Zhaoxing
Wang
a,
Tejas
Goculdas
ab,
Yung Wei
Hsiao
a,
Wei
Fan
bc and
Dionisios G.
Vlachos
*ab
aDepartment of Chemical and Biomolecular Engineering, 151 Academy St, University of Delaware, Newark, DE 19716, USA. E-mail: vlachos@udel.edu
bCatalysis Center for Energy Innovation, Delaware Energy Institute (DEI), 221 Academy St, University of Delaware, Newark, DE 19716, USA
cDepartment of Chemical Engineering, University of Massachusetts, Amherst, MA 01003, USA
First published on 3rd July 2024
Continuous manufacturing of platform chemicals from lignocellulose is highly desirable for a fossil fuel independent future. We demonstrate highly selective production of para-xylene (pX) from ethylene and 2,5-dimethylfuran (DMF) in a packed bed microreactor using phosphorous-decorated zeolite beta (P-BEA), with pX selectivity up to 97% at 80% DMF conversion. We map the effect of reactor temperature, space velocity, concentration, gas-to-liquid ratio, and process pressure. Time-on-stream (TOS) and in situ regeneration studies show minimal productivity degradation over ∼5 h TOS and full productivity restoration upon regeneration for multiple cycles. Most non-selective Brønsted acidity occurs at low TOS and is attributed to the remaining trace Al bridge site. External mass transfer limitations are implicated at low space velocities. We combine the TOS data with NMR, XRD, and Raman to develop structure–performance insights into the catalyst behavior. A comparison with mesoporous P-supported materials illustrates that P-BEA is an excellent catalyst for size selectivity and long-term stability.
Fig. 1 Cycloaddition of 5-dimethylfuran (DMF) and ethylene and dehydration of the oxanorbornene cycloadduct to form pX. |
Cho et al. demonstrated the highest pX yield of 97% in batch mode using the P-BEA catalyst prepared by dealumination of the CP814E commercial zeolite beta and incorporation of phosphoric acid.12 Gulbinski et al. further showed the interplay between phosphoric acid and the silica support for high pX yields in batch.13 Kim et al. investigated mesoporous titanium phosphate catalysts for converting biomass-derived furans to pX and toluene via Diels–Alder cycloaddition. Hydrothermally synthesized MTiP catalysts, particularly MTiP-E, showed superior performance in converting DMF and ethylene to pX, with over 90% selectivity and conversion. The same catalysts also efficiently converted 2-MF to toluene.16 Feng et al. demonstrated DMF and ethylene to pX chemistry over tin phosphate catalysts. The SnPO catalysts, featuring tetrahedrally coordinated Sn(IV) active sites, achieved a high pX yield of 93% after 18 h in batch. The superior catalytic performance of these SnPO catalysts was attributed to the enhanced main reaction via adjustable acid sites upon varying the P/Sn molar ratio, improved mass transfer efficiency, and carbon tolerance stemming from the mesoporous support structure.17 Wu et al. investigated the same reaction using zirconium phosphate (ZrP-x) catalysts. ZrP-2.5 achieved a pX yield of 89.2% at 72.3 mmol pX per g per h at 250 °C after 12 h. This high performance was attributed to a balance of Brønsted and Lewis acid sites and the catalyst's mesoporous structure.18
Large-scale implementation of biomass conversion requires continuous flow reactors for the manufacturing of chemicals. From a process development perspective, flow reactors allow TOS data collection, a better understanding of catalyst deactivation, and higher temperatures with shorter residence times, mostly unattainable by batch reactors. The distributed valorization of lignocellulosic biomass can also benefit from continuous operation of flow reactors, reducing the demand for cycling batch reactors. Prior works exploring the feasibility of flow chemistry have been reported. Yu et al. demonstrated for the first time this tandem reaction in a continuous flow reactor using H-, Sn-, and Zr-BEA catalysts. They found that both Brønsted and Lewis acid sites can catalyze the oxanorbornene dehydration reaction at similar rates, with Sn-BEA achieving the highest pX selectivity of 94% at 7.5% DMF conversion and the highest DMF conversion of 35% with 74% selectivity at 423 °C.14 The Brønsted acid sites in H-BEA were unstable, primarily due to oligomerizing DMF and 2,5-hexanedione.14 In another continuous flow reactor effort, Mendoza Mesa et al.15 proposed using liquid acrylic acid as the dienophile instead of ethylene and achieved over 80% pX selectivity over H-BEA (Si:Al = 150) using 0.3 M DMF in n-heptane for over 8 h time-on-stream (TOS). These works show the potential to further enhance pX chemistry productivity via catalyst optimization and rational reactor design. In this work, we explore pX production from ethylene and DMF in a gas/liquid three phase packed bed microreactor using phosphorous-decorated zeolite beta (P-BEA). We demonstrate high performance compared to previous flow reactor experiments with pX selectivity up to 97% at 80% DMF conversion. We map the effect of reactor temperature, space velocity, concentration, gas-to-liquid ratio, process pressure, and TOS. The near complete dealumination of zeolite beta in this work, coupled with flow reactor experiments, reveals transient catalyst behavior not typically seen in batch reactors due to prolonged startup and heating times typical of bench-scale batch reactors. The remnant aluminum bridge sites are strong Brønsted acids that lead to nonspecific reactions seen in the flow reactor, as the early collectible liquid outlet stream experiences all possible active sites.
During a typical flow reaction (Fig. 2), the reactor was first heated to the reaction temperature under slow N2 flow at 1 atm, then pressurized with ethylene to the desired process pressure before starting the gas and liquid flows immediately after. The first liquid samples exit the outlet after ∼40 minutes. The gas is automatically separated from the liquid upon cooling and depressurization. The liquid product was characterized on an Agilent 7890B gas chromatograph (GC) equipped with an HP-INNOWAX column (30 m length, 0.25 mm film thickness, 0.25 µm ID). An Agilent GCMS with an identical HP-INNOWAX column was used to identify product species (Fig. S1†). In all samples with high pX yield, meta-xylene (mX) was also observed in the gas chromatogram at approximately 2% of the pX yield. In samples with >1% yield of alkylated products, 2-ethyl-p-xylene was the dominant product and was considered a model compound of alkylation reactions beyond the primary reaction pathway. DMF (Acros Organics, 99%) and pX (Sigma-Aldrich, 99%) in n-heptane (Fisher Scientific, 99%) external calibration curves were created for the concentration ranges relevant to this work. The pX calibration curves were used for the alkylated products. For in situ catalyst regeneration, the reactor column was placed in a tube furnace; its inlet was connected to flowing air at 15 sccm at 1 atm, heated to 550 °C at 10 °C min−1, and held for 5 h. In these experiments, the conversion, yield, selectivity, and carbon balance are evaluated as follows:
Our optimization efforts have led to optimum conditions near 750 psig and 375 °C. Increasing the pressure from 300 and 750 psig (Fig. 3a) led to monotonic pX yield and selectivity improvement. We attribute this to increased cycloadduct concentration at higher ethylene partial pressures, as the retro Diels–Alder reaction is heavily favored at higher temperatures.11 When changing the gas-to-liquid (G:L) flow ratio (Fig. 3b), a volcano-type behavior is seen as the pX yield and DMF conversion peak near a G:L ratio of 400 v/v. The increase in DMF conversion with increasing gas flow rate is probably due to enhanced external mass transfer and the decline at high flow rates to reduced residence time, while the pX selectivity increases monotonically due to the higher ethylene availability from enhanced external mass transfer. We use a G:L volume ratio of 400 for operational ease for subsequent experiments. We further illustrate this behavior by analyzing the Thiele modulus and Mears criteria in the ESI.†
We vary the weight hourly space velocity (WHSV) to optimize productivity further (Fig. 4). Specifically, 1/WHSV was increased to 9.3 h at varied DMF feed concentrations and temperatures. Interestingly, the DMF conversion, pX yield, and pX selectivity showed non-monotonic behavior, except for DMF conversion at 20 wt%, where DMF conversion increases monotonically with inverse WHSV, potentially due to non-selective reactions.
To understand the process stream phase behavior under the experimental conditions in the flow reactor, COSMO-RS (Amsterdam Modeling Suite) and NRTL (ASPEN Plus) models were employed. Detailed simulation setup and results are discussed in the ESI Note 1.† The process streams are either gas phase or a gas-like supercritical phase. Short residence times at fast flows lead to high external mass transfer and limited contact time of the cycloadduct over the active site. Conversely, long residence times come with slow flow and mass transfer, and thus external mass transfer limitations. The concave curve shapes in Fig. 4 demarcate a clear transition from external mass transfer to potentially internal diffusion or kinetically limited with increasing space velocity.
Further productivity optimization included a 1/WHSV study with 20 wt% DMF feed at various temperatures (Fig. 5). A temperature of 375 °C achieves the highest pX selectivity. DMF appears particularly prone to non-selective condensation reactions at 400 °C, as indicated by the early drop in selectivity at 1/WHSV above 2 h, lack of quantifiable liquid phase byproducts, and a product mixture turning brown (inset in Fig. 5).
Other phosphorous-decorated mesopore supports, P-SiO2 and P-SBA-15, show enhanced productivity of ethyl-p-xylene, with slightly reduced pX yield for P-SiO2(25) at 50% and P-SBA-15(25) show comparable pX yield (57% vs. 56%) to P-BEA (25). However, the reduced pX selectivity due to a higher occurrence of alkylated products results in lower pX selectivity for both P-SiO2(25) and P-SBA-15(25). Compared to P-BEA(25), P-BEA(12.5) exhibits comparable ethyl-p-xylene yield, a reduced pX yield, and a slightly higher DMF conversion. The GC-FID shows an abundance of other alkylated products. This could result from aggregated P sites giving rise to non-selective chemistry. High phosphoric acid concentrations in batch reactions have also reduced pX selectivity.13
Fig. 8 Thermogravimetric analysis (TGA) of fresh and spent P-BEA(25). 20 wt% DMF in feed. Catalyst after10 h overall TOS exposed between 250 °C and 425 °C. |
Continuous flow reactors provided ease of catalyst regeneration without the need to recover the catalysts after each batch reaction. In situ regeneration of the catalyst performed for multiple cycles shows little degradation in pX yield despite a slight decrease in DMF conversion (Fig. S5 & S6†). Motivated by this, we characterized small catalyst quantities (∼10 mg) near the end of the reactor at short TOS before resealing the reactor and resuming the reaction. A slight reduction in productivity over time is seen in Fig. 7, attributed to catalyst loss from sampling for characterization.
Raman spectroscopy on the fresh samples shows an utterly flat baseline between 600 and 1850 cm−1 (Fig. 9). Raman spectra on the spent catalysts show typical coking signatures. No significant change in coking between 1 and 8 h TOS and on different supports is seen. A strong signature of G (1620 cm−1) and D (broad peak at 1350 cm−1) bands without apparent differences in sub-signals from the D1–D4 bands, indicative of identical coking pathways with TOS, are seen.24 The same analysis on fresh and spent (2 h TOS) P-SiO2 and P-SBA15 shows that the spent spectra are nearly identical to P-BEA (Table 1), indicating a similar coking mechanism.25
Sample | q0 (0 shift), % | q1 (−11 ppm), % | Q2, Q3, Q4 |
---|---|---|---|
Fresh | 73.4 | 26.6 | Not detected |
1 h TOS | 75.3 | 24.7 | |
2 h TOS | 72.9 | 27.1 | |
70 h TOS + regeneration | 57.8 | 42.2 |
We conducted solid-state 31P NMR on the P-BEA(25) catalysts to investigate the P speciation (Fig. 10). The intense signal at 0 ppm (q0) is from H3PO4, likely trapped in the micropores without chemical bonding. The −11 ppm q1 signal is from OP(OSi or OP)(OH)2. Signals indicating higher degree of P agglomeration, such OP(OSi or OP)2(OH) at approximately −24 ppm and OP(OP)m(OSi)n between −30 and −35 ppm, (m + n = 3), are absent.25,26 Comparison of fresh and TOS samples shows negligible change in P speciation over short TOS, except a slight reduction in peak sharpness at longer TOS. As minimal reactivity loss is seen and portions of the catalyst were removed from the reactor, the signal reduction is unlikely an effect of significant P loss. This indicates a low degree of P aggregation within the P-BEA(25) zeolite, and while the overall signal intensity decreases with increasing TOS, the relative q0/q1 ratio remains constant. The combination of modest P loading and low mesoporosity of P-BEA(25) catalyst gives high activity and stability compared to other supports and the higher loading of P-BEA(12.5). After approximately 70 h TOS and in situ catalyst regeneration, the q0/q1 ratio slightly decreases, reflecting potential P loss in the form of H3PO4 even though the catalyst activity is largely sustained post-regeneration.
The XRD patterns of the P-BEA(25) show the typical zeolite beta characteristics after synthesis (Fig. 11).27 The peak widths at 2θ = 8° and 22° of the fresh and 8 h TOS samples are the same despite a decrease in peak intensities, potentially due to coke. Slight crystallinity degradation upon long TOS and in situ regeneration (from pressure, DMF concentration, temperature effects, and WHSV experiments) without an impact on productivity was also observed in our prior batch experiments.
Fig. 11 X-ray diffraction patterns of fresh P-BEA(25) and spent catalysts (1, 2, and 8 h time on stream), and after approx. 70 h time on stream and one regeneration cycle. |
Footnote |
† Electronic supplementary information (ESI) available. See DOI: https://doi.org/10.1039/d4gc01904k |
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