Xiang Shenab,
Yanxin Wang*c,
Birgitte K. Ahring*a,
Hanwu Leia,
Qiang Gaob and
Hui Liuc
aBioproducts Science and Engineering Laboratory, Washington State University, Richland, WA 99352, USA. E-mail: bka@tricity.wsu.edu; hlei@tricity.wsu.edu; Fax: +1 5093726782; Tel: +1 5093726782
bEngineering Research Center of Nano-Geo Materials of Ministry of Education, China University of Geosciences, Wuhan 430074, China. E-mail: xiang.shen@tricity.wsu.edu
cState Key Laboratory of Biogeology and Environmental Geology & School of Environmental Studies, China University of Geosciences, Wuhan 430074, China. E-mail: yx.wang@cug.edu.cn
First published on 26th October 2015
A cost-effective K1.5Mg/SiO2 catalyst with a K2MgSiO4 component was employed to help transfer several hexoses into hydroxylmethylfurfural (HMF) in a biphasic water/butanol system. The solid catalysts with rod-like structures and moderate base sites could promote the aldose–ketose isomerization of glucose and have potential for the synthesis of lactic acid via a retro-aldol condensation. In the presence of sulfonated titania/mordenite solid acid, the K1.5Mg/SiO2 catalyst presented heat-stability and prolonged activity in the one-pot conversion of glucose to HMF, leading to an optimal yield of 62.2%. The one-pot catalysis of saccharides from the enzymatic hydrolysate of poplar sawdust achieved a high HMF yield of 56.9% at a glucose conversion of 91.6%.
As an important intermediate, HMF can be produce from glucose by heterogenous catalysis,16–18 which would be used for biodegradable surfactants, pharmaceuticals, furanic polyesters, polyamides, and biofuels.19–22 However, glucose only contained 1% of furanose tautomers in aqueous solutions, which gave poor HMF yield in direct dehydration due to side reactions. Integrating isomerization of hexose to ketose and subsequent ketose dehydration to HMF was considered as an effective method. For this purpose, some research teams focused on combining metal chloride salts (e.g., AlCl3, CrCl3, SnCl4, LaCl3) with a Brønsted acid (e.g. HCl) to perform the glucose isomerization/dehydration reactions, leading to high HMF yield of 67 mol%.23,24 However, metal halides were generally inactive in neutral aqueous solution, the use of strong mineral acids incurred environmental problems, and the separation of HMF was difficult. Interestingly, Davis group found that a Sn-beta zeolite could isomerize glucose to fructose with high activity in water under acidic conditions.25,26 The unique performance of the Sn-beta solid Lewis acid created new opportunities for the facile integration of isomerization with dehydration steps. Nikolla group27 developed the synergistic catalysis of Sn-beta with HCl for glucose conversion in a water/butanol biphasic system, leading to 55 mol% HMF selectivity under a glucose conversion of 75%. However, Sn-beta is not a commercially available zeolite and complex preparation leading to high cost. In addition, the enzymatic hydrolysate of poplar sawdust included glucose, cellobiose, xylose, mannose, and galactose; efficient conversion of these saccharides to HMF will be a substantial challenge.
Given the fact, the work focused on the aldose–ketose isomerization using low leaching solid catalysts for improving the selectivity of HMF in a one-pot system. A combination of sulfonated titania/mordenite (TM) with different KxMg/SiO2 catalysts could afford high HMF yield under a moderate reaction temperature. The one-pot reaction using heterogeneous catalysts would provide the best solution to process the complex saccharides from poplar sawdust.
The KxMgSiO4 catalysts were prepared by precipitation-gel method. In a typical procedure, 8.8 g of Mg(NO3)2·6H2O and 0.3 g CTAB was dissolved with 10 mL mixed solution of deionized water and ethanol (50% by volume). The solution was added into 20 mL acidic industrial silica sol (31 wt% SiO2, pH of 3) under vigorous stirring for 15 minutes. The stoichiometric potassium carbonate was dissolved with about 10 mL deionized water and added into the above mixed sol under homogeneously stirring for 30 minutes. The forming gel was aged overnight at 403 K and then washed with ethanol. The resultant precursors were dried and calcined at 973 K for 2 h. Thermally activated catalysts were denoted as KxMg/SiO2 (as K/Si molar ratio, x = 1.0, 1.2, 1.5, 1.7).
The microstructure of prepared solid catalysts was analyzed by a FEI Sirion 200 field emission scanning electron microscope (FESEM), FEI Tecnai G2 20 Transmission Electron Microscope (TEM) and X'Pert PRO DY2198 X-ray diffractometer (XRD). The mean crystallite size of samples was calculated by the XRD line width of 220 peak using the Scherrer formula. The alkalinity of samples was studied with TPD using CO2 as molecular probe. Each sample was treated at 573 K with N2 flow of 30 mL min−1 for 1 h and then in a reacting CO2 flow of 15 mL min−1 at 323 K for 30 min. The physical adsorbed CO2 was eliminated by pure nitrogen. The oven temperature of the TPD was programmed from 323 K to 1073 K at 10 °C min−1 in He flow of 15 mL min−1 and desorbed CO2 was detected using TP-5075 apparatus (Tianjin Xianquan Co.) with thermal conductivity detector. The potassium and magnesium analyses were carried out by using inductively coupled palama-atomic emission spectrometer (Thermo IRIS Interpid XSP ICP-AES, USA). Refer to digestion procedure, about 0.1 g catalyst sample was transferred into a Teflon vessel containing 5 mL hydrochloric acid (37%) and heated on a hot plate at 120 °C until the residual liquid was 2–3 mL. Next, 5 mL nitric acid (69%) was added into the Teflon vessel to obtain colorless solution by evaporation, followed by drying at the same temperature by the addition of 2 mL hydrofluoric acid (40%). At last, 2 mL nitric acid was added to dissolve the residue. As an analytical sample, 0.1 mL of the digestion solution was suctioned with a pipette into a volumetric flask to 25 mL by addition of ultra pure water. Blank tests and parallel experiments were conducted to improve the measurement accuracy and precision. Thermogravimetric analysis (TG) and differential thermal analysis (DTA) was carried out on a PerkinElmer Diamond TG/DTA instrument from 25 to 500 °C at a ramp of 10 °C min−1 under a flow of N2 for evaluating the thermal stability of prepared catalysts.
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| Fig. 1 XRD patterns of prepared solid bases: (a) K1.0Mg/SiO2, (b) K1.2Mg/SiO2, (c) K1.5Mg/SiO2, (d) K1.7Mg/SiO2; (◇) KNO3, (◆) K2MgSiO4, (¤) K2O. | ||
To provide additional evidence, morphologies of prepared catalysts were analyzed. The TEM images of K1.5Mg/SiO4 showed rodlike crystal (Fig. 2f–h) and exhibited small round-shape particles on the surface (Fig. 2e). Comparing with Fig. 2c and i scanning micrograph, it could be seen that the crystalline particles decreased gradually with the increase of potassium amount in prepared catalysts. Electron micrographs (Fig. 2b, d, f and k) showed that the K1.5Mg/SiO2 catalysts presented a cluster of well-developed rodlike structure with a certain length–diameter ratio different from other catalysts, implying a difference in catalytic activity owing to their different composition. And the K1.5Mg/SiO2 catalysts can be well dispersed in reaction medium, which would be beneficial to the one-pot reaction. We noted that the K1.5Mg/SiO2 catalyst with lower amount led to incomplete crystallization and an unclear image (Fig. 2a), implying an unmatched synergism between the active components and the silica support. Another, too much potassium loading could increase the moisture absorbency of prepared K1.7Mg/SiO2 catalysts leading to agglomerated particles.
Advancing a step, we investigated CO2-TPD profiles (Fig. 3) to validate the correlation between composition of prepared catalysts and their alkalinities. The broadening peaks corresponding to different temperature demonstrate the different basic sites on the surface of catalysts. The desorption peaks at about 373 K or 573 K demonstrated the moderate basic sites on the catalysts, which are associated with the surface OH– groups adsorbed on the K–O or Mg–O species.30,31 The K2MgSiO4 component of catalyst would be the source of the moderate basicity, which would induce excellent catalytic activity. Nevertheless, excess KNO3 adsorbed on the catalyst could increase the moisture absorbency of prepared K1.7Mg/SiO2 catalysts leading to agglomerated particles, which is unfavourable to the isomerization reaction.
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| Fig. 3 CO2-TPD profiles of prepared solid catalysts: (a) K1.0Mg/SiO2, (b) K1.2Mg/SiO2, (c) K1.5Mg/SiO2, (d) K1.7Mg/SiO2. | ||
In order to mitigate the negative effect of oligosaccharides and acetic acid, we chose the low concentration of enzymatic hydrolysate for the same reaction using TM0.3 solid-acid and different KxMg/SiO2 catalysts. The composition of saccharides solution included glucose of 19.57 g L−1, acetic acid of 3.59 g L−1, cellobiose of 1.44 g L−1, xylose of 3.28 g L−1, mannose of 0.86 g L−1 and furfural of 1.32 g L−1. The yield of HMF was significantly improved (Table 1). Moreover, the competitive adsorption was weakened due to less reactant molecules at relatively low concentration, which could improve the interaction of active sites on catalysts with reactants. Considering the similar conditions, the catalytic activity corresponding to HMF yield increased as follows: K1.0Mg/SiO2 < K1.2Mg/SiO2 < K1.7Mg/SiO2 < K1.5Mg/SiO2. Therefore, it was reasonable to assume that the moderate base sites played a significant role in determining the conversion of hexoses to HMF.
| Run | Catalyst | Feedstock | Conversion of glucose (mole%) | Yield of HMF (mole%) | Selectivity of HMF (mole%) |
|---|---|---|---|---|---|
| a Amount of K1.5Mg/SiO2 catalyst was set to 0.3 g.b Amount of K1.5Mg/SiO2 catalyst was set to 0.5 g. | |||||
| 1 | K1.5Mg/SiO2 + TM0.3 | Enzymatic hydrolyzate | 91.62 | 56.94 | 62.15 |
| 2 | K1.7Mg/SiO2 + TM0.3 | Enzymatic hydrolyzate | 81.45 | 47.59 | 58.43 |
| 3 | K1.2Mg/SiO2 + TM0.3 | Enzymatic hydrolyzate | 76.14 | 32.78 | 43.05 |
| 4 | K1.0Mg/SiO2 + TM0.3 | Enzymatic hydrolyzate | 52.78 | 33.36 | 63.2 |
| 5 | K1.5Mg/SiO2 | Glucose | 88.17 | 7.58 | 8.6 |
| 6 | TM0.3 | Glucose | 35.14 | 16.98 | 48.32 |
| 7 | K1.5Mg/SiO2 + TM0.3 | Glucose | 94.32 | 62.24 | 65.98 |
| 8 | K1.7Mg/SiO2 + TM0.3 | Glucose | 90.05 | 53 | 58.86 |
| 9 | K1.2Mg/SiO2 + TM0.3 | Glucose | 83.53 | 39.17 | 45.09 |
| 10 | K1.0Mg/SiO2 + TM0.3 | Glucose | 74.4 | 36.74 | 49.38 |
| 11 | K1.5Mg/SiO2 + TM0.3a | Glucose | 70.3 | 34.6 | 49.22 |
| 12 | K1.5Mg/SiO2 + TM0.3b | Glucose | 96.5 | 58.5 | 60.62 |
| K (ppm) | Leaching ratio | Mg (ppm) | Leaching ratio | |
|---|---|---|---|---|
| K1.5Mg/SiO2 (fresh) | 66.72 ± 0.5 | 13.36 | ||
| KMg-1 | 2.51 ± 0.5 | 3.76% | 0.019 | 0.14% |
| KMg-2 | 1.79 ± 0.5 | 2.68% | 0.016 | 0.12% |
| KMg-3 | 0.87 ± 0.5 | 1.3% | 0.007 | 0.05% |
| KMg-4 | 0.38 ± 0.5 | 0.57% | 0.007 | 0.05% |
| KMg-5 | 0.26 ± 0.5 | 0.39% | — | — |
| K1.5Mg/SiO2 (used) | 60.96 ± 0.5 | 13.25 |
Furthermore, we conducted the conversion of glucose to HMF by integrating different KxMg/SiO2 catalyst with TM0.3 catalysts (Fig. 5). The HMF selectivity increased with increasing glucose conversions, and a maximum of 65.98% with K1.5Mg/SiO2 and TM0.3 catalysts at a glucose conversion of 94.32% was achieved. This coincided with the trend that was for catalyst with relatively high base sites and Brønsted acid sites. Additionally, the high selectivity was attributed to the mesoporous structure of solid catalysts, which increased active sites of inner surface of catalysts. It was noted that lactic acid as a by-product was observed for all experiments due to the moderate base sites of KxMg/SiO2 catalyst.32,33 The catalyst with K2MgSiO4 component could have potential for the synthesis of lactic acid from glucose. From Table 1, it can be seen that glucose can be converted in the presence of the K1.5Mg/SiO2 catalyst, and the selectivity of HMF was only 7% at 88% glucose conversion. In the absence of either the K1.5Mg/SiO2 catalyst or TM0.3 solid-acid, the yield of HMF was low (run 5 and 6). It could mean that the K1.5Mg/SiO2 catalyst was in favor of the conversion of glucose, and TM0.3 solid-acids with mesoporous structure helped improve the selectivity of HMF. The surface of TM0.3 catalyst was in the presence of Lewis acid sites due to Ti4+ and Si–O–Al bond of mordenite skeleton, and Brønsted acid sites were due to the sulphation process. The Lewis acid and Brønsted acid sites facilitated the dehydration reaction of fructose. The addition of KxMg/SiO2 catalysts improved significantly the conversion of glucose, as shown in runs 7–10, which led to an optimal HMF yield of 62.24% with a considerable reaction time. The effectiveness of the K1.5Mg/SiO2 catalyst for the conversion of glucose to fructose can be understood in terms of the intrinsic properties of base sites and dispersed rodlike microstructure. The product distribution was also influenced by the amount of the K1.5Mg/SiO2 catalyst. Decreasing the amount of K1.5Mg/SiO2 catalyst from 0.4 g to 0.3 g resulted in a declining yield of HMF (34%) with 49% selectivity, ascribed to a decrease in fructose formation by base-catalyzed isomerization (run 11). In contrast, increasing the amount of the K1.5Mg/SiO2 catalyst to 0.5 g improved the HMF yield to 58% with 60% selectivity (run 12). It was very interesting to note that the moderate base sites and anisotropic structure would promote the aldose–ketose isomerization and the formation of lactic acid. Initially, the formation of D-fructose and D-mannose was observed. It was possible that the K1.5Mg/SiO2 catalyst or Lewis acid sites promoted the isomerisation of D-glucose to the intermediate of D-mannose and D-fructose.34 The formation of HMF could follow a mechanism, in which the open-chain form of fructose was dehydrated at the C-2 position using TM0.3 solid acid, forming a carbocation which reacted with the hydroxyl group at C-5 position, forming furaldehyde intermediate followed by further dehydration to form HMF. Lactic acid, the main by-product, was likely formed from the hexoses via a complex reaction pathway without the formation of furaldehyde intermediate.32,35 The first step was believed to consist of the formation of glyceraldehyde from the saccharides through a retro-aldol condensation reaction. In a subsequent step glyceraldehyde was dehydrated to pyruvaldehyde, which subsequently rearranged to lactic acid.
Further, the thermal behavior of the dried K1.5Mg/SiO2 catalyst was shown in Fig. 6. Several ambiguous endothermic peaks were detected from on the DTA curve. The first endothermic peak is due to the release of adsorbed water of the catalyst sample around 150 °C resulting in 1.76% weight loss. The second peak at ca. 380 °C is attributed to the decomposition of the small amount of potassium nitrate. From TG plot, the weight remained almost unchanged above 600 °C, indicating the stability of the structure of solid catalyst.
Solid catalyst's stability played an important role in determining the economical application for large-scale production. The previous work36 reflected massive potassium salt was soluble in the water of ethanol system and potassium leaching from the catalyst resulted in reducing the activity of catalyst. Here, using the silica gel as supporter is necessary to stabilize the active sites and to prevent the leaching procedure. The excellent catalytic properties confirmed that the components of the solid catalyst are synergetically assembled by the precipitation-gel-thermally activated process.
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