Continuous Conversion of Glucose into Methyl Lactate over the Sn-Beta Zeolite: Catalytic Performance and Activity Insight

Homogeneous and Heterogeneous Catalysis of Glucose to Lactic Acid and Lactates: A Review

The current societal demand to replace polymers derived from petroleum with sustainable bioplastics such as polylactic acid (PLA) has motivated industry to commercialize ever-larger facilities for biobased monomers like lactic acid. Even though most of the lactic acid is produced by fermentation, long reaction times and high capital costs compromise the economics and thus limit the appeal of biotechnological processes. Catalytic conversion of hexose from biomass is a burgeoning alternative to fermentation. Here we identify catalysts to convert glucose to lactic acid, along with their proposed mechanisms. High Lewis acidity makes erbium salts among the most active homogeneous catalysts, while solvent coordination with the metal species polarize the substrate, increasing the catalytic activity. For heterogeneous catalysts, Sn-containing bimetallic systems combine the high Lewis acidity of Sn while moderating it with another metal, thus decreasing byproducts. Hierarchical bimetallic Sn-Beta zeolites combine a high number of open sites catalyzing glucose isomerization in the mesoporous regions and the confinement effect assisting fructose retro-aldol in microporous regions, yielding up to 67% lactic acid from glucose. Loss of activity is still an issue for heterogeneous catalysts, mostly due to solvent adsorption on the active sites, coke formation, and metal leaching, which impedes its large scale adoption.

Computational Study of the Solid-State Incorporation of Sn(II) Acetate into Zeolite β

Sn-doped zeolites are potent Lewis acid catalysts for important reactions in the context of green and sustainable chemistry; however, their synthesis can have long reaction times and harsh chemical requirements, presenting an obstacle to scale-up and industrial application. To incorporate Sn into the β zeolite framework, solid-state incorporation (SSI) has recently been demonstrated as a fast and solvent-free synthetic method, with no impairment to the high activity and selectivity associated with Sn-β for its catalytic applications. Here, we report an ab initio computational study that combines periodic density functional theory with high-level embedded-cluster quantum/molecular mechanical (QM/MM) to elucidate the mechanistic steps in the synthetic process. Initially, once the Sn(II) acetate precursor coordinates to the β framework, acetic acid forms via a facile hydrogen transfer from the β framework onto the monodentate acetate ligand, with low kinetic barriers for subsequent dissociation of the ligand from the framework-bound Sn. Ketonization of the dissociated acetic acid can occur over the Lewis acidic Sn(II) site to produce CO2 and acetone with a low kinetic barrier (1.03 eV) compared to a gas-phase process (3.84 eV), helping to explain product distributions in good accordance with experimental analysis. Furthermore, we consider the oxidation of the Sn(II) species to form the Sn(IV) active site in the material by O2- and H2O-mediated mechanisms. The kinetic barrier for oxidation via H2 release is 3.26 eV, while the H2O-mediated dehydrogenation process has a minimum barrier of 1.38 eV, which indicates the possible role of residual H2O in the experimental observations of SSI synthesis. However, we find that dehydrogenation is facilitated more significantly by the presence of dioxygen (O2), introduced in the compressed air gas feed, via a two-step process oxidation process that forms H2O2 as an intermediate and has greatly reduced kinetic barriers of 0.25 and 0.26 eV. The results provide insight into how Sn insertion into β occurs during SSI and demonstrate the possible mechanism of top-down synthetic procedures for metal insertion into zeolites.

Catalytic Performances of Sn-Beta Catalysts Prepared from Different Heteroatom-Containing Beta Zeolites for the Retro-Aldol Fragmentation of Glucose

Beta zeolites with different heteroatoms incorporated into the lattice at two loadings (Si/M = 100 or 200, where M = Al, Fe, Ga, B) were hydrothermally synthesised and used as starting materials for the preparation of Sn-Beta using Solid-State Incorporation. 119Sn CPMG MAS NMR showed that various Sn species were formed, the distribution of which depended on the identity of the initial heteroatom and the original Si/M ratio. The final Sn-Beta materials (with Si/Sn = 200) were explored as catalysts for the retro-aldol fragmentation of glucose to α-hydroxy-esters in the continuous regime. Amongst these materials, B-derived Sn-Beta was found to exhibit improved levels of selectivity and stability, particularly compared to Sn-Beta catalysts synthesised from commercially available Al-Beta materials, achieving a combined yield of methyl lactate and methyl vinyl glycolate > 80% at short times on the stream. Given that B atoms can be removed from the Beta lattice in mild conditions without the use of highly concentrated acidic media, this discovery demonstrates that B-Beta is an attractive starting material for the future post-synthetic preparation of Lewis acidic zeolites.

Catalytic Conversion of High Fructose Corn Syrup to Methyl Lactate with CoO@silicalite-1

Methyl lactate (MLA), a versatile biomass platform, was typically produced from the catalytic conversion of high-priced fructose. High fructose corn syrup (HFCS) is a mixture of glucose, fructose, water, etc., which is viewed as an economical substitute for fructose to produce MLA due to the much lower cost of separation and drying processes. However, the transformation of HFCS to MLA is still a challenge due to its complex components and the presence of water. In this work, the catalytic conversion of HFCS to MLA over CoO@silicalite-1 catalyst synthesized via a straightforward post citric acid treatment approach was reported. The maximum MLA yield reached 43.8% at 180 °C for 18 h after optimizing the reaction conditions and Co loading. Interestingly, adding extra 3% water could further increase the MLA yield, implying that our CoO@silicalite-1 catalyst is also capable for upgrading wet HFCS. As a result, the costly drying process of wet HFCS can be avoided. Moreover, the activity of CoO@silicalite-1 catalyst can be regenerated for at least four cycles via facile calcination in air. This study, therefore, will provide a new opportunity to not only solve the HFCS-overproduction issues but also produce value-added MLA.

High-Productivity Continuous Conversion of Glucose to α-Hydroxy Esters over Postsynthetic and Hydrothermal Sn-Beta Catalysts

The retro-aldol fragmentation of glucose is a complex reaction of industrial relevance, which provides a potentially sustainable route for the production of α-hydroxyester compounds of relevance to the green polymer industry, such as methyl lactate and methyl vinyl glycolate. Although the zeolite catalyst, Sn-Beta, has shown itself to be a promising catalyst for this process, important information concerning the stability of the catalyst during continuous operation is not yet known, and improvements to its yield of retro-aldol products are also essential. Here, we perform detailed spectroscopic studies of a selection of Sn-Beta catalysts and evaluate their performances for the retro-aldol fragmentation of glucose under continuous processing conditions, with the dual aims of developing new structure-activity-lifetime relationships for the reaction and maximizing the productivity and selectivity of the process. Kinetic studies are performed under both established reaction conditions and in the presence of additional promoters, including water and alkali salts. Generally, this study demonstrates that the reaction conditions and choice of catalyst cannot be optimized in isolation, since each catalyst explored in this study responds differently to each particular process perturbation. However, by evaluating each type of the Sn-Beta catalyst under each set of reaction conditions, we reveal that postsynthetic Sn-Beta catalysts exhibit the best levels of performance when activity, selectivity, and stability are taken into account. Specifically, the best levels of performance are obtained with a postsynthetic Sn-Beta catalyst that is preactivated in a flow of methanol prior to reaction, which provides α-hydroxyester yields over 90% at the early stages of continuous operation and operates at high yield and selectivity for over 60 h on stream. Space-time-yields over two orders of magnitude higher than any previously reported for this reaction are achieved, setting a new benchmark in terms of the retro-aldol fragmentation of glucose.

Sn-Beta Catalyzed Transformations of Sugars—Advances in Catalyst and Applications

Beta zeolite modified with Sn in the framework (Sn-Beta) was synthesized and introduced as a heterogeneous catalyst for Baeyer–Villiger oxidations about twenty years ago. Since then, both syntheses strategies, characterization and understanding as well as applications with the material have developed significantly. Remarkably, Sn-Beta zeolite has been discovered to exhibit unprecedented high catalytic efficiency for the transformation of glucose to fructose (i.e., aldoses to ketoses) and lactic acid derivatives in both aqueous and alcoholic media, which has inspired an extensive interest to develop more facile and scalable syntheses routes and applications for sugars transformations. This review survey the progress made on both syntheses approaches of Sn-Beta and applications of the material within catalyzed transformations of sugar, including bottom-up and top-down syntheses and catalyzed isomerization, dehydration, and fragmentation of sugars.