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through steric effects. Others authors also studied the aqueous 823 K during 4 h, to exchange NH4+ to H+. The ZrO2/SO42−
reaction of FA, without reporting LA yields. Hronec et al.6 superacid catalyst was synthesized via a precipitation method,
found that the major compound obtained was 4-hydroxy-2- using an ultrasound system at low temperature, according to
cyclopentenone (4-HCP), which is catalyzed by hydrogen ions the following procedure. ZrN2O7·H2O was dissolved in distilled
formed via the autodissociation of water. Maldonado et al.7 water, and then the pH was adjusted at 9.0 via the addition of
asserted that germinal diol species (4,5,5-trihydroxypentan-2- aqueous ammonium (NH4OH, 30%). The solution was
one) were formed as main intermediate to LA via the use of introduced into ultrasonic equipment, and it was dried at 383
Amberlyst 15 as a catalyst. In addition to this, some other K by 6 h. The dried solid was immersed in 50 mL of H2SO4(0.5
authors have also studied the effect of using organic solvents to M) for 12 h, and then the solid was separated by filtration and
extract organic molecules from the aqueous acidic reaction dried at 383 K. Finally, the solid was calcinated at 923 K. The
medium and minimize the undesired condensation products, hydrated PTA (Alfa Aesar) was supported on ultrastable Y-
using alkyl alcohols,14 alkyl phenols,15 cyclopentyl methyl zeolite and ZSM5 zeolite (referenced hereafter as PTA-USY
ether,16 or traditional solvents (such as toluene or tetrahy- and PTA-Z(50), respectively). These materials were prepared
drofuran (THF)).5 Furthermore, if an alcohol is incorporated containing 10 wt % PTA (12WO3·H3PO4·xH2O), equivalent to
in the FA acid reaction medium, then high yields to levulinate 7.6 wt % tungsten; in both cases, 0.3 g of PTA was dissolved in
esters are obtained.17 doubly distilled water (50 mL), and the content was transferred
Since the best result was reached by Otsuka et al.,2 using to a rotary evaporator with 3 g of previously degasified zeolite.
homogeneous catalysis, this work is focused on the study of the The temperature and pressure of impregnation were set to 313
production of LA from FA via the hydration and ring opening K and 5 mbar, respectively. The solids obtained were calcined
of FA, using different heterogeneous acids catalysts as a in air at 523 K. The Amberlyst 47 (A47) and Amberlyst 35 Wet
substitute for hydrochloric acid (HCl). Even more, a water- (A35) are commercial ion exchange resins that were provided
soluble aliphatic ketone was added to the reaction media in by Rohm Haas. They were dried overnight to 333 K before use.
order to obtain a higher efficiency in the production of LA.2 2.2. Characterization of Catalysts. Textural parameters
were determined by using N2 adsorption−desorption techni-
2. EXPERIMENTAL SECTION ques at 77.35 K. The specific surface areas were obtained by
2.1. Preparation of Catalysts. The screening of catalyst applying the Brunauer−Emmett−Teller (BET) method, and
was carried out by preparing the following catalysts: inorganic the total pore volume was calculated at a relative pressure of P/
catalysts as HZSM-5 zeolite (H-Z(50)), beta zeolite (H-β), P0 = 0.976.
ultrastable zeolite (H-USY), heteropolyacid-type phospho- Temperature-programmed desorption of ammonia (NH3-
tungstic acid (PTA), zirconia sulfated superacid (ZrO2/ TPD) was used in order to measure the amount and strength of
SO42−), and the organic commercial ion exchange resins acid sites on the catalysts. The TPD profiles were monitored
Amberlyst 35 Wet (A35) and Amberlyst 47 (A47). These using a thermal conductivity (TCD) detector and recorded
materials have a substantial amount of Brönsted acid sites,18−22 from 272 K to 823 K at a heating rate of 10 K/min. The catalyst
and different textural properties as surface area and pore size, as was pretreated in a helium flow at 773 K for 1 h to remove the
well as thermal stability. The ZSM5 (SiO2/Al2O3:50) and β- physisorbed water and the intracrystalline water. Then, the
zeolites (SiO2/Al2O3:25) were purchased from Zeolyst Interna- sample was cooled to 373 K and then NH3 was adsorbed using
tional (ammonia form). These were calcined at 823 K to their pulsed injections at 373 K until saturation. The TCD signal was
protonated forms H-Z(50) and H-β. The H-ZD(50) is the collected and processed to obtain the results.
zeolite H-Z(50), which was subjected to a desilication process, 2.2.1. Catalytic Tests. For the activity tests, a semibatch-type
via the extraction of silica in a solution of NaOH (0.2 M), reactor with a capacity of 50 mL (Parker-Autoclave Engineers)
according to the following procedure. H-ZD(50) was added to was used with a temperature and stirring controller (Iberfluid,
NaOH (0.2 M) at 353 K and stirred for 2 h. Then, the solids Model IB-50), and a liquid pump (Gilson, Model 307). The
were separated by centrifugation and washed with doubly reactor was loaded with 20 mL of a mixture that consisted of
distilled water until neutral pH; afterward, these were dried 4.2 mL of water (double-distilled) and 15.8 mL of the organic
overnight at 383 K. The obtained zeolites were also treated solvent. The organic solvents used were methyl ethyl ketone
with NH4Cl (0.5 M) to 333 K; the samples were newly (MEK) (Alfa Aesar, 99%), cyclopentyl methyl ether (CPME)
centrifuged and washed until all chlorides were eliminated; (Sigma−Aldrich, ≥99.90%), THF (Panreac, 99.5%), and
then, the solid was dried to 383 K and subsequently calcined at acetone (Scharlau, 99.5%). The selected quantity of catalyst
5140 DOI: 10.1021/acs.iecr.5b04190
Ind. Eng. Chem. Res. 2016, 55, 5139−5144
Industrial & Engineering Chemistry Research Article
Table 1. Properties of Different Solid-Acid Catalysts Studied and Activity Results Obtaineda
LA yield conversion surface area determined via the BET method, average pore diameter, dp mesoporosity
catalyst (%) (%) SBET (m2/g) (Å) (%) acidity
A47 26.01 99.55 50 240 100 4.7 mequiv H+/g
A35 62.39 99.12 50 300 100 ≥5.2 mequiv H+/g
H-β 20.70 91.56 441 6 0 1.282 mmol NH3/g
PTA-USY 19.79 90.18 494 20 10 0.720 mmol NH3/g
H-Z(50) 58.22 99.45 395 24 50 0.826 mmol NH3/g
H-ZD(50)b 56.38 99.80 407 37 75 0.661 mmol NH3/g
H-ZDR(50) 300 42 70 0.727 mmol NH3/g
PTA-Z(50) 58.10 100.00 342 25 34 0.703 mmol NH3/g
ZrO2/SO42− 0.18 58.93 108 34 95 0.338 mmol NH3/g
a
Reaction conditions: 0.4 g of catalyst, 413 K, 10 bar of H2, MEK as solvent, 26.2 vol % FA in MEK, 1 h of reaction after 3.5 h of flow being fed. bH-
ZD(50) denotes zeolite obtained by using a desilication process.
was introduced in the reactor. Once the reactor was closed, it also observed for the sulfated zirconium catalyst which showed
was purged with N2 gas and then the pressure was increased up the lowest FA conversion (59 mol %), without a relevant
to 10 bar using a gaseous medium (N2 or H2). Finally, it was selectivity to LA; the low acidity value reported in Table 1
preheated to the desired temperature, and the pumping was explains the inactivity of this catalyst in the reaction studied.
started. A side solution consisting of organic solvent and FA According to the results obtained, the H-Z(50) zeolite, in its
(Sigma−Aldrich, 98%) was pumped for 3.5 h at a liquid flow protonated form, was selected to be used for optimization of
rate of 0.03 mL min−1. After this time, the pump was switched operating parameters in the reaction system, because this
off and the time set at t = 0. The test continued with heating catalyst has better thermomechanical stability than the
and stirring. Once the test was finished, the product inside the Amberlyst catalysts.
reactor was filtered with 0.45 μm filters and weighed for later 3.1. Optimization of Operating Parameters Using H-
calculations. A sample was taken to be analyzed via gas ZSM5 Zeolite (H-Z(50)). The optimization consisted of the
chromatography in an Agilent Model 6890N GC with flame evaluation of the effect of the main operation conditions in the
ionization (FID) and TCD detectors. LA yield. The variables that were considered for optimization
included the following: the use of hydrogen and nitrogen as
3. RESULTS AND DISCUSSION reaction atmospheres, the effect of solvent, the effect of the
amount of catalyst loaded, variation in the concentration of FA
The results obtained in the preliminary screening are shown in in the feed stream, and the effect of temperature.
Table 1. The high reactivity of FA can be observed. Only the 3.1.1. Effect of the Reaction Atmosphere. In the
superacid catalyst did not reach complete conversion of the FA; preliminary catalytic screening, the reaction atmosphere was
nevertheless, the LA yield was very different. The higher LA hydrogen. The first step in the optimization of operating
yield corresponds with the lower carbon balance error. The parameters was the effect of the reaction atmosphere. For this
main problem was the formation of furanic resins (the presence purpose, the initial operating conditions chosen in the catalytic
of these furanic resins was confirmed by the brown-black color screening were 0.4 g of catalyst, 413 K, 10 bar of H2, MEK as
of the reaction media); consequently, their contribution in the solvent, 26.2 vol % FA in MEK, and 1 h of reaction. The
carbon balances was not included. In addition, there were some reaction was studied under inert and hydrogenating atmos-
small peaks that were not identified in the gas chromatog-
pheres, excluding the oxidant atmosphere, which is not suitable
raphy−mass spectroscopy (GC-MS) analysis; therefore, they
for this reaction, because of the negative effect which is caused
also were not included in the carbon balance. In any case, for
by the formation of undesirable byproducts from furfuryl
the best LA yields. the mass balance error of the carbon balance
alcohol oxidation. In Figure 1, it can be observed that the
was ∼20%.
presence of hydrogen increased the LA yield by almost 20
In the preliminary results, it can be observed (Table 1) that,
mol %. This increment of the LA yield is related to the decrease
under the conditions studied, the A35 ion-exchange resin
in the formation of furanic polymers. The liquid obtained in the
exhibited the best performance, attaining LA yields of up to 62
mol %, followed by H-Z(50) zeolite (58 mol %) and PTA-
Z(50) (58 mol %). The catalyst properties are also summarized
in Table 1, showing that the high acidity and mesoporosity of
A35 influenced the increase in LA yield. The incorporation of
PTA on Z(50) zeolite did not present improvements in the LA
yield, with respect to the support. The modified zeolite H-
ZD(50) did not show differences in LA yield, with respect to
the original support. In this case, although the desilication
process caused a slight increase in pore diameter and surface
area, the decrease in LA yield can be related to the acidity loss.
The activity results using H-β zeolite showed a low LA yield;
the surface characterization indicates that H-β has a high
acidity, but a low pore diameter value, and this property could
affect the reaction mechanism related to the access of molecules
to acid sites, causing the low LA yield. Very low activity was Figure 1. Effect of the reaction atmosphere.
3.1.4. Effect of Temperature. Figure 4 shows the effect of confirms the existence of an intermediate compound in the
temperature on the LA yield. A slight decrease in the LA yield reaction mixture, which could not be detected in the gas
chromatographic analysis (Figure 5). A maximum LA yield was
observed 23 h after the feeding pump was stopped. This value
corresponds to a LA yield of 77.7 mol % and 100 mol % FA
conversion (Figure 6). The differences in yield obtained
4. CONCLUSIONS
Figure 5. Effect of reaction time in the product distribution in the GC After the screening of catalysts with inorganic structure, the H-
(FID signal). (Operation conditions: 0.5 g of H-ZSM5 catalyst, 413 K, ZSM5 zeolite showed higher levulinic acid (LA) yields,
20 bar of H2, MEK as cosolvent, 36.8 vol % FA.) compared to other materials evaluated as heteropolyacids
5143 DOI: 10.1021/acs.iecr.5b04190
Ind. Eng. Chem. Res. 2016, 55, 5139−5144
Industrial & Engineering Chemistry Research Article
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■ AUTHOR INFORMATION
Corresponding Author
(17) Khusnutdinov, R. I.; Baiguzina, A. R.; Smirnov, A. A.;
Mukminov, R. R.; Dzhemilev, U. M. Furfuryl Alcohol in Shyntesis
of Levulinic Acid Esters and Difuylmethane with Fe and Rh
Complexes. Russ. J. Appl. Chem. 2007, 80, 1687−1690.
*Tel.: +34 96 6017242. E-mail: jesus.requies@ehu.eus. (18) Jentys, A.; Warecka, G.; Lercher, J. A. Surface chemistry of
Notes HZSM-5 studied by time-resolved IR spectroscopy. J. Mol. Catal.
1989, 51, 309−327.
The authors declare no competing financial interest. (19) Tzoulaki, D.; Jentys, A.; Pérez-Ramírez, J.; Egeblad, K.; Lercher,
■ ACKNOWLEDGMENTS
In memorial of Arkaitz Heras: you will always be alive in our
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hierarchical ZSM-5 particles. Catal. Today 2012, 198, 3−11.
(20) van Bokhoven, J. A. Strong Bronsted Acidity in Alumina-
Silicates: Influence of Pore Dimesion, Steaming and Acid Site Density
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Country (UPV/EHU), European Union through the European Prospects, 1st Edition; Valtchev, V., Mintova, S., Tsapatsis, M., Eds.;
Regional, Development Fund (FEDER) (Spanish MICIN Elsevier: Amsterdam, 2009; Chapter 24, pp 651−668.
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