Amin
Osatiashtiani
,
Lee J.
Durndell
,
Jinesh C.
Manayil
,
Adam F.
Lee
and
Karen
Wilson
*
European Bioenergy Research Institute, Aston University, Birmingham B4 7ET, UK. E-mail: k.wilson@aston.ac.uk; Tel: +44 (0)121 2045456
First published on 13th July 2016
The impact of alkyl chain length on the esterification of C2–C16 organic acids with C1–C4 alcohols has been systematically investigated over bulk and SBA-15 supported sulfated zirconias (SZs). Rates of catalytic esterification for methanol with acetic acid are directly proportional to the sulfur content for both SZ and SZ/SBA-15, with the high dispersion of SZ achievable in conformal coatings over mesoporous SBA-15 confering significant rate-enhancements. Esterification over the most active 0.24 mmol gcat−1 bulk SZ and 0.29 mmol gcat−1 SZ/SBA-15 materials was inversely proportional to the alkyl chain length of alcohol and acid reactants; being most sensitive to changes from methanol to ethanol and acetic to hexanoic acids respectively. Kinetic analyses reveal that these alkyl chain dependencies are in excellent accord with the Taft relationship for polar and steric effects in aliphatic systems and the enthalpy of alcohol adsorption, implicating a Langmuir–Hinshelwood mechanism. The first continuous production of methyl propionate over a SZ fixed-bed is also demonstrated.
Carboxylic acid esterification is also of growing importance in the context of renewable fuels, wherein concerns over depleting fossil fuel resources, climate change and CO2 emissions are driving the quest for clean catalytic technologies for biofuels production from the conversion of (non-edible) lignocellulose and/or triacylglycerides to alkane fuels or biodiesel.6,7 Likewise, esterification of biomass derived platform chemicals,8,9 including lactic, levulinic, itaconic, succinic and furan dicarboxylic acid, offers a sustainable route to produce a diverse range of esters and polyesters for use as bio-based solvents, fuel additives or materials.10–12 However, despite these opportunities, significant technical hurdles exist to the use of such biomass feedstocks which limit their economic deployment.8
The availability of a well-defined solid acid catalyst capable of esterifying short (C1–C3) and long chain (C12–C20) organic acids is particularly important for biofuel synthesis. Pyrolytic thermal decomposition of biomass, commonly used to generate liquid bio-oil for energy applications, produces an oil of low pH due to significant levels of C1–C3 organic acids. The corrosive nature of these bio-oils is detrimental for the lifetime of deoxygenation catalysts used in their downstream reforming, hence pre-treatment processes are required to neutralise their acidity and thereby improve oil stability.6 Similar pre-treatments are required to remove C12–C20 fatty acids from waste cooking, non-edible plant and algal oils to facilitate biodiesel production.3 Biodiesel typically comprises fatty acid methyl esters (FAMEs) formed via the esterification and transesterification of free fatty acids (FFAs) and triacyl glycerides (TAGs) respectively.13 Commercial biodiesel production currently employs energy-intensive and environmentally unfriendly processes utilising homogenous base catalysts such as sodium or potassium methoxide.5 Such liquid catalysts are highly active for transesterification, but very sensitive to water and FFAs, with saponification during aqueous quench and neutralisation steps generating vast quantities of inorganic salt contaminated aqueous waste, which hinders biodiesel purification and results in a high E-factor for the process.5,14 Life-cycle calculations on biodiesel synthesis from soybean feedstock show that fuel purification and associated water treatment is the single most energy intensive step in biodiesel production, accounting for 87% of the total primary energy input.15 Reducing the production of contaminated water during biomass conversion processes is critical to minimise any negative impact on society.16
Various solid acid catalysts have been studied for carboxylic acid esterification, including sulfonic acid functionalised (hierarchical) mesoporous SBA-15,14,17–21 KIT-65 and PMO13 silicas, Cs-exchanged heteropolyacids,22–26 tungstated zirconia,27 zirconium phosphate28–30 and Nafion/SiO2 composite (SAC-13),31 and sulphated zirconia (SZ).32–34 Of these solid acids, SZ is an attractive candidate because of its superacidic properties, low cost and good thermal stability.35–37 However, previous studies have either focused on use of bulk SZ for the esterification of short chain acids with methanol or ethanol, or the esterification of >C10 fatty acids.36,38,39 While such bulk SZs are promising solid acid catalysts, their low surface areas present significant opportunities to improve efficiency through the development of highly porous and nanocrystalline SZ phases with tunable acidity. To date, the impact of sulfur loading and associated acid strength on catalytic esterification has not been systematically investigated, and is important for optimising both product yield and also catalyst stability.
Herein, we report on the application of two systematic families of bulk and highly dispersed SZs40 (synthesised as conformal monolayers over an ordered mesoporous silica support) to the esterification of carboxylic acids in batch and continuous flow reactors. Alkyl chain length of both alcohol and acid influenced activity, reflecting a combination of steric and electronic effects and consistent with a bimolecular surface reaction. A first demonstration of the continuous liquid phase esterification of methanol with propanoic acid is also demonstrated for the most active SZ catalyst.
All catalysts were fully characterised by N2 physisorption, CHNS elemental analysis, acid site titration by propylamine chemisorption/TPD. Heats of adsorption of methanol, ethanol and 1-propanol on 0.05SZ were measured using a fully-automated Surface Measurement Systems Ltd Inverse GC system, with surface properties determined according to literature methods.44,45 Full details of the experimental procedures and equipment are given in the ESI.§
Continuous flow esterification of propanoic acid and methanol was conducted at 60 °C using a commercial Uniqsis FlowSyn reactor. Briefly, 75 mg catalyst was diluted with quartz beads (Sigma Aldrich, mesh size = 325), and packed within a 10 mm i.d. × 100 mm OMNIFIT® glass column to give a total bed volume of 1.7 cm3. A liquid stream of methanol (150 mmol) and propanoic acid (5 mmol) was then delivered to the packed bed at flow rates between 0.1 to 1 cm3 min−1. Samples were collected periodically for analysis by GC. Full details of the reaction conditions and analytical procedure are given in the ESI.§
Catalyst | Surface areaa/m2 g−1 | S loadingb/wt% | Acid site loadingc/mmol g−1 | −ΔHads (NH3)d/kJ mol−1 |
---|---|---|---|---|
a BET. b CHNS. c Propylamine TGA-MS. d NH3 calorimetry. | ||||
ZrO2 | 93 | 0.00 | 0.03 | 85 |
0.015SZ | 142 | 0.25 | 0.06 | 91 |
0.025SZ | 175 | 0.53 | 0.11 | 99 |
0.05SZ | 189 | 1.09 | 0.24 | 102 |
0.075SZ | 175 | 1.49 | 0.33 | 115 |
0.1SZ | 203 | 1.80 | 0.37 | 115 |
0.25SZ | 194 | 2.24 | 0.36 | 115 |
0.5SZ | 118 | 2.53 | 0.24 | 115 |
ZrO2/SBA-15 | 450 | 0.00 | 0.15 | 112 |
0.015SZ/SBA-15 | 433 | 0.48 | 0.20 | 113 |
0.025SZ/SBA-15 | 445 | 0.78 | 0.22 | 114 |
0.05SZ/SBA-15 | 463 | 1.52 | 0.27 | 114 |
0.1SZ/SBA-15 | 390 | 1.74 | 0.29 | 121 |
0.17SZ/SBA-15 | 489 | 2.16 | 0.29 | — |
0.25SZ/SBA-15 | 441 | 2.10 | 0.32 | 116 |
Bulk SZ samples possessed a relatively low BET surface area in the range of 140 to 200 m2 g−1 typical of non-porous sulfated zirconia catalysts. Mesoporous SZ/SBA-15 catalysts with surface areas between 430 and 490 m2 g−1 are consistent with previously reported materials.42 CHNS analysis and quantification of acid sites by propylamine adsorption/TGA-MS revealed that for bulk SZ the sulfur and acid site loading increased monotonically with the concentration of impregnating H2SO4 solution up to 0.25 M. While the sulfur content increased further for higher [H2SO4], the acid site loading reached a plateau due to the formation of multilayer sulfate compounds which do not contribute to the acidity.41 The sulfur and acid site loadings of the SZ/SBA-15 series likewise increased with [H2SO4] up to ∼0.1 M before reaching a plateau when the surface saturated at ∼0.17 M H2SO4. Previous NH3 calorimetry on these samples has shown that while increasing the S loading from 0 to 1.8 wt% enhanced the acid strength of bulk SZ, further increases in S loading did not affect the acid strength, consistent with the formation of SO4 multilayers at this point. This is also reflected in the peak propene desorption temperature for propylamine decomposition (Fig. S2§) which decreases from 440 °C to 425 °C with [H2SO4], consistent with increased acid strength. The acid strengths of the SZ/SBA-15 series were comparable to the highest loading bulk SZ catalysts, and exhibit a weak dependence on SO4 content; suggesting that surface Zr4+ sites are more readily polarised in conformal SZ coatings, even at the lowest SO42− loadings.
![]() | ||
Fig. 2 TOFs for propanoic acid esterification with different alcohols over bulk 0.05SZ, and of C2–C16 acids with methanol over bulk 0.05SZ and 0.05SZ/SBA-15 catalysts. |
The preceding results are consistent with a Langmuir–Hinshelwood bimolecular surface reaction model (Scheme 1).47 For this two site mechanism, coordination of the alcohol (via the hydroxyl oxygen) and the organic acid (via the carbonyl oxygen to form a carbocation) is required at adjacent Brönsted acid sites. The nucleophilic species generated upon deprotonation of the alcohol OH can then attack the carbocation to generate a tetrahedral intermediate which finally eliminates water to form the ester. Based on this proposed reaction mechanism, the lower activity of longer chain alcohols/acids is in accordance with previous observations,48,49 and can be attributed to polar and steric effects50 in the aliphatic systems, and is well described by the Taft relationship as shown in Fig. S11.§ The gradient of the plot of log(k/k(CH3)) versus polar substituent (σ*) or steric substituent constant (Es) gives rise to the sensitivity factors for the reaction towards polar (ρ) or steric effects (δ) respectively. Fig. S11§ shows that ρ is >1 suggesting the reaction accumulates negative charge in the transition state which is accelerated by electron withdrawing groups, while δ is also positive indicating steric effects are greater in the transition state, with increased in steric bulk leading to decreased reaction rate. While such steric and polar effects dictate activity for short chain acids, for long chain fatty acids diffusion limitation and reduced accessibility of acid sites may also contribute to decreased TOF.
![]() | ||
Scheme 1 Mechanism of esterification over Brönsted acid (B+) sites of a sulfated zirconia catalyst. (Adapted from ref. 47.) |
For alcohols, enhanced electron-donating properties with increased alkyl chain length are expected to destabilise the protonated transition state, explaining the concomitant decrease in esterification rate. Inverse gas chromatography measurements (Fig. S12§) also demonstrate that the adsorption enthalpy of C1–C3 alcohols on bulk SZ also decreases linearly with alkyl chain length (and pKa) (Fig. 3). Hence, the higher reactivity of shorter chain alcohols can be understood in terms of their weaker adsorption relative to more strongly bound C3 alcohols (of higher pKa), which favour alkoxide formation and concomitant blocking of catalytic sites.
Larger, more sterically-demanding alcohols may also experience limited accessibility to protonated (or activated) carboxylates, likewise hindering catalytic turnover, as reported previously for the esterification of primary secondary and tertiary alcohols over bulk SZ wherein activity decreased from 1° > 2° > 3° alcohols.36 The relative insensitivity of TOFs for longer chain alcohols is in agreement with studies of lauric acid esterification with C1–C6 alcohols,36 although the study by Grecea and co-workers observed the same activity for methanol as longer chain alcohols (possibly a consequence of their lower alcohol:
acid ratio of 1
:
1 and higher reaction temperature of 133 °C).
In the case of carboxylic acids, the inductive effect increases with chain length, with increases in the electron-donating ability of the acid, favouring protonation of the carboxylate oxygen. However, as a consequence, the electrophilicity of the carbonyl carbon is lowered, and hence the rate-limiting nucleophilic attack by an alcohol becomes disfavoured. This so called ‘steric effect’ increases with alkyl chain length of the carboxylic acid, and is widely assumed to dictate the reactivity of carboxylic acids in acid-catalysed esterification.50–52 Our observations in Fig. 2 are also consistent with the work of Liu et al.50 who investigated the effect of alkyl chain length on FFA esterification with methanol using sulfuric acid and a commercial Nafion/silica composite (SAC-13). Thus, for acids >C6 it seems likely that esterification is rate-limited not only by restricted access to active sites.
Table 2 summarises the conversions and initial rates of the esterification of all saturated organic acids explored, along with functional levulinic acid and unsaturated oleic and linoleic acids with methanol, to test the versatility of the 0.05SZ in esterification reactions of relevance to biomass conversion (Fig. S13§). It is interesting to note that under these mild conditions conversion of both oleic and linoleic acid is comparable to saturated palmitic acid suggesting that unsaturation is not detrimental to performance. The conversion of levulinic acid conversion also compares favourably to literature reports for SZ in levulinic acid esterification despite being under such mild conditions.53,54
The influence of residence time (τ) on propanoic acid conversion was first investigated (Fig. 4A). A monotonic rise in acid conversion was observed as the residence time was increased from τ = 4 to 19 min, reaching a maximum of 0.55 mmol h−1 g(cat)−1 for a residence time of 17.3 min, with single pass conversions reaching 45% and methyl propanoate selectivity ≥98%. The maximum acid conversion may be limited by poor mass-transport and the resulting accumulation of ester and water products at the catalyst surface for longer residence times, displacing the reaction equilibrium. Catalyst deactivation can be a significant barrier to the commercialisation of solid acid catalysts, with sulfate leaching and irreversible water adsorption often reported responsible for the deactivation of SZ catalysts.33,58 An extended propanoic acid esterification reaction was therefore performed to probe catalyst stability, employing a long residence time (τ = 17.3 min) in order to maximise reactant–catalyst contact. Fig. 4B shows the resulting TOFs for continuous flow versus batch esterification. In batch, the TOF fell continuously from a high initial value of 175 after 1 h to only 80 after 6 h. This activity loss will certainly reflect consumption of the acid, but may also be conflated with displacement of the equilibrium by reactively-formed water and/or deactivation. In contrast, continuous esterification revealed an extremely stable and high TOF of 140 (with ≥98% ester selectivity) throughout the 6 h reaction, evidencing excellent catalyst stability, and discounting deactivation as the cause of the poor longer term batch performance. Furthermore post reaction analysis of the reaction medium and catalyst by CHNS revealed no evidence for SO4 loss. It seems likely that literature reports of sulfate leaching from SZ are a consequence of the higher sulfuric acid concentrations (typically >0.25 M)59 employed in their synthesis, which may leave significant unstable sulfoxy species following calcination60 that are more susceptible towards leaching than our optimum SZ catalyst prepared with only 0.05 M H2SO4; control over the surface sulfate density may thus be integral to SZ stability.
Continuous esterification of propanoic acid with methanol under mild conditions is successfully demonstrated for the first time over a fixed-bed of bulk SZ, affording extremely stable operation with good conversion and excellent selectivity to methyl propanoate, and evidencing negligible S leaching.
Footnotes |
† The authors dedicate this paper to Professor James H. Clark in honour of his 65th birthday and immense contributions to the field of green chemistry to date. |
‡ To access the research data supporting this publication see http://dx.doi.org/10.17036/819fb053-e8b2-4541-aec6-07754a611d16 |
§ Electronic supplementary information (ESI) available: Sulfur loading analysis, temperature dependant propylamine desorption on TGA-MS, porosimetry isotherms, measurement of heat of adsorption, reaction profiles and TOFs, calculation of rate constant and Taft plots. See DOI: 10.1039/c6gc01089j |
This journal is © The Royal Society of Chemistry 2016 |