Irantzu Sádaba

Furfural: a renewable and versatile platform molecule for the synthesis of chemicals and fuels

The production of future transportation fuels and chemicals requires the deployment of new catalytic processes that transform biomass into valuable products under competitive conditions. Furfural has been identified as one of the most promising chemical platforms directly derived from biomass. With an annual production close to 300 kTon, furfural is currently a commodity chemical, and the technology for its production is largely established. The aim of this review is to discuss the most relevant chemical routes for converting furfural to chemicals, biofuels, and additives. This review focuses not only on industrially produced chemicals derived from furfural, but also on other not yet commercialised products that have a high potential for commercialisation as commodities. Other chemicals that are currently produced from oil but can also be derived from furfural are also reviewed. The chemical and engineering aspects such as the reaction conditions and mechanisms, as well as the main achievements and the challenges still to come in the pursuit of advancing the furfural-based industry, are highlighted.

Deactivation of solid catalysts in liquid media: the case of leaching of active sites in biomass conversion reactions

This review is aimed to be a brief tutorial covering the deactivation of solid catalysts in the liquid phase, with specific focus on leaching, which can be especially helpful to researchers not familiarized with catalytic processes in the liquid phase. Leaching refers to the loss of active species from the solid that are transferred into the liquid medium, causing eventually a deactivation of the catalyst. Intriguingly, not many published studies have dealt with leaching, since this is a specific phenomenon in the liquid phase and heterogeneous catalysis is mainly carried out in gaseous phase. However, as a consequence of the development of new processes for biorefineries, an increasing number of reactions deal with liquid media, and thus, the stability and reusability of a solid catalyst in this situation represent a huge challenge that requires specific attention. Leaching of active phases is particularly problematic because of its irreversibility and it can be one of the main causes of catalyst deactivation in liquid media, threatening the sustainability of the process. This tutorial review presents a survey of the main aspects concerning the deactivation due to leaching of active species from the solid catalyst such as mechanisms, detection methods, impact of these factors on global activity and finally, some procedures to try and minimize the leaching or to cope with it. A decision flowchart is presented to help in the study of catalyst stability and reusability. Interesting biomass conversion reactions have been chosen as examples to illustrate the importance of these aspects.

Tin‐containing Silicates: Alkali Salts Improve Methyl Lactate Yield from Sugars

This study focuses on increasing the selectivity to methyl lactate from sugars using stannosilicates as heterogeneous catalyst. All group I ions are found to have a promoting effect on the resulting methyl lactate yield. Besides, the alkali ions can be added both during the preparation of the catalyst or directly to the solvent mixture to achieve the highest reported yield of methyl lactate (ca. 75 %) from sucrose at 170 °C in methanol. The beneficial effect of adding alkali to the reaction media applies not only to highly defect-free Sn-Beta prepared through the fluoride route, but also to materials prepared by post-treatment of dealuminated commercial Beta zeolites, as well as ordered mesoporous stannosilicates, in this case Sn-MCM-41 and Sn-SBA-15. These findings open the door to the possibility of using other preparation methods or different Sn-containing silicates with equally high methyl lactate yields as Sn-Beta.

Catalytic dehydration of xylose to furfural: vanadyl pyrophosphate as source of active soluble species

The acid-catalysed, aqueous phase dehydration of xylose (a monosaccharide obtainable from hemicelluloses, e.g., xylan) to furfural was investigated using vanadium phosphates (VPO) as catalysts: the precursors, VOPO(4)·2H(2)O, VOHPO(4)·0.5H(2)O and VO(H(2)PO(4))(2), and the materials prepared by calcination of these precursors, that is, γ-VOPO(4), (VO)(2)P(2)O(7) and VO(PO(3))(2), respectively. The VPO precursors were completely soluble in the reaction medium. In contrast, the orthorhombic vanadyl pyrophosphate (VO)(2)P(2)O(7), prepared by calcination of VOHPO(4)·0.5H(2)O at 550°C/2 h, could be recycled by simply separating the solid acid from the reaction mixture by centrifugation, and no drop in catalytic activity and furfural yields was observed in consecutive 4 h-batch runs (ca. 53% furfural yield, at 170°C). However, detailed catalytic/characterisation studies revealed that the vanadyl pyrophosphate acts as a source of active water-soluble species in this reaction. For a concentration of (VO)(2)P(2)O(7) as low as 5 mM, the catalytic reaction of xylose (ca. 0.67 M xylose in water, and toluene as solvent for the in situ extraction of furfural) gave ca. 56% furfural yield, at 170°C/6 h reaction.

Incorporation of tin affects crystallization, morphology, and crystal composition of Sn-Beta

The crystallization of Sn-Beta in fluoride medium is greatly influenced by the amount and type of tin source present in the synthesis gel. By varying the amount of tin in the form of tin(IV) chloride pentahydrate, the time required for crystallization was studied. It was found that tin not only drastically affects the time required for crystallization, but also that the presence of tin changes the morphology of the formed Sn-Beta crystals. For low amounts of tin (Si/Sn = 400) crystallization occurs within four days and the Sn-Beta crystals are capped bipyramidal in shape, whereas for high amounts of tin (Si/Sn = 100) it takes about sixty days to reach full crystallinity and the resulting crystals are highly truncated, almost plate-like in shape. Using SEM-WDS to investigate the tin distribution along transverse sections of the Sn-Beta crystals, a gradient distribution of tin was found in all cases. It was observed that the tin density in the outer parts of the Sn-Beta crystals is roughly twice as high as in the tin depleted core of the crystals. Sn-Beta was found to obtain its maximum catalytic activity for the conversion of dihydroxyacetone to methyl lactate close to the minimum time required for obtaining full crystallinity. At excessive crystallization times, the catalytic activity decreased, presumably due to Ostwald ripening.

Dehydration of Xylose to Furfural over MCM-41-Supported Niobium-Oxide Catalysts

A series of silica-based MCM-41-supported niobium-oxide catalysts are prepared, characterized by using XRD, N2 adsorption-desorption, X-ray photoelectron spectroscopy, Raman spectroscopy, and pyridine adsorption coupled to FTIR spectroscopy, and tested for the dehydration of D-xylose to furfural. Under the operating conditions used all materials are active in the dehydration of xylose to furfural (excluding the MCM-41 silica support). The xylose conversion increases with increasing Nb2 O5 content. At a loading of 16 wt % Nb2 O5 , 74.5 % conversion and a furfural yield of 36.5 % is achieved at 170 °C, after 180 min reaction time. Moreover, xylose conversion and furfural yield increase with the reaction time and temperature, attaining 82.8 and 46.2 %, respectively, at 190 °C and after 100 min reaction time. Notably, the presence of NaCl in the reaction medium further increases the furfural yield (59.9 % at 170 °C after 180 min reaction time). Moreover, catalyst reutilization is demonstrated by performing at least three runs with no loss of catalytic activity and without the requirement for an intermediate regeneration step. No significant niobium leaching is observed, and a relationship between the structure of the catalyst and the activity is proposed.

Poly(styrenesulphonic) acid: an active and reusable acid catalyst soluble in polar solvents

This article reports on the catalytic activity of soluble poly(styrenesulphonic) acid (PSSA) in three different reactions driven by acidic sites: tributyrin methanolysis, biodiesel synthesis and xylose dehydration to furfural. The PSSA catalyst, soluble in the polar media used in these reactions, displayed larger catalytic activity than other non-soluble sulphonic solid catalysts studied (Amberlyst 36, Amberlyst 70 and Nafion®-SAC13). The ultrafiltration of the used PSSA catalyst allowed retention and reutilisation of the catalyst for several runs. No significant decay in catalytic activity was observed for the three reaction repeats investigated. All these results demonstrated that PSSA, a material that can be obtained from polystyrene waste, is an excellent reusable catalyst for conducting reactions demanding acidic sites.

Tin-containing silicates: identification of a glycolytic pathway via 3-deoxyglucosone

Inorganic glycolytic systems, capable of transforming glucose through a cascade of catalytic steps, can lead to efficient chemical processes utilising carbohydrates as feedstock. Tin-containing silicates, such as Sn-Beta, are showing potential for the production of lactates from sugars through a cascade of four to five sequential steps. Currently, there is a limited understanding of the competing glycolytic pathways within these systems. Here we identify dehydration of glucose to 3-deoxyglucosone as an important pathway that occurs in addition to retro-aldol reaction of hexoses when using tin-containing silicates. It is possible to influence the relative carbon flux through these pathways by controlling the amount of alkali metal salts present in the reaction mixture. In the absence of added potassium carbonate, at least 15–30% carbon flux via 3-deoxyglucosone is observed. Addition of just a few ppm of potassium carbonate makes retro-aldol pathways dominant and responsible for about 60–70% of the overall carbon flux. The 3-deoxyglucosone pathway results in new types of chemical products accessible directly from glucose. Furthermore, it is argued that 3-deoxyglucosone is a contributing source of some of the methyl lactate formed from hexoses using tin-containing silicates in the presence of alkali metal salts. Further catalyst design and system tuning will permit even better control between these two different glycolytic pathways and will enable highly selective catalytic transformations of glucose to a variety of chemical products using tin-containing silicates.

Synthesis of a novel polyester building block from pentoses by tin-containing silicates

We report here the direct formation of the new chemical product trans-2,5-dihydroxy-3-pentenoic acid methyl ester from pentoses using tin-containing silicates as catalysts. The product is formed under alkali-free conditions in methanol at temperatures in the range 140–180 °C. The highest yields are found using Sn-Beta as the catalyst. Under optimised conditions, a yield of 33% is achieved. Purified trans-2,5-dihydroxy-3-pentenoic acid methyl ester was used for co-polymerisation studies with ethyl 6-hydroxyhexanoate using Candida antarctica lipase B as the catalyst. The co-polymerisation yields a product containing functional groups originating from trans-2,5-dihydroxy-3-pentenoic acid methyl ester in the polyester backbone. The reactivity of the incorporated olefin and hydroxyl moieties was investigated using trifluoroacetic anhydride and thiol–ene chemistry, thus illustrating the potential for functionalising the new co-polymers.

Preparation and characterization of Mg-Zr mixed oxide aerogels and their application as aldol condensation catalysts.

A series of Mg-Zr mixed oxides with different nominal Mg/(Mg+Zr) atomic ratios, namely 0, 0.1, 0.2, 0.4, 0.85, and 1, is prepared by alcogel methodology and fundamental insights into the phases obtained and resulting active sites are studied. Characterization is performed by X-ray diffraction, transmission electron microscopy, X-ray photoelectron spectroscopy, N(2) adsorption-desorption isotherms, and thermal and chemical analysis. Cubic Mg(x)Zr(1-x)O(2-x) solid solution, which results from the dissolution of Mg(2+) cations within the cubic ZrO(2) structure, is the main phase detected for the solids with theoretical Mg/(Mg+Zr) atomic ratio ≤0.4. In contrast, the cubic periclase (c-MgO) phase derived from hydroxynitrates or hydroxy precursors predominates in the solid with Mg/(Mg+Zr)=0.85. c-MgO is also incipiently detected in samples with Mg/(Mg+Zr)=0.2 and 0.4, but in these solids the c-MgO phase mostly arises from the segregation of Mg atoms out of the alcogel-derived c-Mg(x)Zr(1-x)O(2-x) phase during the calcination process, and therefore the species c-MgO and c-Mg(x)Zr(1-x)O(2-x) are in close contact. Regarding the intrinsic activity in furfural-acetone aldol condensation in the aqueous phase, these Mg-O-Zr sites located at the interface between c-Mg(x)Zr(1-x)O(2-x) and segregated c-MgO display a much larger intrinsic activity than the other noninterface sites that are present in these catalysts: Mg-O-Mg sites on c-MgO and Mg-O-Zr sites on c-Mg(x)Zr(1-x)O(2-x). The very active Mg-O-Zr sites rapidly deactivate in the furfural-acetone condensation due to the leaching of active phases, deposition of heavy hydrocarbonaceous compounds, and hydration of the c-MgO phase. Nonetheless, these Mg-Zr materials with very high specific surface areas would be suitable solid catalysts for other relevant reactions catalyzed by strong basic sites in nonaqueous environments.