Liquid-Phase Oxidation of Toluene and p-toluic Acid under Mild Conditions: Synergistic Effects of Cobalt, Zirconium, Ketones, and Carbon Dioxide

Facile Production of 2,5-Furandicarboxylic Acid via Oxidation of Industrially Sourced Crude 5-Hydroxymethylfurfural

The oxidation of 5-hydroxymethylfurfural (HMF) produces value-added chemicals such as 2,5-diformylfuran (DFF) and 2,5-furandicarboxylic acid (FDCA). In this work, FDCA production was achieved by oxidation of crude HMF solution containing around 45 % HMF and unwanted byproducts such as 5,5'-[oxy-bis(methylene)]bis-2-furfural (HMF dimer) and polymers. At optimized reaction conditions similar to the Mid-Century process, homogeneous oxidation of the crude HMF (up to 20 wt% in the feed) by Co/Mn/Br catalyst in acetic acid solution produced FDCA at >95 % yield. The solid FDCA product contained <4000 ppm 5-formyl-2-furancarboxylic acid (FFCA). Such high yields were observed because the impurities in crude HMF were also converted to FDCA, as confirmed by the facile oxidation of HMF dimer to FDCA under reaction conditions. The successful demonstration of crude HMF as feed, obviating the need for HMF purification, suggests potential for cost-effectively producing FDCA in existing terephthalic plants.

Manganese and Cobalt Doped Hierarchical Mesoporous Halloysite-Based Catalysts for Selective Oxidation of p-Xylene to Terephthalic Acid

Bimetallic MnCo catalyst, supported on the mesoporous hierarchical MCM-41/halloysite nanotube composite, was synthesized for the first time and proved its efficacy in the selective oxidation of p-xylene to terephthalic acid under conditions of the AMOCO process. Quantitative yields of terephthalic acid were achieved within 3 h at 200–250 °C, 20 atm. of O2 and at a substrate to the Mn + Co ratio of 4–4.5 times higher than for traditional homogeneous system. The influence of temperature, oxygen, pressure and KBr addition on the catalyst activity was investigated, and the mechanism for the oxidation of p-toluic acid to terephthalic acid, excluding undesirable 4-carboxybenzaldehyde, was proposed.

Bioderived Muconates by Cross-Metathesis and Their Conversion into Terephthalates

Polyethylene terephthalate that is 100 % bioderived is in high demand in the market guided by the ever-more exigent sustainability regulations with the challenge of producing renewable terephthalic acid remaining. Renewable terephthalic acid or its precursors can be obtained by Diels-Alder cycloaddition and further dehydrogenation of biomass-derived muconic acid. The cis,cis isomer of the dicarboxylic acid is typically synthesized by fermentation with genetically modified microorganisms, a process that requires complex separations to obtain a high yield of the pure product. Furthermore, the cis isomer has to be transformed into the trans,trans form and has to be esterified before it is suitable for terephthalate synthesis. To overcome these challenges, we investigated the synthesis of dialkyl muconates by cross-metathesis. The Ru-catalyzed cross-coupling of sorbates with acrylates, which can be bioderived, proceeded selectively to yield diester muconates in up to 41 % yield by using very low catalyst amounts (0.5-3.0 mol %) and no solvent. In the optimized procedure, the muconate precipitated as a solid and was easily recovered from the reaction medium. Analysis by GC-MS and NMR spectroscopy showed that this method delivered exclusively the trans,trans isomer of dimethyl muconate. The Diels-Alder reaction of dimethyl muconate with ethylene was studied in various solvents to obtain 1,4-bis(carbomethoxy)cyclohexene. The cycloaddition proceeded with very high conversions (77-100 %) and yields (70-98 %) in all of the solvents investigated, and methanol and tetrahydrofuran were the best choices. Next, the aromatization of 1,4-bis(carbomethoxy)cyclohexene to dimethyl terephthalate over a Pd/C catalyst resulted in up to 70 % yield in tetrahydrofuran under an air atmosphere. Owing to the high yield of the reaction of dimethyl muconate to 1,4-bis(carbomethoxy)cyclohexene, no separation step was needed before the aromatization. This is the first time that cross-metathesis is used to produce bioderived trans,trans-muconates as precursors to renewable terephthalates, important building blocks in the polymer industry.