Catalytic upgrading of levulinic acid to ethyl levulinate using reusable silica-included Wells-Dawson heteropolyacid as catalyst

Perspective of reactive separation of levulinic acid in conceptual mixer settler reactor

Levulinic acid is a carboxylic acid present in industrial downstream. It is an important chemical and can be transformed into various important chemicals such as 1,4-pentanediol, aminolevulinic acid, succinic acid, gamma valarolactone, hydoxyvaleric acid, and diphenolic acid. It is considered one of the top ten most important building block chemicals and bio-derived acids. Levulinic acid can be directly produced using biomass, chemical synthesis, and fermentation processes at industrial and laboratory scales. The biomass process produces the char, whereas the fermentation process generates waste during the production of levulinic acid, leading to an increase in the production cost and waste streams. The separation of levulinic acid from the waste is expensive and challenging. In the present study, reactive extraction was employed using trioctylamine in i-octanol for the separation of levulinic acid. The experimental results were expressed in terms of performance parameters like distribution coefficient (0.099-6.14), extraction efficiency (9-86%), loading ratio (0.09-0.7), and equilibrium complexation constant (11.34-1.05). The mass action law model was also applied and found the predicted values were in close agreement with the experimental results. The mixer settler extraction in series was used to achieve more than 98% separations of acid. Furthermore, the conceptual approach for separation of levulinic acid using a mixer settler reactor scheme was discussed and presented various design parameters including extraction efficiency, diffusion coefficient, equilibrium complexation constant, and loading ratio. The study is helpful in recovering the valuable chemicals present in industrial downstream and reducing their environmental impacts if any.

Solvent Free Upgrading of 5-Hydroxymethylfurfural (HMF) with Levulinic Acid to HMF Levulinate Using Tin Exchanged Tungstophosphoric Acid Supported on K-10 Catalyst

The manufacture of high-value products from biomass derived platform chemicals is becoming an integral part of the biorefinery industry. In this study, we demonstrate a green catalytic process using solvent free conditions for the synthesis of hydroxymethylfurfural (HMF) levulinate from HMF and levulinic acid (LA) over tin exchanged tungstophosphoric acid (DTP) supported on K-10 (montmorillonite K-10 clay) as the catalyst. The structural properties of solid acid catalysts were characterized by using XRD, FT-IR, UV-vis, titration, and SEM techniques. Partial exchange of the H⁺ of DTP with Sn (x = 1) resulted in enhanced acidity of the catalyst and showed an increase in the catalytic activity as compared to the unsubstituted DTP/K-10 as the catalyst. The effects of different reaction parameters were studied and optimized to get high yields of HMF levulinate. The kinetic model was developed by considering the Langmuir-Hinshelwood-Hougen-Watson (LHHW) mechanism, and the activation energy was calculated to be 41.2 kJ mol^-1. The prepared catalysts were easily recycled up to four times without any noticeable loss of activity, and hot filtration test indicated the heterogeneous nature of the catalytic activity. The overall process is environmentally benign and suitable for easy scale up.

Sulfated Well-Defined Mesoporous Nanostructured Zirconia for Levulinic Acid Esterification

Well-organized zirconia (ZrO₂) nanoparticles forming mesoporous materials have been successfully synthesized via a facile micelle-templating method using cetyltrimethylammonium bromide as a structure-directing template to control the nucleation/growth process and porosity. The systematic use of such a surfactant in combination with a microwave-assisted solvothermal (cyclohexane/water) reaction enabled the control of pore size in a narrow-size distribution range (3-17 nm). The effect of solvent mixture ratio on the porosity of the synthesized oxide was determined, and the controlled growth of zirconia nanoparticles was confirmed by means of powder X-ray diffraction, small-angle X-ray scattering, transmission electron microscopy, selected area electron diffraction, high-resolution transmission electron microscopy, X-ray photoelectron spectroscopy, thermogravimetric analysis, and Fourier transform infrared spectroscopy as well as N₂ physisorption isotherm analysis. Then, the as-prepared nanostructured zirconia oxides were treated with sulfuric acid to have sulfated samples. The catalytic performances of these mesoporous zirconia nanoparticles and their sulfated samples were tested for levulinic acid (LA) esterification by ethanol, with quantitative conversions of LA to ethyl levulinate after 8 h of reaction.

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

Biomass is a kind of renewable and abundant resource that can be seen as an important candidate to solve the energy crisis. Levulinic acid (LA) and levulinate esters (LEs) have been widely researched as biomass-based platform compounds. In recent years, efficient, green, and environment-friendly solid acid catalysts have been developed for the fast production and resolution of the problems, such as low yield, high equipmental requirements, and difficulty in product separation, in the preparation of LA and LE from biomass. In this paper, the preparation routes of LA and LEs from various raw materials are introduced, and the solid acid catalysts involved in their production are emphatically reviewed. The challenges and prospects in LA and LE production from biomass are proposed to achieve a more economical and energy efficient process with the concept of sustainable development in the future.

Ozonolysis of α-angelica lactone: a renewable route to malonates

Industrially relevant intermediates such as malonic acid, malonates and 3-oxopropionates can be easily accessed by ozonolysis of α-angelica lactone, derived from the platform chemical levulinic acid. The roles of the solvent and of the quenching conditions are of key importance for the outcome of the reaction.

Reactive Chromatography Applied to Ethyl Levulinate Synthesis: A Proof of Concept

Levulinic acid (LA) has been highlighted as one of the most promising platform chemicals, providing a wide range of possible derivatizations to value-added chemicals as the ethyl levulinate obtained through an acid catalyzed esterification reaction with ethanol that has found application in the bio-fuel market. Being a reversible reaction, the main drawback is the production of water that does not allow full conversion of levulinic acid. The aim of this work was to prove that the chromatographic reactor technology, in which the solid material of the packed bed acts both as stationary phase and catalyst, is surely a valid option to overcome such an issue by overcoming the thermodynamic equilibrium. The experiments were conducted in a fixed-bed chromatographic reactor, packed with Dowex 50WX-8 as ion exchange resin. Different operational conditions were varied (e.g., temperature and flow rate), pulsing levulinic acid to the ethanol stream, to investigate the main effects on the final conversion and separation efficiency of the system. The effects were described qualitatively, demonstrating that working at sufficiently low flow rates, LA was completely converted, while at moderate flow rates, only a partial conversion was achieved. The system worked properly even at room temperature (303 K), where LA was completely converted, an encouraging result as esterification reactions are normally performed at higher temperatures.

Intensification of Processes for the Production of Ethyl Levulinate Using AlCl3·6H2O

A process for obtaining ethyl levulinate through the direct esterification of levulinic acid and ethanol using AlCl3·6H2O as a catalyst was investigated. AlCl3·6H2O was very active in promoting the reaction and, the correspondent kinetic and thermodynamic data were determined. The reaction followed a homogeneous second-order reversible reaction model: in the temperature range of 318–348 K, Ea was 56.3 kJ·K−1·mol−1, whereas Keq was in the field 2.37–3.31. The activity of AlCl3·6H2O was comparable to that of conventional mineral acids. Besides, AlCl3·6H2O also induced a separation of phases in which ethyl levulinate resulted mainly (>98 wt%) dissolved into the organic upper layer, well separated by most of the co-formed water, which decanted in the bottom. The catalyst resulted wholly dissolved into the aqueous phase (>95 wt%), allowing at the end of a reaction cycle, complete recovery, and possible reuse for several runs. With the increase of the AlCl3·6H2O content (from 1 to 5 mol%), the reaction proceeded fast, and the phases’ separation improved. Such a behavior eventually results in an intensification of processes of reaction and separation of products and catalyst in a single step. The use of AlCl3·6H2O leads to a significant reduction of energy consumed for the final achievement of ethyl levulinate, and a simplification of line-processes can be achieved.

Comparative analysis of the chemical and biochemical synthesis of keto acids

Keto acids are essential organic acids that are widely applied in pharmaceuticals, cosmetics, food, beverages, and feed additives as well as chemical synthesis. Currently, most keto acids on the market are prepared via chemical synthesis. The biochemical synthesis of keto acids has been discovered with the development of metabolic engineering and applied toward the production of specific keto acids from renewable carbohydrates using different metabolic engineering strategies in microbes. In this review, we provide a systematic summary of the types and applications of keto acids, and then summarize and compare the chemical and biochemical synthesis routes used for the production of typical keto acids, including pyruvic acid, oxaloacetic acid, α-oxobutanoic acid, acetoacetic acid, ketoglutaric acid, levulinic acid, 5-aminolevulinic acid, α-ketoisovaleric acid, α-keto-γ-methylthiobutyric acid, α-ketoisocaproic acid, 2-keto-L-gulonic acid, 2-keto-D-gluconic acid, 5-keto-D-gluconic acid, and phenylpyruvic acid. We also describe the current challenges for the industrial-scale production of keto acids and further strategies used to accelerate the green production of keto acids via biochemical routes.

The selective conversion of furfuryl alcohol to ethyl levulinate over Zr-modified tungstophosphoric acid supported on β-zeolites

Catalysts of zirconium-exchanged proton-containing tungstophosphoric acid (TPA) supported on β-zeolites were prepared by an impregnation method for the selective alcoholysis of furfuryl alcohol into ethyl levulinate.

Current Approaches to Alkyl Levulinates via Efficient Valorization of Biomass Derivatives

Biomass is a potential non-food, carbon-neutral, and abundant resource, which can be used as an alternative to fossil fuels during the sustainable preparation of various platform chemicals. Alkyl levulinates (ALs) have found widespread application as flavorings, plasticizing agents, and fuel additives, as well as synthetic precursors to various building blocks. Several processes have been investigated to transform biomass and its derivatives into ALs, which mainly include: (i) direct esterification of levulinic acid (LA) with alkyl alcohols and (ii) alcoholysis reactions of renewable biomass feedstocks and their derivatives, including furfuryl alcohol (FAL), chloromethyl furfural (CMF), and saccharides. This review focuses on illustrating the effects of the biomass pretreatment step, catalyst texture, possible mechanisms, acidities, and intermediates on the synthesis of ALs from sustainable resources covering a wide range of intermediates, including diethyl ether (DEE), 4,5,5-triethoxypentan-2-one (TEP), ethoxymethylfuran (EMF), ethyl-D-fructofuranoside (EDFF), and ethyl-D-glucopyranoside (EDGP).

Topotactic transformation of homogeneous phosphotungastomolybdic acid materials to heterogeneous solid acid catalyst for carbohydrate conversion to alkyl methylfurfural and alkyl levulinate

The strong interaction of higher transition metal oxides with inorganic non-metals can be promising for generating highly acidic three-dimensional materials by design. A comprehensive controlled acidity of heteropolyacid-like catalyst and interpretation of the microstructure and mechanism of the formation of a versatile heterogeneous solid acid catalyst, HPW₄Mo₁₀O_x has been heterogenized by biomass-derived cystine as organic linkers to control the acidity of as-synthesized materials, which have greater acidity and complexity in separation from the reaction mixture. The new and unique results obtained in catalysis done in biphasic reaction. Cystine binds to the surface of HPW₄Mo₁₀O_x, and the topotactic transition occurred, change the morphology and lattice parameter. We described here a sustainable transformation of highly acidic (0.84 mmol g⁻¹) heteropoly acid (HPW₄Mo₁₀O_x) to cystine anchored on the active surface of the heteropoly acid and controlled the acidity (0.63 mmol g⁻¹) and heterogenized the materials. As synthesized materials have been showing that for the direct formation of alkyl levulinate and furanics intermediate from carbohydrates. HPW₄Mo₁₀O_x and HPW₄Mo₁₀O_x-Cys, act as acidic catalyst, and catalyse the mono- and disaccharides that are dissolved in primary and secondary alcohols to alkyl levulinate (AL) and alkyl methylfurfural at 170 °C under microwave irradiation with glucose as the substrate, AL yield reaches 62% with 84.95% selectivity. The catalyst can be easily recovered by filtration and minimum five times reused after calcination without any substantial change in the product selectivity. The analytical analysis of as-synthesis materials done by NH₃-TPD, BET, XRD, FESEM, TEM, HRTEM, FTIR, ATR, TGA, DTA to stabilized the morphology and acidity controlled mechanism.

The strong interaction of higher transition metal oxides with inorganic non-metals can be promising for generating highly acidic three-dimensional materials by design.

Study of a recycling reaction system for catalytic transformation of biomass-based carbohydrates via acidic-polar biphasic conditions

Ethyl levulinate was easily produced via one-pot conversion of sucrose under a reusable biphasic system over an active/stable acid catalyst.

Conversion of Furfuryl Alcohol into Ethyl Levulinate over Glucose-Derived Carbon-Based Solid Acid in Ethanol

In this study, a carbon-based solid acid was created through the sulfonation of carbon obtained from the hydrothermal pretreatment of glucose. Additionally, ethyl levulinate, a viable liquid biofuel, was produced from furfuryl alcohol using the environmentally benign and low-cost catalyst in ethanol. Studies for optimizing the reaction conditions, such as reaction time, temperature, and catalyst loading, were performed. Under the optimal conditions, a maximum ethyl levulinate yield of 67.1% was obtained. The recovered catalyst activity (Ethyl levulinate yield 57.3%) remained high after being used four times, and it was easily regenerated with a simple sulfonation process. Moreover, the catalyst was characterized using FT-IR, XRD, SEM, elemental analysis, and acid-base titration techniques.

Lewis-Brønsted acid catalysed ethanolysis of the organic fraction of municipal solid waste for efficient production of biofuels

A combined Lewis-Brønsted acid ethanolysis of sugars was thoroughly investigated with the aim of producing ethyl levulinate (EL) in a single step. Ethanolysis carried out at 453 K for 4 h using H₂SO₄ (1 wt%) and AlCl₃·6H₂O (30 mol % with respect to sugars) produced a yield of 60 mol % of EL respect to glucose and starch. Such optimised conditions were positively applied directly on different food waste, preliminarily characterised and found to be mainly composed by simple (10-15%) and relatively complex sugars (20-60%), besides proteins (6-10%) and lipids (4-10%), even in their wet form. The catalytic system resulted robust enough to the point that the copresence of proteins, lignin, lipids and mineral salts not only did not negatively affect the overall reactivity, but resulted efficiently converted into soluble species, and specifically, into other liquid biofuels of different nature.

Supported cobalt catalysts for the selective hydrogenation of ethyl levulinate to various chemicals

Biomass-derived ethyl levulinate can flexibly convert to GVL, EHP, 1,4-PDO and 2-MTHF with excellent selectivity on a supported cobalt catalyst.