Vapor-phase hydrogenation of levulinic acid and methyl levulinate to γ-valerolactone over non-noble metal-based catalysts

Modeling and Thermodynamic Studies of γ-Valerolactone Production from Bio-derived Methyl Levulinate

The exploitation of biomass to reduce the dependency on fossil fuels represents a challenge that needs to be solved as soon as possible. Nowadays, one of the most fashionable processes is γ-valerolactone (GVL) production from bio-derived methyl levulinate (ML). Deep understanding of the thermodynamic aspects involved in this process is key for a successful outcome, but detailed studies are missing in the existing literature. A thermodynamic study of the reaction of γ-valerolactone (GVL) production from bio-derived methyl levulinate (ML) is performed by the Gibbs free energy minimization method. The effect of various reaction conditions (temperature, concentration, flow rate) and the implication of possible intermediates and byproducts are assessed. Conversion and selectivity are calculated from the simulation of the ML hydrogenation using isopropanol as the hydrogen donor under continuous flow conditions. Significant increases in GVL selectivity can be achieved under dry conditions, keeping the high conversion. Comparison between theoretical and experimental results from a previous article discloses the effect of using 5%RuTiO₂ catalysts, which increases the selectivity from 3-40% to 41-98%. Enthalpy and Gibbs free energy of the reactions at issue are also calculated from models using Barin equations according to Aspen Physical Property System parameters.

Hydrogenation of Carboxylic Acids, Esters, and Related Compounds over Heterogeneous Catalysts: A Step toward Sustainable and Carbon-Neutral Processes

The catalytic hydrogenation of esters and carboxylic acids represents a fundamental and important class of organic transformations, which is widely applied in energy, environmental, agricultural, and pharmaceutical industries. Due to the low reactivity of the carbonyl group in carboxylic acids and esters, this type of reaction is, however, rather challenging. Hence, specifically active catalysts are required to achieve a satisfactory yield. Nevertheless, in recent years, remarkable progress has been made on the development of catalysts for this type of reaction, especially heterogeneous catalysts, which are generally dominating in industry. Here in this review, we discuss the recent breakthroughs as well as milestone achievements for the hydrogenation of industrially important carboxylic acids and esters utilizing heterogeneous catalysts. In addition, related catalytic hydrogenations that are considered of importance for the development of cleaner energy technologies and a circular chemical industry will be discussed in detail. Special attention is paid to the insights into the structure-activity relationship, which will help the readers to develop rational design strategies for the synthesis of more efficient heterogeneous catalysts.

The Role of Copper in the Hydrogenation of Furfural and Levulinic Acid

Currently, there is a great interest in the development of sustainable and green technologies for production of biofuels and chemicals. In this sense, much attention is being paid to lignocellulosic biomass as feedstock, as alternative to fossil-based resources, inasmuch as its fractions can be transformed into value-added chemicals. Two important platform molecules derived from lignocellulosic sugars are furfural and levulinic acid, which can be transformed into a large spectrum of chemicals, by hydrogenation, oxidation, or condensation, with applications as solvents, agrochemicals, fragrances, pharmaceuticals, among others. However, in many cases, noble metal-based catalysts, scarce and expensive, are used. Therefore, an important effort is performed to search the most abundant, readily available, and cheap transition-metal-based catalysts. Among these, copper-based catalysts have been proposed, and the present review deals with the hydrogenation of furfural and levulinic acid, with Cu-based catalysts, into several relevant chemicals: furfuryl alcohol, 2-methylfuran, and cyclopentanone from FUR, and γ-valerolactone and 2-methyltetrahydrofuran from LA. Special emphasis has been placed on catalytic processes used (gas- and liquid-phase, catalytic transfer hydrogenation), under heterogeneous catalysis. Moreover, the effect of addition of other metal to Cu-based catalysts has been considered, as well as the issue related to catalyst stability in reusing studies.

γ-Valerolactone Production from Levulinic Acid Hydrogenation Using Ni Supported Nanoparticles: Influence of Tungsten Loading and pH of Synthesis

γ-Valerolactone (GVL) has been considered an alternative as biofuel in the production of carbon-based chemicals; however, the use of noble metals and corrosive solvents has been a problem. In this work, Ni supported nanocatalysts were prepared to produce γ-Valerolactone from levulinic acid using methanol as solvent at a temperature of 170 °C utilizing 4 MPa of H₂. Supports were modified at pH 3 using acetic acid (CH₃COOH) and pH 9 using ammonium hydroxide (NH₄OH) with different tungsten (W) loadings (1%, 3%, and 5%) by the Sol-gel method. Ni was deposited by the suspension impregnation method. The catalysts were characterized by various techniques including XRD, N₂ physisorption, UV-Vis, SEM, TEM, XPS, H₂-TPR, and Pyridine FTIR. Based on the study of acidity and activity relation, Ni dispersion due to the Lewis acid sites contributed by W at pH 9, producing nanoparticles smaller than 10 nm of Ni, and could be responsible for the high esterification activity of levulinic acid (LA) to Methyl levulinate being more selective to catalytic hydrogenation. Products and by-products were analyzed by ¹H NMR. Optimum catalytic activity was obtained with 5% W at pH 9, with 80% yield after 24 h of reaction. The higher catalytic activity was attributed to the particle size and the amount of Lewis acid sites generated by modifying the pH of synthesis and the amount of W in the support due to the spillover effect.

Supported Bimetallic Catalysts for the Solvent-Free Hydrogenation of Levulinic Acid to γ-Valerolactone: Effect of Metal Combination (Ni-Cu, Ni-Co, Cu-Co)

γ-valerolactone (GVL) is an important value-added chemical with potential applications as a fuel additive, a precursor for valuable chemicals, and polymer synthesis. Herein, different monometallic and bimetallic catalysts supported on γ-Al2O3 nanofibers (Ni, Cu, Co, Ni-Cu, Ni-Co, Cu-Co) were prepared by the incipient wetness impregnation method and employed in the solvent-free hydrogenation of levulinic acid (LA) to GVL. The influence of metal loading, metal combination, and ratio on the activity and selectivity of the catalysts was investigated. XRD, SEM-EDS, TEM, H2-TPR, XPS, NH3-TPD, and N2 adsorption were used to examine the structure and properties of the catalysts. In this study, GVL synthesis involves the single-step dehydration of LA to an intermediate, followed by hydrogenation of the intermediate to GVL. Ni-based catalysts were found to be highly active for the reaction. [2:1] Ni-Cu/Al2O3 catalyst showed 100.0% conversion of LA with >99.0% selectivity to GVL, whereas [2:1] Ni-Co/Al2O3 yielded 100.0% conversion of LA with 83.0% selectivity to GVL. Moreover, reaction parameters such as temperature, H2 pressure, time, and catalyst loading were optimized to obtain the maximum GVL yield. The solvent-free hydrogenation process described in this study propels the future industrial production of GVL from LA.

Continuous Flow Upgrading of Selected C2-C6 Platform Chemicals Derived from Biomass

The ever increasing industrial production of commodity and specialty chemicals inexorably depletes the finite primary fossil resources available on Earth. The forecast of population growth over the next 3 decades is a very strong incentive for the identification of alternative primary resources other than petro-based ones. In contrast with fossil resources, renewable biomass is a virtually inexhaustible reservoir of chemical building blocks. Shifting the current industrial paradigm from almost exclusively petro-based resources to alternative bio-based raw materials requires more than vibrant political messages; it requires a profound revision of the concepts and technologies on which industrial chemical processes rely. Only a small fraction of molecules extracted from biomass bears significant chemical and commercial potentials to be considered as ubiquitous chemical platforms upon which a new, bio-based industry can thrive. Owing to its inherent assets in terms of unique process experience, scalability, and reduced environmental footprint, flow chemistry arguably has a major role to play in this context. This review covers a selection of C₂ to C₆ bio-based chemical platforms with existing commercial markets including polyols (ethylene glycol, 1,2-propanediol, 1,3-propanediol, glycerol, 1,4-butanediol, xylitol, and sorbitol), furanoids (furfural and 5-hydroxymethylfurfural) and carboxylic acids (lactic acid, succinic acid, fumaric acid, malic acid, itaconic acid, and levulinic acid). The aim of this review is to illustrate the various aspects of upgrading bio-based platform molecules toward commodity or specialty chemicals using new process concepts that fall under the umbrella of continuous flow technology and that could change the future perspectives of biorefineries.

Ni Supported on Natural Clays as a Catalyst for the Transformation of Levulinic Acid into γ-Valerolactone without the Addition of Molecular Hydrogen

γ-Valerolactone (GVL) is a valuable chemical that can be used as a clean additive for automotive fuels. This compound can be produced from biomass-derived compounds. Levulinic acid (LA) is a compound that can be obtained easily from biomass and it can be transformed into GVL by dehydration and hydrogenation using metallic catalysts. In this work, catalysts of Ni (a non-noble metal) supported on a series of natural and low-cost clay-materials have been tested in the transformation of LA into GVL. Catalysts were prepared by a modified wet impregnation method using oxalic acid trying to facilitate a suitable metal dispersion. The supports employed are attapulgite and two sepiolites with different surface areas. Reaction tests have been undertaken using an aqueous medium at moderate reaction temperatures of 120 and 180 °C. Three types of experiments were undertaken: (i) without H2 source, (ii) using formic acid (FA) as hydrogen source and (iii) using Zn in order to transform water in hydrogen through the reaction Zn + H2O → ZnO + H2. The best results have been obtained combining Zn (which plays a double role as a reactant for hydrogen formation and as a catalyst) and Ni/attapulgite. Yields to GVL higher than 98% have been obtained at 180 °C in the best cases. The best catalytic performance has been related to the presence of tiny Ni particles as nickel crystallites larger than 4 nm were not present in the most efficient catalysts.

Continuous flow hydrogenation of methyl and ethyl levulinate: an alternative route to γ-valerolactone production

Heterogeneous continuous transformation of methyl levulinate (ML) and ethyl levulinate (EL) to γ-valerolactone (GVL), as a promising C₅-platform molecule was studied at 100°C. It was proved that the H-Cube^® continuous hydrogenation system equipped with 5% Ru/C CatCart^® is suitable for the reduction of both levulinate esters. While excellent conversion rates (greater than 99.9%) of ML and EL could be achieved in water and corresponding alcohols, the selectivities of GVL were primarily affected by the solvent used. In water, 100% conversion and ca 50% selectivity that represent ca 0.45 mol_GVL g_metal ^-1 h^-1 productivity towards GVL, were obtained under 100 bar of total system pressure. The application of alcohols as a solvent, which maintained high conversion rates up to 1 ml min^-1 flow rate, resulted in lower productivities (less than 0.2 mol_GVL g_metal ^-1 h^-1) of GVL. Therefore, from a synthesis point of view, the corresponding 4-hydroxyvalerate esters could be obtained even at a higher reaction rate. The addition of sulfonated triphenylphosphine ligand (TPPTS) allowed reduction of the system pressure and resulted in the higher selectivity towards GVL.

Selective hydroconversion of levulinic acid to γ-valerolactone or 2-methyltetrahydrofuran over silica-supported cobalt catalysts

Levulinic acid can be hydrodeoxygenated either to γ-valerolactone or to 2-methyltetrahydrofuran over the Co/SiO₂ catalyst. Selectivity was controlled by the hydrogenation activity of the catalyst.

Nanostructured Nickel/Silica Catalysts for Continuous Flow Conversion of Levulinic Acid to γ-Valerolactone

Selective transformation of levulinic acid (LA) to γ-valerolactone (GVL) using novel heterogeneous catalysts is one of the promising strategies for viable biomass processing. In this framework, we developed a continuous flow process for the selective hydrogenation of LA to GVL using several nanostructured Ni/SiO₂ catalysts. The structural, textural, acidic, and redox properties of Ni/SiO₂ catalysts, tuned by selectively varying the Ni amount from 5 to 40 wt %, were critically investigated using numerous materials characterization techniques. Electron microscopy images showed the formation of uniformly dispersed Ni nanoparticles on the SiO₂ support, up to 30% Ni loading (average particle size is 9.2 nm), followed by a drastic increase in the particles size (21.3 nm) for 40% Ni-loaded catalyst. The fine dispersion of Ni particles has elicited a synergistic metal-support interaction, especially in 30% Ni/SiO₂ catalyst, resulting in enhanced acidic and redox properties. Among the various catalysts tested, the 30% Ni/SiO₂ catalyst showed the best performance with a remarkable 98% selectivity of GVL at complete conversion of LA for 2 h reaction time. Interestingly, this catalyst showed a steady selectivity to GVL (>97%), with a 54.5% conversion of LA during 20 h time-on-stream. The best performance of 30% Ni/SiO₂ catalyst was attributed to well-balanced catalytic properties, such as ample amounts of strong acidic sites and abundant active metal sites. The obtained results show a great potential of applying earth-abundant nickel/silica catalysts for upgrading biomass platform molecules into value-added chemicals and high-energy-density fuels.

Efficient Vapor-Phase Selective Hydrogenolysis of Bio-Levulinic Acid to γ-Valerolactone Using Cu Supported on Hydrotalcite Catalysts

In this work, Cu nanoparticles (Cu NPs, 2-20 nm) supported on Hydrotalcite catalysts exhibit enhanced selectivity for γ-valerolactone (GVL) during hydrogenolysis of levulinic acid (LA). At 260 °C, over 3 wt% Cu achieved 87.5% of LA conversion with a maximum GVL selectivity (95%). In contrast, LA hydrogenolysis over 3Cu/Hydrotalcite catalyst is highly active and stable toward the production of GVL due to balanced acido-basicity and higher Cu dispersion with ultrasmall particle sizes, which are investigated through the temperature programmed desorption (TPD) of ammonia, N2O titration, and transmission electron microscopy (TEM) analysis. Hydrotalcite in combination with inexpensive Cu catalyst is found to be an efficient and environmentally benign for LA hydrogenolysis.

Nanostructured Metal Catalysts for Selective Hydrogenation and Oxidation of Cellulosic Biomass to Chemicals

Conversion of biomass to chemicals provides essential products to human society from renewable resources. In this context, achieving atom-economical and energy-efficient conversion with high selectivity towards target products remains a key challenge. Recent developments in nanostructured catalysts address this challenge reporting remarkable performances in shape and morphology dependent catalysis by metals on nano scale in energy and environmental applications. In this review, most recent advances in synthesis of heterogeneous nanomaterials, surface characterization and catalytic performances for hydrogenation and oxidation for biorenewables with plausible mechanism have been discussed. The perspectives obtained from this review paper will provide insights into rational design of active, selective and stable catalytic materials for sustainable production of value-added chemicals from biomass resources.

Production of γ-valerolactone from levulinic acid over a Ru/C catalyst using formic acid as the sole hydrogen source

Conversion of levulinic acid (LA) to γ-valerolactone (GVL) over a ruthenium-carbon (Ru/C) catalyst using formic acid (FA) as the sole hydrogen source in cellulose hydrolysis process was investigated. The reaction was accelerated using Ru(5wt%)/C as the catalyst and by adding triethylamine. The highest LA conversion (87.26%) and GVL yield (80.75%) were obtained using 10g/mol (LA) catalyst and 150mL/mol (LA) triethylamine at 160°C for 180min. In this reaction, the hydrogenation process can only be accomplished in the presence of FA, which is the byproduct of LA production from cellulose hydrolysis. The application of this new route not only improves the economy of the process, but also avoids the energy-costly separation of LA from the LA and FA aqueous mixture. A new reaction pathway for the conversion of LA and FA into GVL over Ru/C with triethylamine was proposed.

Highly Active Catalytic Ruthenium/TiO2 Nanomaterials for Continuous Production of γ-Valerolactone

Green energy production from renewable sources is an attractive, but challenging topic to face the likely energy crisis scenario in the future. In the current work, a series of versatile Ru/TiO₂ catalysts were simply synthesized and employed in continuous-flow catalytic transfer hydrogenation of industrially derived methyl levulinate biowaste (from Avantium Chemicals B.V.) to form γ-valerolactone. Different analytical techniques were applied in the characterization of the as-synthesized catalysts, including XRD, SEM, energy-dispersion X-ray spectroscopy, TEM, and X-ray photoelectron spectroscopy. The effects of various reaction conditions (e.g., temperature, concentration, and flow rate) were investigated. Results suggested that optimum dispersion and distribution of Ru on the TiO₂ surface could efficiently promote the production of γ-valerolactone; the 5 % Ru/TiO₂ catalyst provided excellent catalytic performance and stability compared with commercial Ru catalysts.

Vapor-Phase Hydrogenation of Levulinic Acid to γ-Valerolactone Over Bi-Functional Ni/HZSM-5 Catalyst

The hydrogenation of levulinic acid (LA) to γ-valerolactone (GVL) in vapor-phase is economically more viable route if compared to reaction in liquid-phase. To improve the GVL yield in the vapor-phase reaction, the optimization of nickel modified zeolite as bi-functional catalyst (Ni/HZSM-5) was studied. Ni/HZSM-5 materials with fixed Al/Si molar ratio of 0.04 and different nominal Ni/Si molar ratios (from 0.01 to 0.05) were synthesized without the use of organic template and with the most affordable sources of silica and alumina. Materials were characterized by X-ray powder diffraction, SEM-EDX, TEM-EDX, pyridine TPD and DRIFTS, H₂-TPR, N₂ physisorption and isoelectric point. In the synthesized materials, 61–83% of nickel is present as bulk NiO and increases with nickel content. Additionally, in all catalysts, a small fraction of Ni²⁺ which strongly interacts with the zeolite support was detected (10–18%), as well as Ni²⁺ acting as charge compensating cations for Brønsted acid sites (7–21%). Increasing the nickel content in the catalysts leads to a progressive decrease of Brønsted acid sites (BAS) and concomitant increase of Lewis acid sites (LAS). When BAS/LAS is approaching to 1 and at the same time the amount of NiO reducible active sites is around 80%, the bi-functional Ni/HZSM-5-3 catalyst (Ni/Al = 0.59) leads to 99% conversion of LA and 100% selectivity to GVL at 320°C. This catalyst also shows stable levulinic acid hydrogenation to GVL in 3 reaction cycles conducted at 320°C. The concerted action of the following active sites in the catalyst is a key element for its optimized performance: (1) Ni metallic active sites with hydrogenation effect, (2) Lewis acid sites with dehydration effect, and (3) nickel aluminate sites with synergetic and stabilizing effects of all active sites in the catalyst.

Enhancing the conversion of ethyl levulinate to γ-valerolactone over Ru/UiO-66 by introducing sulfonic groups into the framework

The conversion of ethyl levulinate (EL) to γ-valerolactone (GVL) is an important reaction in biomass conversion. This process undergoes two consecutive reactions: hydrogenation and transesterification of the intermediate compound, i.e. ethyl 4-hydroxypentanoate, which are catalyzed by metal nanoparticles and acid sites, respectively. In this study, we explored the catalytic activity of Ru supported on metal organic frameworks aiming to develop efficient metal-acid bifunctional catalysts for this green process. UiO-66 and its analogues with various substituted groups (-SO3H, -NH2 and -NO2) were employed in this study. The Ru particle size, oxidation state and reducibility were characterized by TEM, H2-TPR, and XPS. The results suggest that the introduction of functional groups reduces the hydrogenation activity of pristine Ru/UiO-66 to various extents. Catalyst modified with -SO3H group shows much higher acidic catalytic performance while showing hydrogenation activity towards C[double bond, length as m-dash]O bonds, thus improving the overall transformation of EL to GVL due to the presence of strong Brønsted acid sites.