A review on solid acid catalysis for sustainable production of levulinic acid and levulinate esters from biomass derivatives

Esterification of Levulinic Acid with Different Alcohols Using Mesoporous Stannosilicates As the Catalyst

The mesoporous stannosilicates SnMCM-41-25 and SnMCM-41-80, synthesized, respectively, at 25 and 80 °C and exhibiting a well-ordered hexagonal structure, were applied for the first time as heterogeneous catalysts in the esterification of levulinic acid (LA) with different alcohols. The nonhydrothermal method was effective to obtain materials with a high degree of ordering, high acidity, and promising catalytic activity in this esterification. The SnMCM-41-80 led to conversions of 71.0 and 83.6% in 120 and 180 min, respectively, while the respective values for the material without Sn were 33.2 and 40.1% under the same conditions (MeOH:LA molar ratio of 5:1, 1 wt % catalyst, 3 h, 120 °C). In addition, concerning the use of different alcohols, the reaction rate constants (k ap) were related to the effects of substituents by Taft equation. In general, the polar and steric effects follow the Taft relation, and the length of the chain exerted less influence on the decrease in conversion in comparison to the presence of branches. These results indicate that it is possible to incorporate Sn into the structure of MCM41, thus, making the modified materials more active in the esterification investigated.

From biomass-derived fructose to γ-valerolactone: Process design and techno-economic assessment

This work proposes a process design and techno-economic assessment for the production of γ-valerolactone from lignocellulosic derived fructose at industrial scale, with the aim of exploring its feasibility, identifying potential obstacles, and suggesting improvements in the context of France. First, the conceptual process design is developed, the process modelled and optimized. Second, different potential scenarios for the energy supply to the process are analyzed by means of a set of economic key performance indicators, aimed at highlighting the best potential profitability scenario for the sustainable exploitation of waste biomass in the context analyzed. The lowest Minimum Selling Price for GVL is obtained at 10 kt/y plant fueled by biomass, i.e. 1.89 €/kg, along with the highest end-of-live revenue, i.e. 113 M€. Finally, a sensitivity and uncertainties analysis, based on Monte Carlo simulations, are carried out on the results in order to test their robustness with respect to key input parameters.

Coupling process for preparing biomass-based furfural and levulinic acid from corncob: Extraction, green chemistry and techno-economic assessment

The purpose of this study is to design and investigate two coupling processes for acid-catalyzed hydrolysis of corncob, achieving the simultaneous preparation of biomass-based furfural and levulinic acid (LA). Meanwhile, high concentration and yield of LA were obtained through a situ feeding strategy of pretreated furfural residue with high solids loading (20%, w/v). In Scenario A, 2-methyltetrahydrofuran was selected as the solvent for the LA extraction process compared with the neutralization process in Scenario B. Techno-economic assessment results show that Scenario A is technically feasible and cost-competitive, with an internal rate of return of 21.92%, a net present value of 121 million US dollars, a carbon efficiency of 72%, an environmental factor of 4.38, and a process mass intensity of 32.19. This study will provide new insights for fully utilizing lignocellulosic biomass to prepare renewable energy resources, comprehensively evaluating the economic feasibility, and promoting green and low-carbon development.

Unveiling the mechanisms of carboxylic acid esterification on acid zeolites for biomass-to-energy: A review of the catalytic process through experimental and computational studies

In recent years, there has been significant interest from industrial and academic areas in the esterification of carboxylic acids catalyzed by acidic zeolites, as it represents a sustainable and economically viable approach to producing a wide range of high-value-added products. However, there is a lack of comprehensive reviews that address the intricate reaction mechanisms occurring at the catalyst interface at both the experimental and atomistic levels. Therefore, in this review, we provide an overview of the esterification reaction on acidic zeolites based on experimental and theoretical studies. The combination of infrared spectroscopy with atomistic calculations and experimental strategies using modulation excitation spectroscopy techniques combined with phase-sensitive detection is presented as an approach to detecting short-lived intermediates at the interface of zeolitic frameworks under realistic reaction conditions. To achieve this goal, this review has been divided into four sections: The first is a brief introduction highlighting the distinctive features of this review. The second addresses questions about the topology and activity of different zeolitic systems, since these properties are closely correlated in the esterification process. The third section deals with the mechanisms proposed in the literature. The fourth section presents advances in IR techniques and theoretical calculations that can be applied to gain new insights into reaction mechanisms. Finally, this review concludes with a subtle approach, highlighting the main aspects and perspectives of combining experimental and theoretical techniques to elucidate different reaction mechanisms in zeolitic systems.

Catalytic Conversion of Levulinic Acid into 2-Methyltetrahydrofuran: A Review

Biomass-derived furanics play a pivotal role in chemical industries, with 2-methyltetrahydrofuran (2-MTHF), a hydrogenated product of levulinic acid (LA), being particularly significant. 2-MTHF finds valuable applications in the fuel, polymer, and chemical sectors, serving as a key component in P-series biofuel and acknowledged as a renewable solvent for various chemical processes. Numerous research groups have explored catalytic systems to efficiently and selectively convert LA to 2-MTHF, using diverse metal-supported catalysts in different solvents under batch or continuous process conditions. This comprehensive review delves into the impact of metal-supported catalysts, encompassing co-metals and co-catalysts, on the synthesis of 2-MTHF from LA. The article also elucidates the influence of different reaction parameters, such as temperature, type and quantity of hydrogen source, and time. Furthermore, the review provides insights into reaction mechanisms for all documented catalytic systems.

Direct and efficient conversion of cellulose to levulinic acid catalyzed by carbon foam-supported heteropolyacid with Brønsted-Lewis dual-acidic sites

This study aimed to produce bio-based levulinic acid (LA) via direct and efficient conversion of cellulose catalyzed by a sustainable solid acid. A carbon foam (CF)-supported aluminotungstic acid (HAlW/CF) catalyst with Brønsted-Lewis dual-acidic sites was creatively engineered by a hydrothermal impregnation method. The activity of the HAlW/CF catalyst was determined via the hydrolysis and conversion of cellulose to prepare LA in aqueous system. The cooperative effect of Brønsted and Lewis acids in HAlW/CF resulted in high cellulose conversion (89.4%) and LA yield (60.9%) at 180 °C for 4 h, which were greater than the combined catalytic efficiencies of single HAlW and CF under the same conditions. The HAlW/CF catalyst in block form exhibited superior catalytic activity, facile separation from reaction system, and favorable reusability. This work offers novel perspectives for the development of recyclable dual-acidic catalysts to achieve one-pot catalytic conversion of biomass to value-added chemicals.

Microwave-Assisted One Pot Cascade Conversion of Furfural to γ-Valerolactone over Sc(OTf)3

γ-Valerolactone (GVL) is considered as a star biochemical which can be used as a green solvent, fuel additive and versatile organic intermediate. In this study, metal triflate (M(OTf)n ) was utilized as the catalyst for one-pot transformation of furfural (FF) to GVL in alcohol media under microwave irradiation. Alcohol plays multiple functions including solvent, hydrogen donor and alcoholysis reagent in this cascade reaction process. And process efficiency of GVL production from FF upgrading is strongly related to the effective charge density of selected catalyst and the reduction potential of selected alcohol. Complex (OTf)n -M-O(H)R, presenting both Brønsted acid and Lewis acid, is the real catalytic active species in this cascade reaction process. Among various catalysts, Sc(OTf)3 exhibited the best catalytic activity for GVL production. Various reaction parameters including the Sc(OTf)3 amount, reaction temperature and time were optimized by the response surface methodology with the central composite design (RSM-CCD). Up to 81.2 % GVL yield and 100 % FF conversion were achieved at 143.9 °C after 8.1 h in the presence of 0.16 mmol catalyst. This catalyst exhibits high reusability and can be regenerated by oxidative degradation of humins. In addition, a plausible cascade reaction network was proposed based on the distribution of product.

Covalent Adaptable Polymethacrylate Networks by Hydrazide Crosslinking Via Isosorbide Levulinate Side Groups

Reversible crosslinking offers an attractive strategy to modify and improve the properties of polymer materials while concurrently enabling a pathway for chemical recycling. This can, for example, be achieved by incorporating a ketone functionality into the polymer structure to enable post-polymerization crosslinking with dihydrazides. The resulting covalent adaptable network contains acylhydrazone bonds cleavable under acidic conditions, thereby providing reversibility. In the present work, we regioselectively prepare a novel isosorbide monomethacrylate with a pendant levulinoyl group via a two-step biocatalytic synthesis. Subsequently, a series of copolymers with different contents of the levulinic isosorbide monomer and methyl methacrylate are prepared by radical polymerization. Using dihydrazides, these linear copolymers are then crosslinked via reaction with the ketone groups in the levulinic side chains. Compared to the linear prepolymers, the crosslinked networks exhibit enhanced glass transition temperatures and thermal stability, up to 170 and 286 °C, respectively. Moreover, the dynamic covalent acylhydrazone bonds are efficiently and selectively cleaved under acidic conditions to retrieve the linear polymethacrylates. We next show that recovered polymers can again be crosslinked with adipic dihydrazide, thus demonstrating the circularity of the materials. Consequently, we envision that these novel levulinic isosorbide-based dynamic polymethacrylate networks have great potential in the field of recyclable and reusable biobased thermoset polymers.

Production of Alkyl Levulinates from Carbohydrate-Derived Chemical Intermediates Using Phosphotungstic Acid Supported on Humin-Derived Activated Carbon (PTA/HAC) as a Recyclable Heterogeneous Acid Catalyst

This work reports a straightforward and high-yielding synthesis of alkyl levulinates (ALs), a class of promising biofuel, renewable solvent, and chemical feedstock of renewable origin. ALs were prepared by the acid-catalyzed esterification of levulinic acid (LA) and by the alcoholysis of carbohydrate-derived chemical platforms, such as furfuryl alcohol (FAL) and α-angelica lactone (α-AGL). Phosphotungstic acid (PTA) was chosen as the solid acid catalyst for the transformation, which was heterogenized on humin-derived activated carbon (HAC) for superior recyclability. Using HAC as catalyst support expands the scope of valorizing humin, a complex furanic resin produced inevitably as a side product (often considered waste) during the acid-catalyzed hydrolysis/dehydration of sugars and polymeric carbohydrates. Under optimized conditions (150 °C, 7 h, 25 wt.% of 20%PTA/HAC-600 catalyst), ethyl levulinate (EL) was obtained in an 85% isolated yield starting from FAL. Using the general synthetic protocol, EL was isolated in 88% and 84% yields from LA and α-AGL, respectively. The 20%PTA/HAC-600 catalyst was successfully recovered from the reaction mixture and recycled for five cycles. A marginal loss in the yield of ALs was observed in consecutive catalytic cycles due to partial leaching of PTA from the HAC support.

Ti/Zr/O Mixed Oxides for the Catalytic Transfer Hydrogenation of Furfural to GVL in a Liquid-Phase Continuous-Flow Reactor

This work aims to develop an efficient catalyst for the cascade reaction from furfural to γ-valerolactone in a liquid-phase continuous reactor. This process requires both Lewis and Brønsted acidity; hence, a bifunctional catalyst is necessary to complete the one-pot reaction. Ti/Zr/O mixed oxide-based catalysts were chosen to this end as balancing metal oxide composition allows the acidity characteristics of the overall material to be modulated. Oxides with different compositions were then synthesized using the co-precipitation method. After characterization via porosimetry and NH3-TPD, the catalyst with equimolar quantities of the two components was demonstrated to be the best one in terms of superficial area (279 m2/g) and acid site density (0.67 mmol/g). The synthesized materials were then tested using a plug flow reactor at 180 °C, with a 10 min contact time. Ti/Zr/O (1:1) was demonstrated to be the most promising catalyst during the recycling tests as it allowed obtaining the highest selectivities in the desired products (about 45% in furfuryl isopropyl ether and 20% in γ-valerolactone) contemporaneously with 100% furfural conversion.

Development of bioprocess for corncob-derived levulinic acid production

Levulinic acid is a significant platform chemical obtained from biomass and can potentially be used to produce value-added biofuels, biopolymers, and biopharmaceuticals. This study aims at statistically optimizing levulinic acid production from agrowastes. Based on the total carbohydrate content (71.93 %), corncob was selected as the target feedstock. A Box-Behnken design with four factors, such as feedstock concentration, reaction time, reaction temperature, and catalyst concentration, was used to optimize the hydrothermal conversion of corncob to levulinic acid at 180 °C for 30 min using 1 M H₂SO₄ as the acid catalyst and 120 g/L corncob. The maximum yield of 19.9 % was obtained. Additionally, 8.1 g/L formic acid was co-produced. The results of this study can contribute toward valorization of levulinic acid. Moreover, our results can be useful in developing strategies to utilize agrowastes as a renewable feedstock for recent biorefineries to cope with the climate crisis.

Construction of a stable biochar-supported amorphous aluminum solid acid catalyst with Brønsted–Lewis dual acid sites for efficient conversion of cellulose

The development of sustainable catalysts for the efficient conversion of biomass to desirable chemicals is significant and challenging. Herein, a stable biochar (BC)-supported amorphous aluminum solid acid catalyst with Brønsted-Lewis dual acid sites was constructed through one-step calcination of a mechanical activation (MA)-treated precursor (starch, urea, and Al(NO₃)₃). The as-prepared N-doped BC (N-BC)-supported Al composite (MA-Al/N-BC) was used for the selective catalytic conversion of cellulose to produce levulinic acid (LA). MA treatment promoted uniform dispersion and stable embedding of Al-based components in the N-BC support with nitrogen- and oxygen-containing functional groups. This process provided the MA-Al/N-BC catalyst with Brønsted-Lewis dual acid sites and improved its stability and recoverability. When the MA-Al/N-BC catalyst was used under optimal reaction conditions (180 °C, 4 h), it achieved a cellulose conversion rate of 93.1 % and a LA yield of 70.1 %. Additionally, it also showed high activity for catalytic conversion of other carbohydrates. The results of this study offer a promising solution for the production of sustainable biomass-derived chemicals through the use of stable and eco-friendly catalysts.

Process optimization for enzymatic production of a valuable biomass-based ester from levulinic acid

The enzymatic production of isoamyl levulinate via esterification of isoamyl alcohol (IA) and levulinic acid (LA), a biomass-based platform chemical with attractive properties, in a solvent system has been performed in this study. For such a purpose, a low-cost liquid lipase (Eversa^® Transform 2.0) immobilized by physical adsorption via hydrophobic interactions (mechanism of interfacial activation) on mesoporous poly(styrenene-divinylbenzene) (PSty-DVB) beads was used as heterogeneous biocatalyst. It was prepared at low ionic strength (5 mmol.L^-1 buffer sodium acetate pH 5.0) and 25 ℃ using an initial protein loading of 40 mg.g^-1 of support. Maximum protein loading of 31.2 ± 2.8 mg.g^-1 of support and an immobilization yield of 83% was achieved. The influence of relevant factors (biocatalyst concentration and reaction temperature) on ester production was investigated using a central composite rotatable design (CCRD). Maximum acid conversion percentage of 65% was achieved after 12 h of reaction at 40 °C, 20% of mass of heterogeneous biocatalyst per mass of reaction mixture (20% m.m^-1), and LA:IA molar ratio of 1:1.5 in a methyl isobutyl ketone (MIBK) medium. The biocatalyst retained around of 30% of its initial activity after five consecutive esterification batches under optimal experimental conditions. The proposed experimental procedure can be considered as an acceptable green process (EcoScale score of 66.5), in addition to the fact that a new strategy is proposed to sustainably produce a valuable industrial ester (isoamyl levulinate) from biomass-based materials using an immobilized and low-cost commercial lipase as catalyst.

Alcoholysis of Furfuryl Alcohol to Ethyl Levulinate Catalyzed by a Deep Eutectic Solvent

In this study, the alcoholysis of furfuryl alcohol (FA) into ethyl levulinate (EL) using a deep eutectic solvent (DES) composed of choline chloride (ChCl) and ethanol was investigated by experiments and calculations. Experimental results reveal that the addition of 5-sulfonic acid salicylic acid (5-SSA) can catalyze the alcoholysis of FA to produce EL. The combined presence of ChCl and 5-SSA significantly improved the selectivity for EL. The mechanism of the alcoholysis of FA to EL in acidic DES was investigated by density functional theory (DFT) calculations in Gaussian 03. It was found that hydrogen-bond acceptor ChCl is coupled with hydrogen-bond donor ethanol to form a structure similar to HCl and ethoxy, which facilitates the alcoholysis of FA into EL.

Synthetic Routes for Designing Furanic and Non Furanic Biobased Surfactants from 5-Hydroxymethylfurfural

5-hydroxymethylfurfural (HMF) is one of the most valuable biomass platform molecules, enabling the construction of a plethora of high value-added furanic compounds. In particular, in the last decade, HMF has been considered as a starting material for designing biobased surfactants, not only because of its renewability and carbon footprint, but also because of its enhanced biodegradability. This Review presents recent examples of the different approaches to link the hydrophilic and lipophilic moieties into the hydrophobic furan (and tetrahydrofuran) ring, giving a variety of biobased surfactants that have been classified here according to the charge of the head polar group. Moreover, strategies for the synthesis of different non-furanic structures surfactant molecules (such as levulinic acid, cyclopentanols, and aromatics) derived from HMF are described. The new HMF-based amphiphilic molecules presented here cover a wide range of hydrophilic-lipophilic balance values and have suitable surfactant properties such as surface tension activity and critical micelle concentration, to be an important alternative for the replacement of non-sustainable surfactants.

Titania Nanotubes-Bonded Sulfamic Acid as an Efficient Heterogeneous Catalyst for the Synthesis of n-Butyl Levulinate

The titania nanotubes-bonded sulfamic acid (TNTs-NHSO₃H) catalyst was designed and successfully fabricated by the post-synthesis modification method. The as-prepared catalyst was characterized by a variety of characterization techniques, including Fourier transform infrared (FT-IR) spectroscopy, X-ray photoelectron spectroscopy (XPS), transmission electron microscopy (TEM), scanning electron microscopy (SEM), X-ray diffraction (XRD) analysis, and thermogravimetry-differential thermal gravimetry (TG-DTG). The crystal structure of the TNTs still maintained during the modification process. Although the BET surface area was decreased, the amount of Brønsted acid sites can be efficiently fabricated on the TNTs. The catalytic activity of TNTs-NHSO₃H was examined for the synthesis of n-butyl levulinate (BL) from levulinic acid (LA) and furfuryl alcohol (FA). A relatively high selectivity (99.6%) at 99.3% LA conversion was achieved for esterification of levulinic acid owing to the strong Brønsted acidity sites. And also, the TNTs-NHSO₃H catalyst exhibited a higher reactivity for alcoholysis of FA and the yield of BL reached 90.4% with 100% FA conversion was obtained under the mild conditions.

Efficient Piancatelli rearrangement on a large scale using the Zippertex technology under subcritical water conditions

A series of furyl carbinols, which were directly obtained from a bio-sourced raw material, were efficiently transformed into cyclopentenone derivatives in good yields and on a large scale using the Zippertex technology under subcritical water conditions.

Recyclable Zr/Hf-Containing Acid-Base Bifunctional Catalysts for Hydrogen Transfer Upgrading of Biofuranics: A Review

The massive burning of a large amount of fossil energy has caused a lot of serious environmental issues (e.g., air pollution and climate change), urging people to efficiently explore and valorize sustainable alternatives. Biomass is being deemed as the only organic carbon-containing renewable resource for the production of net-zero carbon emission fuels and fine chemicals. Regarding this, the selective transformation of high-oxygen biomass feedstocks by catalytic transfer hydrogenation (CTH) is a very promising strategy to realize the carbon cycle. Among them, the important Meerwein-Ponndorf-Verley (MPV) reaction is believed to be capable of replacing the traditional hydrogenation strategy which generally requires high-pressure H2 and precious metals, aiming to upgrade biomass into downstream biochemical products and fuels. Employing bifunctional heterogeneous catalysts with both acidic and basic sites is needed to catalyze the MPV reaction, which is the key point for domino/cascade reaction in one pot that can eliminate the relevant complicated separation/purification step. Zirconium (Zr) and hafnium (Hf), belonging to transition metals, rich in reserves, can demonstrate similar catalytic efficiency for MPV reaction as that of precious metals. This review introduced the application of recyclable heterogeneous non-noble Zr/Hf-containing catalysts with acid-base bifunctionality for CTH reaction using the safe liquid hydrogen donor. The corresponding catalysts were classified into different types including Zr/Hf-containing metal oxides, supported materials, zeolites, metal-organic frameworks, metal-organic hybrids, and their respective pros and cons were compared and discussed comprehensively. Emphasis was placed on evaluating the bifunctionality of catalytic material and the key role of the active site corresponding to the structure of the catalyst in the MPV reaction. Finally, a concise summary and prospect were also provided centering on the development and suggestion of Zr/Hf-containing acid-base bifunctional catalysts for CTH.