Ryan M. West

Integrated Catalytic Conversion of γ-Valerolactone to Liquid Alkenes for Transportation Fuels

Lactic Fuels In the quest to find sustainable alternatives to petrochemicals, a small cyclic ester, γ-valerolactone, derived from cellulose offers promising raw material. Bond et al. (p. 1110) show that carbon dioxide can be catalytically excised from the lactone efficiently at high pressure, leaving a mixture of butanes. In a second-stage reactor, the butanes can be strung together to form heavier hydrocarbons similar to those found in automotive and jet fuels. The method simultaneously yields fuel and a relatively pure stream of pressurized carbon dioxide amenable to sequestration or further chemical modification. A biomass-derived compound is transformed into hydrocarbon fuels and a CO2 stream amenable to sequestration. Efficient synthesis of renewable fuels remains a challenging and important line of research. We report a strategy by which aqueous solutions of γ-valerolactone (GVL), produced from biomass-derived carbohydrates, can be converted to liquid alkenes in the molecular weight range appropriate for transportation fuels by an integrated catalytic system that does not require an external source of hydrogen. The GVL feed undergoes decarboxylation at elevated pressures (e.g., 36 bar) over a silica/alumina catalyst to produce a gas stream composed of equimolar amounts of butene and carbon dioxide. This stream is fed directly to an oligomerization reactor containing an acid catalyst (e.g., H ZSM-5, Amberlyst-70), which couples butene monomers to form condensable alkenes with molecular weights that can be targeted for gasoline and/or jet fuel applications. The effluent gaseous stream of CO2 at elevated pressure can potentially be captured and then treated or sequestered to mitigate greenhouse gas emissions from the process.

Catalytic Conversion of Biomass to Monofunctional Hydrocarbons and Targeted Liquid-Fuel Classes

It is imperative to develop more efficient processes for conversion of biomass to liquid fuels, such that the cost of these fuels would be competitive with the cost of fuels derived from petroleum. We report a catalytic approach for the conversion of carbohydrates to specific classes of hydrocarbons for use as liquid transportation fuels, based on the integration of several flow reactors operated in a cascade mode, where the effluent from the one reactor is simply fed to the next reactor. This approach can be tuned for production of branched hydrocarbons and aromatic compounds in gasoline, or longer-chain, less highly branched hydrocarbons in diesel and jet fuels. The liquid organic effluent from the first flow reactor contains monofunctional compounds, such as alcohols, ketones, carboxylic acids, and heterocycles, that can also be used to provide reactive intermediates for fine chemicals and polymers markets.

A process for microbial hydrocarbon synthesis: Overproduction of fatty acids in Escherichia coli and catalytic conversion to alkanes

The development of renewable alternatives to diesel and jet fuels is highly desirable for the heavy transportation sector, and would offer benefits over the production and use of short‐chain alcohols for personal transportation. Here, we report the development of a metabolically engineered strain of Escherichia coli that overproduces medium‐chain length fatty acids via three basic modifications: elimination of β‐oxidation, overexpression of the four subunits of acetyl‐CoA carboxylase, and expression of a plant acyl–acyl carrier protein (ACP) thioesterase from Umbellularia californica (BTE). The expression level of BTE was optimized by comparing fatty acid production from strains harboring BTE on plasmids with four different copy numbers. Expression of BTE from low copy number plasmids resulted in the highest fatty acid production. Up to a seven‐fold increase in total fatty acid production was observed in engineered strains over a negative control strain (lacking β‐oxidation), with a composition dominated by C12 and C14 saturated and unsaturated fatty acids. Next, a strategy for producing undecane via a combination of biotechnology and heterogeneous catalysis is demonstrated. Fatty acids were extracted from a culture of an overproducing strain into an alkane phase and fed to a Pd/C plug flow reactor, where the extracted fatty acids were decarboxylated into saturated alkanes. The result is an enriched alkane stream that can be recycled for continuous extractions. Complete conversion of C12 fatty acids extracted from culture to alkanes has been demonstrated yielding a concentration of 0.44 g L−1 (culture volume) undecane. Biotechnol. Bioeng. 2010;106: 193–202.

Catalytic Conversion of Renewable Biomass Resources to Fuels and Chemicals

Lignocellulosic biomass is renewable and cheap, and it has the potential to displace fossil fuels in the production of fuels and chemicals. Biomass-derived carboxylic acids are important compounds that can be used as platform molecules for the production of a variety of important chemicals on a large scale. Lactic acid, a prototypical biomass derivative, and levulinic acid, an important chemical feedstock produced by hydrolysis of waste cellulosic materials, can be upgraded using bifunctional catalysts (those containing metal and acid sites), which allows the integration of several transformations (e.g., oxygen removal and C-C coupling) in a single catalyst bed. This coupling between active sites is beneficial in that it reduces the complexity and cost of the biomass conversion processes. Deoxygenation of biomass derivatives is a requisite step for the production of fuels and chemicals, and strategies are proposed to minimize the consumption of hydrogen from an external source during this process.

Liquid Alkanes with Targeted Molecular Weights from Biomass-Derived Carbohydrates

Liquid transportation fuels must burn cleanly and have high energy densities, criteria that are currently fulfilled by petroleum, a non-renewable resource, the combustion of which leads to increasing levels of atmospheric CO(2). An attractive approach for the production of transportation fuels from renewable biomass resources is to convert carbohydrates into alkanes with targeted molecular weights, such as C(8)-C(15) for jet-fuel applications. Targeted n-alkanes can be produced directly from fructose by an integrated process involving first the dehydration of this C(6) sugar to form 5-hydroxymethylfurfural, followed by controlled formation of C-C bonds with acetone to form C(9) and C(15) compounds, and completed by hydrogenation and hydrodeoxygenation reactions to form the corresponding n-alkanes. Analogous reactions are demonstrated starting with 5-methylfurfural or 2-furaldehyde, with the latter leading to C(8) and C(13) n-alkanes.

γ-Valerolactone Ring-Opening and Decarboxylation over SiO2/Al2O3 in the Presence of Water

γ-Valerolactone (GVL) has been identified as a promising, sustainable platform molecule that can be produced from lignocellulosic biomass. The chemical flexibility of GVL has allowed the development of a variety of processes to prepare renewable fuels and chemicals. In the present work involving a combination of computational and experimental studies, we explore the factors governing the ring-opening of GVL to produce pentenoic acid isomers, as well as their subsequent decarboxylation over acid catalysts or hydrogenation over metal catalysts. The ring-opening of GVL has shown to be a reversible reaction, while both the decarboxylation and hydrogenation reactions are irreversible and kinetically controlled under the conditions studied (temperatures from about 500 to 650 K). The most significant contributor to lactone reactivity toward ring-opening is the size of the ring, with γ- lactones being more stable and less readily opened than δ- and ε-analogues. We have observed that the presence of either a C═C double bond or a lactone (which opens to form a C═C double bond) is necessary for appreciable rates of decarboxylation to occur. Olefinic acids exhibit higher rates of decarboxylation than the corresponding lactones, suggesting that the decarboxylation of alkene acids provides a lower energy pathway to olefin production than the direct decarboxylation of lactones. We observe lower rates of decarboxylation as the chain length of alkene acids increases; however, acrylic acid (3-carbon atoms) does not undergo decarboxylation at the conditions tested. These observations suggest that particular double bond configurations yield the highest rates of decarboxylation. Specifically, we suggest that the formation of a secondary carbenium ion in the β position leads to high reactivity for decarboxylation. Such an intermediate can be formed from 2- or 3-alkene acids which have at least four carbon atoms.