MOF-based heterogeneous catalysis in continuous flow via incorporation onto polymer-based spherical activated carbon supports

We present an approach to harnessing the tuneable catalytic properties of complex nanomaterials for continuous flow heterogeneous catalysis by combining them with the scalable and industrially implementable properties of carbon pelleted supports. This approach, in turn, will enable these catalytic materials, which largely currently exist in forms unsuitable for this application (e.g. powders), to be fully integrated into large scale, chemical processes. A composite heterogeneous catalyst consisting of a metal-organic framework-based Lewis acid, MIL-100(Sc), immobilised onto polymer-based spherical activated carbon (PBSAC) support has been developed. The material was characterised by focused ion beam-scanning electron microscopy-energy dispersive X-ray analysis, powder X-ray diffraction, N2 adsorption, thermogravimetric analysis, atomic absorption spectroscopy, light scattering and crush testing with the catalytic activity studied in continuous flow. The mechanically robust spherical geometry makes the composite material ideal for application in packed-bed reactors. The catalyst was observed to operate without any loss in activity at steady state for 9 hours when utilised as a Lewis acid catalyst for the intramolecular cyclisation of (±)-citronellal as a model reaction. This work paves the way for further development into the exploitation of MOF-based continuous flow heterogeneous catalysis.

One-Pot Synthesis of Menthol from Citral and Citronellal Over Heterogeneous Catalysts

One-pot synthesis of menthol from citronellal or citral was summarized. Both batch and continuous reactors have been recently applied. This reaction is very complex and a bifunctional catalyst exhibiting especially Lewis acid sites for cyclisation of citronellal to isopulegol are needed, while metal particles are required for its hydrogenation to menthols. Typically, too mild acidity of the catalyst and small particles do not catalyze menthol formation. Furthermore, too high acidity causes catalyst deactivation and dehydration of menthol. Very high menthol yields have been obtained in batch reactor over nobel and transition metal supported bifunctional catalysts. Shape selectivity was demonstrated for Ni-supported on Zr-modified beta zeolite, which gave high diastereoselectivity to the desired L-menthol. Recently one-pot synthesis of menthol in a trickle bed reactor has been investigated. Catalyst suffers only minor deactivation in transformation of citronellal to menthol, while more severe catalyst deactivation occurred in transforming citral to menthols. Noteworthy from the industrial point of view is that the product distribution obtained with the same catalyst under kinetic regime or under diffusional limitations differs from each other. The metal location and synthesis method of extrudates can have a major effect on the catalyst performance. Kinetic modelling of the data obtained from the trickle bed reactor considering the effectiveness factor is discussed.

Graphical Abstract

The results from one-pot synthesis of menthol finding applications in pharmaceuticals and fragrances from citral and its hydrogenated product, citronellal over bifunctional catalysts metal–acid are summarized. The relationship between the catalyst properties and the performance is discussed. In the continuous mode catalyst deactivation becomes apparent and in such mode of operation the product distribution might differ from those obtained in a batch reactor.

One-Pot Transformation of Citronellal to Menthol Over H-Beta Zeolite Supported Ni Catalyst: Effect of Catalyst Support Acidity and Ni Loading

Citronellal was converted to menthol in a one-pot approach using H-Beta zeolite-based Ni catalyst in a batch reactor at 80 °C, under 20 bar of total pressure. The effects of H-Beta acidity (H-Beta-25 with the molar ratio SiO2/Al2O3 = 25 and H-Beta-300 with SiO2/Al2O3 = 300) and Ni loading (5, 10 and 15 wt %) on the catalytic performance were investigated. Ni was impregnated on H-Beta support using the evaporation-impregnation method. The physico-chemical properties of the catalysts were characterized by XRD, SEM, TEM, ICP-OES, N2 physisorption, TPR, and pyridine adsorption–desorption FTIR techniques. Activity and selectivity of catalysts were strongly affected by the Brønsted and Lewis acid sites concentration and strength, Ni loading, its particle size and dispersion. A synergetic effect of appropriate acidity and suitable Ni loading in 15 wt.% Ni/H-Beta-25 catalyst led to the best performance giving 36% yield of menthols and 77% stereoselectivity to ( ±)-menthol isomer at 93% citronellal conversion. Moreover, the catalyst was successfully regenerated and reused giving similar activity, selectivity and stereoselectivity to the desired ( ±)-menthol isomer as the fresh one.

Graphical Abstract

Catalytic transformations of citral in a continuous flow over bifunctional Ru-MCM-41 extrudates

The three-step reaction of citral to menthol was investigated in an autoclave and a trickle-bed reactor over Ru-MCM-41 catalysts in powder and shaped forms, respectively, with the same composition and controlled metal location.

Cascade transformations of (±)-citronellal to menthol over extruded Ru-MCM-41 catalysts in a continuous reactor

Catalytic cascade transformations of (±)-citronellal in a continuous mode over bifunctional ruthenium/MCM-41/binder extrudates with different metal location.