Prasenjit Bhaumik and
Paresh Laxmikant Dhepe*
Catalysis & Inorganic Chemistry Division, CSIR-National Chemical Laboratory, Dr Homi Bhabha Road, Pune-411008, India. E-mail: pl.dhepe@ncl.res.in; Fax: +91-20-25902633
First published on 29th May 2014
Development of stable and recyclable solid acid catalysts in the efficient valorisation of hemicellulose to yield C5 sugars and furfural is vital to boost the prospects of using lignocelluloses for chemicals synthesis. Using an silicoaluminophosphate, namely SAPO-44, as a catalyst, an environmentally benign process of furfural synthesis from diversified real substrates (without any treatment or the need for separation of its components) is shown. In an efficient one-pot methodology, at 443 K and in the presence of a biphasic solvent system, selective conversions of hemicelluloses from raw biomass (bagasse, rice husk and wheat straw) to extraordinarily high yields of furfural of about 93% were attainable. Under similar reaction conditions, an 82% yield of furfural is also achievable directly from isolated hemicellulose within 10 h. Hydrophilic SAPO-44, having higher hydrothermal stability, showed similar activity for all the substrates for a minimum of up to 8 times in recycling runs. Various physico-chemical characterizations (X-ray diffraction, thermogravimetric analysis-derivative thermogravimetry, temperature programmed desorption-NH3, N2 sorption, solid-state nuclear magnetic resonance spectroscopy) of fresh and spent catalysts were used to improve SAPO-44 stability.
Conventional methods use mineral acid technology for the production of furfural7,8 from C5 sugars and hemicelluloses; however, these invariably create environmental issues and several other problems (corrosiveness, toxicity, handling hazards, recovery, generation of neutralization waste and so on). Thus, to avoid these inconveniences, use of non-toxic, recoverable heterogeneous catalysts having acidic functionality (solid acid catalysts) have recently been reported for the production of furfural, and primarily from xylose, a C5 sugar.9–24 These reactions are mainly carried out in water; but to improve the yields of furfural, use of polar aprotic solvents and biphasic solvent systems are also reported.11,12,16,25
Although solid acids are known to convert xylose into furfural, use of xylose as a substrate in the synthesis of furfural is not an economical option as xylose needs to be obtained in the pure form from hemicellulose in yet another reactor. The two-pot methods for the production of C5 sugars and furfural are described in the literature.26–28 Recently, a two-pot method for the conversion of hemicellulose to furfural was demonstrated where wood was first treated with hot water to convert its hemicellulose to yield soluble products and then in the next reactor these products, in the presence of H-mordenite (HMOR) as a catalyst, yielded furfural at the 74% level.28 Similarly, in another report it is shown that soluble products (xylo-oligosaccharides) having a degree of polymerisation of 1–14 (obtained from wood chips after hot-water treatment) can yield ca. 90% furfural using mineral acid (HCl, H2SO4) and NaCl as catalyst.29 To overcome the use of the two-pot method and use of mineral acids, recently a one-pot method for the conversion of hemicellulose into C5 sugars and furfural using solid acid catalysts was disclosed.30,31 Although in these communications it is reported that the zeolite, HUSY (Si/Al = 15), could give a yield of ca. 54% furfural, unfortunately the catalyst underwent morphological changes during the reactions.30 Consequently, it becomes crucial to develop stable solid acid catalysts for the efficient conversion of hemicellulose into furfural in a one-pot fashion (Scheme 1). Additionally, it is also essential to improve the furfural yields in these reactions to make the overall method attractive. In yet another report, microwave heating of hemicellulose and bagasse in the presence of mineral acid and a chloride salt is claimed to give good yields of furfural.32
In the current study the foremost intention was to introduce a stable catalytic system for the selective production of furfural in high yields directly (preferably) from raw (real) biomass. Silicoaluminophosphates (SAPOs) are known to have higher hydrothermal stability33,34 and thus it was thought that those may be stable under the hemicellulose reaction conditions. Further incentive for choosing SAPO catalysts was its expected higher hydrophilicity arising from the presence of ‘P’,35 which may limit the catalyst in the aqueous layer and thereby enhance the prospects of accomplishing higher furfural yields. Here we show that the use of SAPOs in the hemicellulose conversion improves the furfural yields in the absence of any pH-modifying reagents.
To understand this difference in the activity with the change in solvent system, the partition coefficient of furfural in these solvents was calculated (Fig. S1, ESI†). Additionally the miscibility of organic solvents in water was also studied. It was found that the higher partition coefficient of furfural in the water + toluene system, as compared with the other two solvent systems, is responsible for a higher furfural extraction in toluene and thus a better furfural yield was achieved through use of the water + toluene system. A lower furfural yield in water + MIBK compared with water + p-xylene is observed – although the water + MIBK system has a higher partition coefficient compared with water + p-xylene. This latter is because of the higher miscibility of MIBK in water (19.1 g L−1 at 293 K) compared with the miscibility of p-xylene in water (0.18 g L−1 at 293 K), which leads to the availability of furfural in both of the solvents, which then leads in turn to the degradation reaction.
At this juncture, to boost the furfural yield using the SAPO-44 catalyst further, reactions were performed for a longer time at 443 K. A furfural yield of 63% observed after 8 h was increased to 71% after 10 h, but a further increase in time (to 12 h) did not show any significant improvement in the furfural yield (which was then 72%).
To further advance the furfural yield, instead of using a substrate/catalyst (S/C) ratio of 4 (w/w) the ratio was increased to 8 and with this a furfural yield of 57% could be obtained with an 11% yield for xylose + arabinose after 8 h reaction time at 443 K. The marginally lower furfural yields might be because of the non-availability of active sites on the catalyst. In a subsequent reaction, an S/C ratio of 2 was maintained and a similar result (furfural yield of 63%) was observed to the one seen with the S/C ratio of 4. In order to investigate the effect of substrate concentration, reactions were caused while maintaining the S/C ratio at 4. Results demonstrate that an increase in hemicellulose concentration up to 5 wt% gives similar amounts of furfural (63 ± 1%), whereas it decreases to 42% when 10 wt% hemicellulose concentrations are used. At high hemicellulose concentrations, formation of a by-product (humin) leads to inferior furfural yield, as is evident from the formation of a dark-coloured reaction solution.
It is expected that by increasing the extracting-solvent-to-furfural ratio, furfural yields will be enhanced since furfural will be extracted into the extracting solvent and thus are unavailable for further reactions (in water). The water-to-toluene ratio was thus altered from 1:
1 to 1
:
2 and 1
:
4 (v/v) by keeping the substrate/water and substrate/SAPO-44 ratios constant. By employing a 1
:
2 ratio for 8 h reaction time, a superior yield of furfural (75%) (C5 sugar = 7%) was obtained; but when a 1
:
4 ratio was used, the yield was decreased to 49% (C5 sugar = 4%). In comparison with these results with a 1
:
1 ratio, a 63% furfural yield was achieved after 8 h reaction. Earlier results showed us that by carrying out the reaction for a longer time the furfural yield can be improved, so it was decided to perform the reactions with a 1
:
2 ratio for a longer time. The results illustrate that after 10 h, a furfural yield of 82% was accomplished, as compared with 75% after 8 h. With a further increase in time to 12 h, an even greater improved yield of 85% for furfural was feasible – although a subsequent increase in time (13 h and 14 h) did not yield any additional furfural. To the best of our knowledge, this is probably the first report where such a high yield of furfural was obtained directly from hemicellulose in a one-pot method.
By fine tuning the reaction parameters, it was revealed that in order for there to be an efficient conversion of hemicelluloses into furfural, the optimized reaction conditions were: use of 1 or 5 wt% substrate solutions, SAPO-44 catalyst, S/C ratio of 4, water + toluene at 1:
2 (v/v), tempertaure of 443 K, reaction time of 10–12 h. Under these conditions, 82%/85% furfural yield was possible with >99% conversion of softwood hemicellulose. To verify the robustness of the catalyst, recycling studies were carried out with the recovered SAPO-44 catalyst from the previously mentioned reaction (10 h, 82% yield). The catalyst was simply washed with distilled water and then subjected to the next reaction (for details see Experimental section, ESI†). Fig. S2 (ESI†) shows exceedingly good recycling activity of the SAPO-44 catalyst up to the 8th catalytic run, with similar furfural yields (83 ± 1%). Together with furfural, the formation of oligomers (2–3%), sugars (14–16%) and 5-hydroxymethyl furfural (HMF, 2%) accounts for the 100 ± 2% carbon balance. Furthermore, to find out the loss of catalyst after all these reactions, after the 8th run, the SAPO-44 catalyst was recovered from the reaction mixture (by centrifugation), washed with distilled water, dried (in oven and vacuum) and calcined (in air) at 823 K for 12 h. From the calculation of weight difference between the initially charged catalyst (1st reaction) and the catalyst recovered after the 8th run (calcined), minimal weight loss (ca. 10%) was observed.
The catalyst recycling studies were also performed with ion-exchange resins and niobium pentoxide and these showed a decrease in the activity in recycling studies (Amberlyst®15: 61% and 51%, Nafion® SAC-13: 52% and 47%, niobium pentoxide: 56% and 46%). These results strengthen our idea behind the use of hydrothermally stable SAPO.
To confirm the formation of furfural in this reaction, we isolated the furfural from the reaction mixture (toluene) by evaporating the solvent in a rotary evaporator and then the semi-solid obtained was characterized by proton nuclear magnetic resonance (1H-NMR) and 13C-NMR analysis. The NMR data presented in Fig. S3a and b (ESI†) confirms the formation of furfural in a pure form. Later, we calculated the isolated yield of furfural as 79% with an error of ±2% (in repeated attempts), when considering the total furfural yield in the reaction as 100%.
To establish the catalytic system, isolated hemicelluloses from a variety of sources, such as softwood (oat spelt and beechwood) and hardwood (birchwood), were used. When hardwood hemicellulose was processed at 443 K over SAPO-44 for 10 h in water + toluene (1:
2 v/v), yields of 69% furfural with 4% oligomers and 13% xylose + arabinose were obtained (total carbon recovery = 86%). Under similar reaction conditions, conversion of hemicellulose derived from oat spelt and beechwood showed similar activity (ca. 82% furfural yield, ca. 100 ± 2% total carbon recovery).
Parametersa | Substrates | ||||||
---|---|---|---|---|---|---|---|
Bagasse (I) | Bagasse (II) | Bagasse (III) | Rice husk (I) | Rice husk (II) | Rice husk (III) | Wheat straw | |
a TAAPI method is used for composition analysis.b ICP-OES analysis; calculations were done based on 1 g of raw biomass. | |||||||
Inorganic and organic composition in % | |||||||
Ash | 2.1 | 2.8 | 3.3 | 15.7 | 17.0 | 18.6 | 12.4 |
Pentosan | 30.0 | 24.1 | 21.6 | 15.9 | 11.2 | 12.4 | 21.4 |
Holocellulose | 63.2 | 71.1 | 68.3 | 60.5 | 52.4 | 52.6 | 63.2 |
α-Cellulose | 38.5 | 41.2 | 39.9 | 37.1 | 28.5 | 34.3 | 36.7 |
β-Cellulose | 12.9 | 15.2 | 15.3 | 9.9 | 11.7 | 6.8 | 17.1 |
γ-Cellulose | 11.8 | 14.7 | 13.1 | 13.5 | 12.2 | 11.5 | 9.4 |
Total lignin | 15.2 | 20.4 | 21.6 | 24.1 | 21.7 | 22.7 | 17.8 |
Nutrient compositionb in mmol g−1 | |||||||
Na | 0.0 | 0.0 | 0.0 | 0.0 | 0.0 | 0.0 | 0.0 |
K | 0.04 | 0.03 | 0.02 | 0.07 | 0.05 | 0.07 | 0.12 |
Ca | 0.03 | 0.03 | 0.07 | 0.02 | 0.01 | 0.03 | 0.03 |
Mg | 0.03 | 0.02 | 0.03 | 0.01 | 0.04 | 0.04 | 0.02 |
Al | 0.01 | 0.01 | 0.02 | 0.01 | 0.01 | 0.02 | 0.02 |
P | 0.02 | 0.01 | 0.01 | 0.01 | 0.05 | 0.05 | 0.01 |
Fig. 2 illustrates that from real substrates a remarkably high yield of 93% is achievable for furfural when the reactions were performed at 443 K for 8 h. In particular, when bagasse is used a 92 ± 1% yield is possible, while for other substrates an 86–92% yield is realizable. In all these reactions 100 ± 5% mass balance is achieved. The results demonstrate the capability of the SAPO-44 catalyst to process unpurified (non-isolated) hemicellulose from raw biomass to furfural in high yields. It is essential to mention here that in these reactions, formation of a minimal amount of glucose, fructose and HMF was also seen. The origin of these compounds is attributed to the fact that under similar reaction conditions cellulose is undergoing conversion (18%). This was further confirmed with the X-ray diffraction (XRD) analysis of fresh and recovered bagasse (with a catalyst) after reaction. A decrease in intensity for cellulose was observed in the XRD pattern (Fig. S5, ESI†), which proves that part of the cellulose is converted under these reaction conditions. It is also evident that some amorphous and crystalline parts of the cellulose are still not converted (2θ = 12.5–18.5° and 19.2–26.7°). However, a close look at the pattern reveals that because of the overlapping of the peaks of SAPO-44 by cellulose (bagasse), few peaks of SAPO-44 are visible (2θ = 9.5°, 20.6°, 21.8°, 30.9°). But it is certain that SAPO-44 does not undergo any structural changes, as was validated by the XRD of the calcined samples.
![]() | ||
Fig. 2 Utilization of non-isolated hemicellulose from raw biomass. Reaction conditions: substrate (0.67 g), SAPO-44 (0.05 g), water + toluene = 60 mL (1![]() ![]() |
In order to get an insight on the capability of SAPO-44 used in raw biomass work, a catalyst recycling study was undertaken. It is apparent from Fig. 3 that the catalyst showed more or less matching activity in at least eight cycles, even with different substrates. This clearly emphasizes the fact that the SAPO-44 catalyst is very robust and stable under the reaction conditions.
The XRD analysis for SAPO establishes the presence of a crystalline phase in the synthesized material (Fig. 4).38–41 XRD patterns for spent SAPO-44 catalysts recovered from the isolated hemicellulose reactions indicate the presence of all the peaks corresponding to CHA topology, as was seen with the fresh SAPO-44 catalyst, with the intensity of the peaks being almost the same. This data confirms the structural stability of SAPO-44. Furthermore, we have checked the XRD patterns for spent (calcined) SAPO-44 used in raw biomass reactions (during calcination, cellulose and lignin are removed, which is confirmed by CHNS elemental analysis). It was observed that bagasse does not have much effect on the crystallinity of SAPO-44 but, because of the presence of a high SiO2 content (ash) in rice husk and wheat straw (Table 1), a slight hump is observed when 2θ is in the range 16–29°, due to the presence of amorphous silica. This concept is also supported by a NH3− temperature-programmed desorption study of fresh and spent SAPO-44, where Table S1 (ESI†) shows that both the amount of total acid sites and the acid site distribution remain similar in both fresh and spent SAPO-44 catalysts used in either isolated hemicellulose or real biomass reactions.
Moreover, a nitrogen-sorption study confirmed that the surface area of SAPO-44 was approximately the same even after use in either isolated hemicellulose or real biomass reactions (Table S3, ESI†). Consequently, an almost similar pore size was also observed for SAPO-44 in all the cases (Table S3, ESI†). This data further proves that the SAPO-44 is a very stable catalyst under the reaction conditions.
Solid-state 29Si, 27Al and 31P magic-angle spinning NMR spectra further corroborate the structural stability of SAPO-44 (Fig. S8a–c; ESI†). In 29Si-NMR, both fresh and spent SAPO-44 (used in the isolated hemicellulose reaction) shows that the peaks corresponding to Q0, Q1, Q2, Q3 and Q4 species at −92.4, −96.2, −101.7, −107.7 and −112.8 ppm, respectively, have comparable intensity. The presence of a sharp single peak with similar intensity at 38.2 ppm in 27Al-NMR is indicative of the tetrahedral Al environment in both fresh and spent SAPO-44. Besides this sharp peak, another small peak at −15 ppm due to the presence of octahedral Al is observed in both fresh and spent catalysts. 31P-NMR spectra also support the fact that the SAPO-44 structural stability is the only tetrahedral environment for P, which is observed in both fresh and spent catalyst (used in the isolated hemicellulose reaction). The peak corresponding to −31.5 ppm is due to the existence of a P[4Al] environment in the SAPO-44 framework. The presence of additional SiO2 in raw biomass affects the solid-state NMR spectra of the spent catalyst, so it was difficult to confirm the structural stability of SAPO-44 in these reactions. But recycling study data may suggest that the catalysts are stable. In comparisons given in earlier communications, it was shown that zeolites undergo morphological changes.30
It is suggested that these catalysts will be useful for converting a variety of substrates derived from biomass, which need to be processed in the presence of water.
Footnote |
† Electronic supplementary information (ESI) available: Detailed description of materials used, catalyst preparations, characterization techniques, catalytic reaction and calculation, recycling study of SAPO-44 in isolated hemicellulose reaction, worldwide distribution of crops, hydrophilicity–hydrophobicity study, TGA-DTG analysis, TPD-NH3 analysis, solid state NMR studies. See DOI: 10.1039/c4ra04119d |
This journal is © The Royal Society of Chemistry 2014 |