, pentosans or xylan-containing biomass) into furfural. Operating in IL-containing media, the furfural yields can be improved when the product is continuously removed along the reaction (for example, by stripping or extraction), to avoid unwanted side-reactions leading to furfural consumption. These topics are reviewed, as well as the major challenges involved in the large scale utilization of ILs for furfural production.

Genesis of a bi-functional acid–base site on a Cr-supported layered double hydroxide catalyst surface for one-pot synthesis of furfurals from xylose with a solid acid catalyst

The cross boundary between Cr³⁺ oxide and Mg–Al LDH generates highly active bi-functional acid–base sites for xylose isomerization.

Beta zeolite: a universally applicable catalyst for the conversion of various types of saccharides into furfurals

Beta zeolite having both Lewis and Brønsted acid sites universally promoted direct conversion of various types of saccharides into furfurals.

Conversion of xylose into furfural using lignosulfonic acid as catalyst in ionic liquid

Preparation of biopolymer-based catalysts for the conversion of carbohydrate polymers to new energies and chemicals is a hot topic nowadays. With the aim to develop an ecological method to convert xylose into furfural without the use of inorganic acids, a biopolymer-derived catalyst (lignosulfonic acid) was successfully used to catalyze xylose into furfural in ionic acid ([BMIM]Cl). The characteristics of lignosulfonic acid (LS) and effects of solvents, temperature, reaction time, and catalyst loading on the conversion of xylose were investigated in detail, and the reusability of the catalytic system was also studied. Results showed that 21.0% conversion could be achieved at 100 °C for 1.5 h. The method not only avoids pollution from conventional mineral acid catalysts and organic liquids but also maked full use of a byproduct (lignin) from the pulp and paper industry, thus demonstrating an environmentally benign process for the conversion of carbohydrates into furfural.

Catalytic hydrothermal pretreatment of corncob into xylose and furfural via solid acid catalyst

Selectively catalytic hydrothermal pretreatment of corncob into xylose and furfural has been developed in this work using solid acid catalyst (SO4(2-)/TiO2-ZrO2/La(3+)). The effects of corncob-to-water ratio, reaction temperature and residence time on the performance of catalytic hydrothermal pretreatment were investigated. Results showed that the solid residues contained mainly lignin and cellulose, which was indicative of the efficient removal of hemicelluloses from corncob by hydrothermal method. The prepared catalyst with high thermal stability and strong acid sites originated from the acid functional groups was confirmed to contribute to the hydrolysis of polysaccharides into monosaccharides followed by dehydration into furfural. Highest furfural yield (6.18 g/100g) could be obtained at 180°C for 120 min with 6.80 g/100g xylose yield when the corncob/water ratio of was 10:100. Therefore, selectively catalytic hydrothermal pretreatment of lignocellulosic biomass into important platform chemicals by solid acids is considered to be a potential treatment for biodiesel and chemical production.

Dehydration of xylose and glucose to furan derivatives using bifunctional partially hydroxylated MgF2 catalysts and N2-stripping

The current furfural production yield is low due to the use of non-selective homogeneous catalysts and expensive separation.

One-pot synthesis of furfural derivatives from pentoses using solid acid and base catalysts

One-pot synthesis of (2-furanylmethylene)malononitrile, a Knoevenagel product of furfural with malononitrile, from xylose efficiently proceeded by combined use of acid Amberlyst-15 and acid-base Cr/hydrotalcites in 44% yield.

Production of furfural from pentosan-rich biomass: analysis of process parameters during simultaneous furfural stripping

Among the furan-based compounds, furfural (FUR) shows interesting properties as building-block or industrial solvent. It is produced from pentosan-rich biomass via xylose cyclodehydration. The current FUR production makes use of homogeneous catalysts and excessive amounts of steam. The development of greener furfural production and separation techniques implies the use of heterogeneous catalysts and innovative separation processes. This work deals with the conversion of corncobs as xylose source to be dehydrated to furfural. The results reveal differences between the use of direct corncob hydrolysis and dehydration to furfural and the prehydrolysis and dehydration procedures. Moreover, this work focuses on an economical analysis of the main process parameters during N2-stripping and its economical comparison to the current steam-stripping process. The results show a considerable reduction of the annual utility costs due to use of recyclable nitrogen and the reduction of the furfural purification stages.

Dehydration of xylose to furfural over MCM-41-supported niobium-oxide catalysts

A series of silica-based MCM-41-supported niobium-oxide catalysts are prepared, characterized by using XRD, N2 adsorption-desorption, X-ray photoelectron spectroscopy, Raman spectroscopy, and pyridine adsorption coupled to FTIR spectroscopy, and tested for the dehydration of D-xylose to furfural. Under the operating conditions used all materials are active in the dehydration of xylose to furfural (excluding the MCM-41 silica support). The xylose conversion increases with increasing Nb2 O5 content. At a loading of 16 wt % Nb2 O5 , 74.5 % conversion and a furfural yield of 36.5 % is achieved at 170 °C, after 180 min reaction time. Moreover, xylose conversion and furfural yield increase with the reaction time and temperature, attaining 82.8 and 46.2 %, respectively, at 190 °C and after 100 min reaction time. Notably, the presence of NaCl in the reaction medium further increases the furfural yield (59.9 % at 170 °C after 180 min reaction time). Moreover, catalyst reutilization is demonstrated by performing at least three runs with no loss of catalytic activity and without the requirement for an intermediate regeneration step. No significant niobium leaching is observed, and a relationship between the structure of the catalyst and the activity is proposed.

A one-pot method for the selective conversion of hemicellulose from crop waste into C5 sugars and furfural by using solid acid catalysts

We present a solid-acid catalyzed one-pot method for the selective conversion of solid hemicellulose without its separation from other lignocellulosic components, such as cellulose and lignin. The reactions were carried out in aqueous and biphasic media to yield xylose, arabinose, and furfural. To overcome the drawbacks posed by mineral acid methods in converting hemicelllulose, we used heterogeneous catalysts that work at neutral pH. In a batch reactor, these heterogeneous catalysts, such as solid acids (zeolites, clays, metal oxides etc.), resulted in >90 % conversion of hemicellulose. It has been shown that the selectivity for the products can be tuned by changing the reaction conditions, for example, a reaction carried out in water at 170 °C for 1 h with HBeta (Si/Al=19) and HUSY (Si/Al=15) catalysts gave yields of 62 and 56 % for xylose and arabinose, respectively. With increased reaction time (6 h) and in presence of only water, HUSY resulted in yields of 30 % xylose + arabinose and 18 % furfural. However, in a biphasic reaction system (water + p-xylene, 170 °C, 6 h) yields of 56 % furfural with 17 % xylose+arabinose could be achieved. It was shown that with the addition of organic solvent the furfural yield could be increased from 18 to 56 %. Under optimized reaction conditions, >90 % carbon balance was observed. The study revealed that catalysts were recyclable with a 20 % drop in activity for each subsequent run. It was observed that temperature, pressure, reaction time, substrate to catalyst ratio, solvent, and so forth had an effect on product formation. The catalysts were characterized by means of X-ray diffraction, temperature-programmed desorption of NH(3), inductively coupled plasma spectroscopy, elemental analysis, and solid-state NMR ((29)Si, (27)Al) spectroscopy techniques.