WO2010144873A1 - Production of adipic acid and derivatives from carbohydrate-containing materials - Google Patents
Production of adipic acid and derivatives from carbohydrate-containing materials Download PDFInfo
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- WO2010144873A1 WO2010144873A1 PCT/US2010/038422 US2010038422W WO2010144873A1 WO 2010144873 A1 WO2010144873 A1 WO 2010144873A1 US 2010038422 W US2010038422 W US 2010038422W WO 2010144873 A1 WO2010144873 A1 WO 2010144873A1
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- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C51/00—Preparation of carboxylic acids or their salts, halides or anhydrides
- C07C51/347—Preparation of carboxylic acids or their salts, halides or anhydrides by reactions not involving formation of carboxyl groups
- C07C51/377—Preparation of carboxylic acids or their salts, halides or anhydrides by reactions not involving formation of carboxyl groups by splitting-off hydrogen or functional groups; by hydrogenolysis of functional groups
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- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C209/00—Preparation of compounds containing amino groups bound to a carbon skeleton
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- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C253/00—Preparation of carboxylic acid nitriles
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- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C29/00—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring
- C07C29/132—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of an oxygen containing functional group
- C07C29/136—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of an oxygen containing functional group of >C=O containing groups, e.g. —COOH
- C07C29/147—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of an oxygen containing functional group of >C=O containing groups, e.g. —COOH of carboxylic acids or derivatives thereof
- C07C29/149—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of an oxygen containing functional group of >C=O containing groups, e.g. —COOH of carboxylic acids or derivatives thereof with hydrogen or hydrogen-containing gases
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
- C08G63/02—Polyesters derived from hydroxycarboxylic acids or from polycarboxylic acids and polyhydroxy compounds
- C08G63/12—Polyesters derived from hydroxycarboxylic acids or from polycarboxylic acids and polyhydroxy compounds derived from polycarboxylic acids and polyhydroxy compounds
- C08G63/16—Dicarboxylic acids and dihydroxy compounds
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G69/00—Macromolecular compounds obtained by reactions forming a carboxylic amide link in the main chain of the macromolecule
- C08G69/02—Polyamides derived from amino-carboxylic acids or from polyamines and polycarboxylic acids
- C08G69/08—Polyamides derived from amino-carboxylic acids or from polyamines and polycarboxylic acids derived from amino-carboxylic acids
- C08G69/14—Lactams
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G69/00—Macromolecular compounds obtained by reactions forming a carboxylic amide link in the main chain of the macromolecule
- C08G69/02—Polyamides derived from amino-carboxylic acids or from polyamines and polycarboxylic acids
- C08G69/26—Polyamides derived from amino-carboxylic acids or from polyamines and polycarboxylic acids derived from polyamines and polycarboxylic acids
Definitions
- the present invention generally relates to processes for the chemocatalytic conversion of a carbohydrate source to an adipic acid product.
- the present invention includes processes for the conversion of a carbohydrate source to an adipic acid product via a furanic substrate, such as 2,5-furandicarboxylic acid or derivatives thereof.
- the present invention also includes processes for producing an adipic acid product comprising the catalytic hydrogenation of a furanic substrate to produce a tetrahydrofuranic substrate and the catalytic hydrodeoxygenation of at least a portion of the tetrahydrofuranic substrate to an adipic acid product.
- the present invention also relates to processes for the preparation of industrial chemicals such as adiponitrile, hexamethylene diamine, caprolactam, caprolactone, adipate esters, 1,6-hexanediol, polyamides (e.g., nylons) and polyesters from an adipic acid product obtained from processes including the catalytic hydrodeoxygenation of a tetrahydrofuranic substrate.
- industrial chemicals such as adiponitrile, hexamethylene diamine, caprolactam, caprolactone, adipate esters, 1,6-hexanediol, polyamides (e.g., nylons) and polyesters from an adipic acid product obtained from processes including the catalytic hydrodeoxygenation of a tetrahydrofuranic substrate.
- the invention is further directed to such industrial chemicals produced from adipic acid product produced by the processes of the present invention.
- Adipic acid is among the end products producible from biorenewable feedstocks. Such processes have been disclosed in, for example, US Patent Nos. 4,400,468 and 5,487,987 and, for example, in "Benzene-Free Synthesis of Adipic Acid", Frost et al. Biotechnol. Prog. 2002, Vol. 18, pp. 201-211. However, to date, no process for producing adipic acid from biorenewable feedstocks has been commercialized.
- the present invention is directed to processes for preparing an adipic acid product from a carbohydrate source comprising the steps of converting the carbohydrate source to a furanic substrate and converting at least a portion of the furanic substrate to the adipic acid product.
- processes for producing an adipic acid product from a furanic substrate comprise converting by chemocatalytic means at least a portion of the furanic substrate to the adipic acid product.
- processes for producing an adipic acid product further comprise converting at least a portion of the furanic substrate to a tetrahydro furanic substrate and converting at least a portion of the tetrahydro furanic substrate to the adipic acid product.
- the process for preparing an adipic acid product comprises converting by chemocatalytic means to the adipic acid product a substrate of formula I
- each X is independently selected from the group consisting of -OH, -OR 2 , and -H, or, in some embodiments, X is independently selected from the group consisting of - OH and -H, or, in some embodiments, each X is -OH, or, in some embodiments, each X is -H; Y is selected from the group consisting of -C(O)OH, -C(O)OR 1 , -C(O)NR 3 R 4 , and -CH 2 N R 3 R 4 ; Z is selected from the group consisting of -C(O)OH, -C(O)OR 1 , -C(O)NR 3 R 4 , and - CH 2 N R 3 R 4 ; each R 1 is independently selected from the group consisting of hydrocar
- the present invention is directed to processes for preparing an adipic acid product comprising reacting a tetrahydrofuranic substrate with hydrogen, in the presence of a hydrodeoxygenation catalyst, a solvent and a source of halogen, to convert at least a portion of the tetrahydrofuranic substrate to the adipic acid product, wherein the tetrahydrofuranic substrate is a compound of formula III (and salts thereof),
- each X is independently selected from the group consisting of -OH, -OR 2 , and -H, or, in some embodiments, X is independently selected from the group consisting of -OH and -H, or, in some embodiments, each X is -OH, or, in some embodiments, each X is -H;
- Y is selected from the group consisting of -C(O)OH, -C(O)OR 1 , -C(O)NR 3 R 4 , and -CH 2 N R 3 R 4 ;
- Z is selected from the group consisting of -C(O)OH, -C(O)OR 1 , -C(O)NR 3 R 4 , and -CH 2 N R 3 R 4 ;
- each R 1 is independently selected from the group consisting of hydrocarbyl, and substituted hydrocarbyl;
- each R 2 is independently selected from the group consisting of hydrocarbyl and substituted hydrocarbyl;
- each R 3 is independently selected from the group
- the present invention is further directed to processes for preparing adipic acid or derivative thereof by reacting a tetrahydrofuranic substrate comprising tetrahydrofuran-2,5- dicarboxylic acid (THFDCA) with hydrogen in the presence of hydrogen iodide or hydrogen bromide and a solvent, wherein at least a portion of the tetrahydrofuran-2,5-dicarboxylic acid is converted to adipic acid or derivative thereof.
- THFDCA tetrahydrofuranic substrate comprising tetrahydrofuran-2,5- dicarboxylic acid
- the present invention is further directed to processes for preparing adipic acid or derivative thereof comprising reacting a furanic substrate with hydrogen, in the presence of a hydrogenation catalyst and a solvent, but in the absence of an added source of halogen, to convert at least a portion thereof to a tetrahydrofuranic substrate, and reacting at least a portion of the tetrahydrofuranic substrate with hydrogen, in the presence of a hydrodeoxygenation catalyst, a solvent and an added source of halogen, to convert at least a portion of the tetrahydrofuranic substrate to adipic acid or derivative thereof.
- processes for preparing adipic acid product comprise reacting a furanic substrate with hydrogen, in the presence of a hydrogenation catalyst and acetic acid, but in the absence of an added source of halogen, to convert at least a portion thereof to a tetrahydrofuran-2,5-dicarboxylic acid and reacting at least a portion of the tetrahydrofuran-2,5-dicarboxylic acid with hydrogen, in the presence of a hydrodeoxygenation catalyst, solvent and hydrogen iodide or hydrogen bromide, to convert at least a portion of the tetrahydrofuran-2,5-dicarboxylic acid to an adipic acid product comprising adipic acid.
- the present invention is further directed to processes for the preparation of industrial chemicals such as adiponitrile, hexamethylene diamine, caprolactam, caprolactone, adipate esters, 1,6-hexanediol, polyamides (e.g., nylons) and polyesters from an adipic acid product obtained from processes for the chemocatalytic conversion of a carbohydrate source, which processes typically include the catalytic hydrodeoxygenation of a tetrahydrofuranic substrate.
- industrial chemicals such as adiponitrile, hexamethylene diamine, caprolactam, caprolactone, adipate esters, 1,6-hexanediol, polyamides (e.g., nylons) and polyesters from an adipic acid product obtained from processes for the chemocatalytic conversion of a carbohydrate source, which processes typically include the catalytic hydrodeoxygenation of a tetrahydrofuranic substrate.
- the present invention is further directed to processes for the preparation of industrial chemicals such as adiponitrile, hexamethylene diamine, caprolactam, caprolactone, 1,6-hexanediol and polyamides (e.g., nylons) from an adipic acid product obtained from processes for the chemocatalytic conversion of a carbohydrate source, which processes include the catalytic hydrogenation of a furanic substrate and the catalytic hydrodeoxygenation of a tetrahydrofuranic substrate.
- industrial chemicals such as adiponitrile, hexamethylene diamine, caprolactam, caprolactone, 1,6-hexanediol and polyamides (e.g., nylons) from an adipic acid product obtained from processes for the chemocatalytic conversion of a carbohydrate source, which processes include the catalytic hydrogenation of a furanic substrate and the catalytic hydrodeoxygenation of a tetrahydrofuranic substrate.
- the present invention is further directed to adipic acid product, polyamides, polyesters and caprolactam produced at least in part from adipic acid product produced by processes comprising the chemocatalytic conversion of a tetrahydrofuranic substrate, and, more particularly, a tetrahydrofuranic substrate comprising tetrahydrofuran-2,5-dicarboxylic acid or derivative thereof into an adipic acid product.
- the present invention is further directed to adipic acid product, polyamides, polyesters and caprolactam produced at least in part from adipic acid product produced by processes comprising the catalytic hydrogenation of a furanic substrate and the catalytic hydrodeoxygenation of a tetrahydrofuranic substrate.
- Biorenewable sources such as corn grain (maize), sugar beet, sugar cane as well as energy crops, plant biomass, agricultural wastes, forestry residues, sugar processing residues, plant-derived household wastes, municipal waste, spent paper, switch grass, miscanthus, cassava, trees (hardwood and softwood), vegetation, crop residues (e.g., bagasse and corn stover) are all rich in hexoses, which can be used to produce furan derivatives, such as 5 -hydroxy methylfurfural (HMF). Hexoses are readily produced from such carbohydrate sources by hydrolysis. It is also generally known that biomass carbohydrates can be enzymatically converted to glucose, fructose and other sugars.
- HMF 5 -hydroxy methylfurfural
- HMF furan derivatives
- Acid hydrolysis of glucose is also known to produce HMF; see, for example, U.S. Pat. No. 6,518,440.
- HMF acid hydrolysis of glucose
- Various other methods have been developed for producing HMF including, for example, those described in U.S. Pat. Nos.
- HMF can be converted to 2,5-furandicarboxylic acid (FDCA) by selective oxidation.
- FDCA 2,5-furandicarboxylic acid
- Examples of processes for the production of FDCA from HMF are disclosed in, for example, U.S. Pat. Nos. 3,326,944 and 4,977,283, U.S. Pat, App. 2008/0103318, and Japanese Laid-open Application No. H02-088569. See also, Corma et al., ChemSusChem., 2009, p 1138.
- Derivatives of FDCA can also be produced from HMF by processes such as those illustrated in Moreau, Topics in Catalysis 2004, Vol. 27, pp.11; Lewkowski, Arkivoc, 2001 (i), p.
- an adipic acid product of formula II, below can be produced from a carbohydrate source by processes which comprise converting by chemocatalytic means a substrate of formula I, below, or a salt thereof, or an intermolecular homomer or heteromer thereof, or intermolecular and intramolecular anhydrides or stereoisomers thereof, hereinafter all collectively referred to as "furanic substrate", derivable by means known in the art, in accordance with the following overall reaction
- each X is independently selected from the group consisting of -OH, -OR 2 , and -H or, in some embodiments, X is independently selected from the group consisting of -OH and -H, or in some embodiments, each X is -OH, or, in some embodiments, each X is -H;
- Y is selected from the group consisting of -C(O)OH, -C(O)OR 1 , -C(O)NR 3 R 4 , and -CH 2 N R 3 R 4 ;
- Z is selected from the group consisting of -C(O)OH, -C(O)OR 1 , -C(O)NR 3 R 4 , and -CH 2 N R 3 R 4 ;
- each R 1 is independently selected from the group consisting of hydrocarbyl, and substituted hydrocarbyl;
- each R 2 is independently selected from the group consisting of hydrocarbyl and substituted hydrocarbyl;
- each R 3 is independently selected from the group consisting
- R 1 , R 2 , R 3 , and/or R 4 can be preferably substituted with one or more Of Ci-C 4 alkyl, hydroxyl, amine, Ci-C 4 alkylamino, thiol, and Ci-C 4 thioalkyl.
- the furanic substrate is initially reacted with hydrogen in the presence of a hydrogenation catalyst to convert at least a portion of the furanic substrate to a tetrahydrofuranic substrate, and at least a portion of the tetrahydrofuranic substrate is converted to adipic acid product.
- the hydrogenation reaction is typically conducted under conditions known in the art. See for example, "Catalytic Hydrogenation and Dehydrogenation” in Fine Chemicals Through Heterogeneous Catalysis, 2nd ed., Sheldon and van Bekkum, p. 351; See also Handbook of Heterogeneous Catalytic Hydrogenation for Organic Synthesis, Nishimura 2001 Wiley, New York .
- the hydrogenation reaction is conducted in the presence of a solvent to the furanic substrate.
- Solvents suitable for the hydrogenation reaction include water, alcohols, esters, ethers, ketones, weak carboxylic acids and mixtures thereof.
- weak carboxylic acid means any unsubstituted or substituted carboxylic acid having a pKa of at least about 3.5, more preferably at least about 4.5 and, more particularly, is selected from among unsubstituted acids such as acetic acid, propionic acid or butyric acid, or mixtures thereof.
- acetic acid is more preferred because it also is useful as a solvent in the subsequent hydrodeoxygenation of the tetrahydrofuranic substrate.
- the temperature of the hydrogenation reaction is at least about 30 0 C, more typically 60 0 C, or higher. In various embodiments, the temperature of the hydrogenation reaction is from about 60°C to about 200°C, and more preferably from about 60°C to about 160 0 C.
- the partial pressure of hydrogen is at least about 50 pounds per square inch absolute (psia) (345 kPa), at least about 100 psia (689 kPa), at least about 250 psia (1724 kPa), or at least about 500 psia (3447 kPa).
- the partial pressure of hydrogen is up to about 2000 psia (13790 kPa), or more typically in the range of from about 500 psia (3447 kPa) to about 2000 psia (13790 kPa) and still more typically in the range of about 1000 psia (6890 kPa) to about 2000 psia (13790 kPa).
- the hydrogenation reaction can be conducted in a batch, semi- batch, or continuous reactor design using fixed bed reactors, trickle bed reactors, slurry phase reactors, moving bed reactors, or any other design that allows for heterogeneous catalytic reactions.
- reactors can be seen in Chemical Process Equipment - Selection and Design, Couper et al, Elsevier 1990, which is incorporated herein by reference. It should be understood that the furanic substrate, hydrogen, any solvent, and the hydrodeoxygenation catalyst may be introduced into a suitable reactor separately or in various combinations.
- Catalysts suitable for the hydrogenation reaction include heterogeneous catalysts, including solid-phase catalysts comprising one or more supported or unsupported metals. Suitable catalysts are disclosed in “Catalytic Hydrogenation and Dehydrogenation,” Fine Chemicals Through Heterogeneous Catalysis, 2nd ed., Sheldon and van Bekkum, p. 351 and Handbook of Heterogeneous Catalytic Hydrogenation for Organic Synthesis, Nishimura 2001 Wiley, New York .
- metal is present at a surface of a support (i.e., at one or more surfaces, external or internal).
- metal comprises at least one d-block metal (i.e., transition metal; groups 3 - 12 of the periodic table).
- the metal is selected from the group consisting of palladium, platinum, rhodium, ruthenium, nickel, cobalt, iron and combinations thereof. Additional other metals may be present, including one or more d-block metals, alone or in combination with one or more rare earth metals (e.g. lanthanides), alone or in combination with one or more main group metals (e.g. Al, Ga, Tl, In, Sn, Pb or Bi).
- the metals may be present in various forms (e.g., elemental, metal oxide, metal hydroxides, metal ions, etc.).
- the metal(s) at a surface of a support may constitute from about 0.25% to about 10%, or from about 1% to about 8%, or from about 2.5% to about 7.5% (e.g., 5%) of the total weight of the catalyst.
- the hydrogenation catalyst comprises a first metal (Ml) and a second metal (M2) at a surface of a support, wherein the Ml metal is selected from the group consisting of ruthenium, rhodium palladium, platinum, nickel, cobalt and iron and the M2 metal is selected from the group consisting of d-block metals, rare earth metals, and main group metals, wherein the Ml metal is not the same metal as the M2 metal.
- M2 is selected from the group consisting of molybdenum, ruthenium, rhodium, palladium, iridium, platinum and gold.
- the Ml metal is palladium and the M2 metal is selected from the group consisting of manganese, iron, and cobalt.
- the Ml :M2 molar ratio may vary, for example, from about 500: 1 to about 1: 1, from about 250: 1 to about 1 : 1, from about 100: 1 to about 1 : 1, from about 50: 1 to about 1 : 1, from about 20: 1 to about 1 : 1, or from about 10: 1 to about 1: 1.
- the Ml :M2 molar ratio may vary, for example, from about 1 : 100 to about 1 : 1, from about 1 :50 to about 1: 1, from about 1: 10 to about 1: 1, from about 1 :5 to about 1 : 1, or from about 1:2 to about 1 : 1.
- the weight percents of Ml and M2 relative to the catalyst weight may vary.
- the weight percent of Ml may range from about 0.5% to about 10%, more preferably from about 1% to about 8%, and still more preferably from about 2.5% to about 7.5% (e.g., about 5%).
- the weight percent of M2 may range from about 0.25% to about 10%, from about 0.5% to about 8%, or from about 0.5% to about 5%.
- a third metal may be added to produce a M1/M2/M3 catalyst wherein the M3 metal is not the same metal as the Ml metal and the M2 metal.
- a fourth metal may be added to produce a M1/M2/M3/M4 catalyst wherein the M4 metal is not the same metal as the Ml metal, the M2 metal or the M3 metal.
- M3 and M4 may each be selected from the group consisting of d-block metals, rare earth metals (e.g. lanthanides), or main group metals (e.g. Al, Ga, Tl, In, Sn, Pb or Bi).
- Suitable catalyst supports include carbon, alumina, silica, ceria, titania, zirconia, niobia, zeolite, magnesia, clays, iron oxide, silicon carbide, aluminosilicates, and modifications, mixtures or combinations thereof.
- the support materials may be modified using methods known in the art such as heat treatment, acid treatment or by the introduction of a dopant (for example, metal-doped titanias, metal-doped zirconias (e.g., tungstated-zirconia), metal-doped cerias, and metal-modified niobias).
- Particularly preferred supports are carbon (which may be activated carbon, carbon black, coke or charcoal), alumina, zirconia, titania, zeolite and silica.
- the support of the oxidation catalyst is selected from the group consisting of carbon, zirconia, zeolite, and silica.
- the metals may be deposited using procedures known in the art including, but not limited to incipient wetness, ion-exchange, deposition-precipitation, and vacuum impregnation. When two or more metals are deposited on the same support, they may be deposited sequentially or simultaneously.
- the catalyst is dried at a temperature of at least about 50 0 C, more typically at least about 120 0 C for a period of time of at least about 1 hour, more typically 3 hours or more. In these and other embodiments, the catalyst is dried under sub- atmospheric pressure conditions.
- the catalyst is reduced after drying (e.g., by flowing 5% H 2 in N 2 at 350 °C for 3 hours). Still further, in these and other embodiments, the catalyst is calcined, for example, at a temperature of at least about 500°C for a period of time (e.g., at least about 3 hours).
- the hydrogenation reaction is preferably conducted in the substantial absence of added halogen. It is currently believed that the introduction of a source of halogen independent of that which, if any, is within the furanic substrate inhibits the conversion rate and selectivity of the reaction to tetrahydrofuranic substrate.
- the reaction product of the hydrogenation step is a tetrahydrofuranic substrate, which substrate is unexpectedly convertible to an adipic acid product in high yield.
- the tetrahydrofuranic substrate of the present invention is set forth in formula III, below (and further includes salts thereof):
- each X is independently selected from the group consisting of -OH, -OR , and -H, or, in some embodiments, X is independently selected from the group consisting of -OH and -H, or, in some embodiments, each X is -OH, or, in some embodiments, each X is -H;
- Y is selected from the group consisting of -C(O)OH, -C(O)OR 1 , -C(O)NR 3 R 4 , and -CH 2 N R 3 R 4 ;
- Z is selected from the group consisting of -C(O)OH, -C(O)OR 1 , -C(O)NR 3 R 4 , and -CH 2 N R 3 R 4 ;
- each R 1 is independently selected from the group consisting of hydrocarbyl, and substituted hydrocarbyl;
- each R 2 is independently selected from the group consisting of hydrocarbyl and substituted hydrocarbyl;
- each R 3 is independently selected from the group consist
- R 1 , R 2 , R 3 , and/or R 4 can be preferably substituted with one or more Of Ci-C 4 alkyl, hydroxyl, amine, Ci-C 4 alkylamino, thiol, and Ci-C 4 thioalkyl.
- hydrocarbyl refers to hydrocarbyl moieties, preferably containing 1 to about 50 carbon atoms, preferably 1 to about 30 carbon atoms, and even more preferably 1 to about 18 carbon atoms, including branched or unbranched, and saturated or unsaturated species.
- Preferred hydrocarbyl can be selected from the group consisting of alkyl, alkylene, alkoxy, alkylamino, thioalkyl, haloalkyl, cycloalkyl, cycloalkylalkyl, heterocyclyl, N-heterocyclyl, heterocyclylalkyl, aryl, aralkyl heteroaryl, N- heteroaryl, heteroarylalkyl, and the like.
- a hydrocarbyl may be optionally substituted hydrocarbyl.
- various hydrocarbyls can be further selected from substituted alkyl, substituted cycloalkyl and the like.
- an adipic acid product is produced by processes comprising the step of hydrodeoxygenating a tetrahydrofuranic substrate by reacting the same with hydrogen in the presence of a hydrodeoxygenation catalyst (i.e., catalyst suitable for the step of hydrodeoxygenation), an added source of halogen and a solvent, to convert at least a portion of the tetrahydrofuranic substrate to an adipic acid product.
- a hydrodeoxygenation catalyst i.e., catalyst suitable for the step of hydrodeoxygenation
- an added source of halogen and a solvent to convert at least a portion of the tetrahydrofuranic substrate to an adipic acid product.
- the tetrahydrofuranic substrate comprises THFDCA, and a portion of the acid is converted by hydrodeoxygenation to an adipic acid product comprising adipic acid.
- THFDCA ring opened and halogenated in the presence of the halogen source to produce a ring opened halogenated intermediate containing a carbon-halogen bond
- the carbon-halogen bond of the halogenated intermediate is believed to be converted to a carbon-hydrogen bond via one or more of the following pathways.
- the halogenated intermediate reacts with hydrogen in the presence of the hydrodeoxygenation catalyst leading to the formation of a carbon-hydrogen bond along with the generation of hydrohalic acid.
- the halogenated intermediate undergoes a dehydrohalogenation reaction to form an olefin intermediate and hydrohalic acid.
- the olefin is further reduced in the presence of the hydrodeoxygenation catalyst leading to the formation of a carbon-hydrogen bond. Effecting the reaction pursuant to the above described first and second pathways generates hydrohalic acid as a by-product, which is available for further reaction.
- the halogenated intermediate reacts with hydrohalic acid leading to the formation of a carbon-hydrogen bond along with the formation of molecular halogen (or interhalogen). Effecting the reaction pursuant to the third pathway generates molecular halogen as a by-product, which is available for further reaction.
- One or more of the various pathways described above may occur concurrently.
- the halogen source may be in a form selected from the group consisting of atomic, ionic, molecular and mixtures thereof.
- the halogen source is hydrohalic acid.
- Preferred halogen sources include HBr and HI and mixtures thereof.
- HI has enabled the conversion of greater than 90% of THFDCA to adipic acid product.
- the molar ratio of halogen source to the tetrahydrofuranic substrate is equal to or less than about 1.
- the mole ratio of the halogen source to the substrate is from about 0.9: 1 to about 0.1: 1, more typically from about 0.7: 1 to about 0.3:1, and still more typically about 0.5:1.
- the reaction allows for recovery of the halogen source and catalytic quantities (where molar ratio of halogen to the hydrodeoxygenation substrate is less than about 1) of halogen can be used, recovered and recycled for continued use as a halogen source.
- the temperature of the hydrodeoxygenation reaction of the furanic substrate is at least about 20 0 C, typically at least about 80 0 C, and more typically at least about 100 0 C.
- the temperature of the hydrodeoxygenation reaction is conducted in the range of from about 20 0 C to about 250 0 C, from about 80 0 C to about 200 0 C, more preferably from about 120 0 C to about 180 0 C, and still more preferably from about 140 0 C to about 180 0 C.
- the partial pressure of hydrogen is at least about 25 psia (172 kPa), more typically at least about 200 psia (1379 kPa) or at least about 400 psia (2758 kPa). In various embodiments, the partial pressure of hydrogen is from about 25 psia (172 kPa) to about 2500 psia (17237 kPa), from about 200 psia (1379 kPa) to about 2000 psia (13790 kPa), or from about 400 psia (2758 kPa) to about 1500 psia (10343 kPa).
- the hydrodeoxygenation reaction is typically conducted in the presence of a solvent.
- Solvents suitable for the selective hydrodeoxygenation reaction include water and carboxylic acids, amides, esters, lactones, sulfoxides, sulfones and mixtures thereof.
- Preferred solvents include water, mixtures of water and weak carboxylic acid, and weak carboxylic acid.
- a preferred weak carboxylic acid is acetic acid.
- Hydrodeoxygenation of the tetrahydrofuranic substrate can be conducted in a batch, semi-batch, or continuous reactor design using fixed bed reactors, trickle bed reactors, slurry phase reactors, moving bed reactors, or any other design that allows for heterogeneous catalytic reactions. Examples of reactors can be seen in Chemical Process Equipment - Selection and Design, Couper et al., Elsevier 1990, which is incorporated herein by reference. It should be understood that the hydrodeoxygenation substrate, halogen source, hydrogen, any solvent, and the hydrodeoxygenation catalyst may be introduced into a suitable reactor separately or in various combinations.
- the hydrogenation and hydrodeoxygenation reactions can be conducted in the same reactor, particularly when the solvent for each reaction is the same and a catalyst effective both as a catalyst for hydrogenation and hydrodeoxygenation reactions is employed.
- a catalyst effective both as a catalyst for hydrogenation and hydrodeoxygenation reactions is employed.
- Methods for determining optimized conversion conditions can include, for example, periodic sampling of the reaction mixture via known reactor off-take mechanisms, analysis of the sampled product and control of the process conditions in response thereto.
- the source of halogen is, most preferably, added to the reactor after the hydrogenation reaction has been conducted under process conditions sufficient to convert a suitable portion of the furanic substrate to the tetrahydrofuranic substrate.
- the hydrogenation and hydrodeoxygenation reactions can be conducted in separate reactors, wherein the solvent for each reaction is the same and the product from the hydrogenation reaction is passed directly into the hydrodeoxygenation reactor.
- the reactors above disclosed are typically capable of being operated under a variety of conditions and can be readily controlled in order to optimize reaction conditions for the desired conversion of reactants.
- the hydrodeoxygenation catalysts are heterogeneous, but a suitable homogeneous catalyst may be employed.
- the hydrodeoxygenation catalyst comprises a solid-phase heterogeneous catalyst in which one or more metals is present at a surface of a support (i.e., at one or more surfaces, external or internal).
- Preferred metals are d-block metals which may be used alone, in combination with each other, in combination with one or more rare earth metals (e.g. lanthanides), and in combination with one or more main group metals (e.g., Al, Ga, Tl, In, Sn, Pb or Bi).
- Preferred d-block metals are selected from the group consisting of cobalt, nickel, ruthenium, rhodium, palladium, osmium, iridium, platinum and combinations thereof. More preferred d-block metals are selected from the group consisting of ruthenium, rhodium, palladium, platinum, and combinations thereof.
- the metals may be present in various forms (e.g., elemental, metal oxide, metal hydroxides, metal ions etc.).
- the metal(s) at a surface of a support may constitute from about 0.25% to about 10%, or from about 1% to about 8%, or from about 2.5% to about 7.5% (e.g., 5%) of the catalyst weight.
- the hydrodeoxygenation catalyst comprises two or more metals.
- two of more metals may be co-supported on or within the same support (e.g., as a mixed-metal catalyst on silica; Ml/M2/Silica catalyst), or they may be supported on different support materials.
- the hydrodeoxygenation catalyst comprises a first metal (Ml) and a second metal (M2) at a surface of a support, wherein the Ml metal comprises a d-block metal and the M2 metal is selected from the group consisting of d-block metals, rare earth metals, and main group metals, wherein the Ml metal is not the same metal as the M2 metal.
- the Ml metal is selected from the group consisting of cobalt, nickel, ruthenium, rhodium, palladium, osmium, iridium, and platinum. In more preferred embodiments, the Ml metal is selected from the group consisting of ruthenium, rhodium, palladium, and platinum. In various embodiments, the M2 metal is selected from the group consisting of titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, molybdenum, ruthenium, rhodium, palladium, silver, tungsten, iridium, platinum, and gold. In more preferred embodiments, the M2 metal is selected from the group consisting of molybdenum, ruthenium, rhodium, palladium, iridium, platinum, and gold.
- the M 1 metal of the hydrodeoxygenation catalyst is selected from the group of platinum, rhodium and palladium
- the M2 metal is selected from the group consisting of ruthenium, rhodium, palladium, platinum, and gold.
- the M1 :M2 molar ratio of the hydrodeoxygenation catalyst may vary, for example, from about 500: 1 to about 1: 1, from about 250: 1 to about 1: 1, from about 100: 1 to about 1 : 1, from about 50: 1 to about 1 : 1, from about 20: 1 to about 1: 1, or from about 10: 1 to about 1: 1.
- the Ml :M2 molar ratio may vary, for example, from about 1: 100 to about 1: 1, from about 1:50 to about 1: 1, from about 1 : 10 to about 1 : 1, from about 1 :5 to about 1 : 1, or from about 1 :2 to about 1 :1.
- the weight percents of Ml and M2 of the hydrodeoxygenation catalyst relative to the total catalyst weight may vary.
- the weight percent of Ml may range from about 0.5% to about 10%, more preferably from about 1% to about 8%, and still more preferably from about 2.5% to about 7.5% (e.g., about 5%).
- the weight percent of M2 may range from about 0.25% to about 10%, from about 0.5% to about 8%, or from about 0.5% to about 5%.
- a third metal may be added to produce a M1/M2/M3 hydrodeoxygenation catalyst wherein the M3 metal is not the same metal as the Ml metal and the M2 metal.
- a fourth metal may be added to produce a M1/M2/M3/M4 hydrodeoxygenation catalyst wherein the M4 metal is not the same metal as the Ml metal, the M2 metal or the M3 metal.
- M3 and M4 may each be selected from the group consisting of d-block metals, rare earth metals (e.g. lanthanides), or main group metals (e.g. Al, Ga, Tl, In, Sn, Pb or Bi).
- Preferred hydrodeoxygenation catalyst supports include carbon, alumina, silica, ceria, titania, zirconia, niobia, zeolite, magnesia, clays, iron oxide, silicon carbide, aluminosilicates, and modifications, mixtures or combinations thereof.
- the supports may be modified through methods known in the art such as heat treatment, acid treatment, the introduction of a dopant (for example, metal-doped titanias, metal-doped zirconias (e.g. tungstated zirconia), metal-doped cerias, and metal-modified niobias).
- the hydrodeoxygenation catalyst support is selected from the group consisting of carbon, silica, zirconia and titania.
- the metals may be deposited using procedures known in the art including, but not limited to incipient wetness, ion-exchange, deposition-precipitation and vacuum impregnation. When the two or more metals are deposited on the same support, they may be deposited sequentially, or simultaneously.
- the hydrodeoxygenation catalyst is dried at a temperature of at least about 50 0 C, more typically at least about 120 0 C or more for a period of time of at least about 1 hour, more typically at least about 3 hours or more. In these and other embodiments, the catalyst is dried under sub-atmospheric conditions.
- the hydrodeoxygenation catalyst is reduced after drying (e.g., by flowing 5% H 2 in N 2 at 350 °C for 3 hours). Still further, in these and other embodiments, the hydrodeoxygenation catalyst is calcined, for example, at a temperature of at least about 500°C for a period of time (e.g., at least about 3 hours).
- the hydrodeoxygenation catalysts useful for the hydrodeoxygenation of the tetrahydrofuranic substrate are also effective as catalysts for the hydrogenation of the furanic substrate.
- catalysts mixtures (co-catalysts or mixed metal catalysts) containing more than one metal may affect separate steps of the mechanistic reaction pathway.
- adipic acid product from the tetrahydrofuranic substrate is quite facile. Yields of adipic acid product from the hydrodeoxygenation of this substrate can be at least about 90%, or more.
- Adipic acid product produced in accordance with the processes of the present invention may be recovered from the hydrodeoxygenation reaction by, for example, one or more combinations of conventional methods known in the art such as, for example, separation of the reaction liquids from catalyst (typically a solid) and the halogen (as, for example, vapor phase separation thereof), followed by solvent extraction/evaporation or adipic acid product crystallization.
- catalyst typically a solid
- halogen as, for example, vapor phase separation thereof
- adipic acid to downstream chemical products or intermediates including adipate esters, polyesters, adiponitrile, hexamethylene diamine (HMDA), caprolactam, caprolactone, 1,6-hexanediol, aminocaproic acid, and polyamide such as nylons.
- HMDA hexamethylene diamine
- caprolactam caprolactone
- 1,6-hexanediol aminocaproic acid
- polyamide such as nylons.
- the acyl group(s) of such compounds can readily be hydrolyzed (for example, in the presence of a base), wherein they are reconverted to an -H, and the acetic acid can then be regenerated.
- hexamethylenediamine (HDMA) can be produced.
- an adipic acid product is converted to adiponitrile wherein the adipic acid product is prepared in accordance with the present invention.
- Adiponitrile can be used industrially for the manufacture of hexamethylenediamine, see Smiley, "Hexamethylenediamine” in Ullmann's Encyclopedia of Industrial Chemistry, Wiley-VCH 2009. Therefore, in further embodiments, an adipic acid product is converted to hexamethylenediamine wherein the adipic acid product is prepared in accordance with the present invention.
- Adipic acid is useful in the production of polyamides, such as nylon 6,6 and nylon 4,6.
- polyamides such as nylon 6,6 and nylon 4,6.
- the hexamethylenediamine formed from an adipic acid product prepared in accordance with the present invention can likewise be further used for the preparation of polyamides such as nylon 6,6 and nylon 6,12.
- adipic acid and a polymer precursor derived from an adipic acid product may be reacted to produce a polyamide, wherein the adipic acid product is prepared in accordance with the present invention.
- Polymer precursor refers to a monomer which can be converted to a polymer (or copolymer) under appropriate polymerization conditions.
- the polyamide comprises nylon 6,6.
- nylon 6,6 is produced by reacting an adipic acid product with a polymer precursor derived from an adipic acid product, wherein the polymer precursor comprises hexamethylenediamine.
- hexamethylenediamine may be prepared by converting an adipic acid product to adiponitrile which then may be converted to hexamethylene diamine, wherein the adipic acid product is prepared in accordance with the present invention.
- an adipic acid product is converted to caprolactam wherein the adipic acid product is prepared in accordance with the present invention.
- the caprolactam formed can be further used for the preparation of polyamides by means generally known in the art. Specifically, caprolactam can be further used for the preparation of nylon 6. See, for example Kohan, Mestemacher, Pagilagan, Redmond, "Polyamides" in Ullmann's Encyclopedia of Industrial Chemistry, Wiley -VCH, Weinheim, 2005.
- nylon 6 is produced by reacting caprolactam derived from an adipic acid product prepared in accordance with the present invention.
- adipic acid and a polymer precursor may be reacted to produce a polyester, wherein the adipic acid product is prepared in accordance with the present invention.
- an adipic acid product is converted to 1 ,6-hexanediol wherein the adipic acid product is prepared in accordance with the present invention.
- 1,6- hexanediol is a valuable chemical intermediate used in the production of polyesters and polyurethanes.
- polyester may be prepared by reacting adipic acid and 1,6-hexandiol derived from an adipic acid product, prepared in accordance with the present invention.
- a salt of adipic acid may be produce wherein the process comprises reacting adipic acid with hexamethylenediamine, thereby forming the salt, wherein adipic acid is prepared in accordance with the present invention.
- the Ml/Silica mixtures were dried in a furnace at 120 0 C for 12 hours, followed by calcination at 500 0 C for 3 hours. Upon cooling the catalysts were stored in a dessicator until used.
- Ml/Silica catalysts were transferred to 1 mL glass vials within a 96-well reactor insert (Symyx Solutions). Each vial within each array received a glass bead and 250 ⁇ L of 0.2 M THFDCA, 0.1 to 0.3 M of HBr (Sigma-Aldrich) in Acetic Acid (Sigma-Aldrich), or HI (Sigma-Aldrich). Upon solution addition, the arrays of vials were covered with a Teflon pin-hole sheet, a silicone pin-hole mat and steel gas diffusion plate (Symyx Solutions).
- the reactor insert was placed in a pressure vessel, pressurized and vented 3 times with nitrogen and 3 times with hydrogen before being pressurized with hydrogen to 710 psig, heated to 140 0 C or 160 0 C and shaken for 3 hours. After 3 hours the reactors were cooled, vented and purged with nitrogen. 750 ⁇ l of water was then added to each vial. Following the water addition, the arrays were covered and shaken to ensure adequate mixing. Subsequently, the covered arrays were placed in a centrifuge to separate the catalyst particles. Each reaction samples was then diluted 100-fold with water to generate a sample for analysis by mass spectrometry. The results are presented in Table 1. Table 1.
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Abstract
Description
Claims
Priority Applications (11)
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PCT/US2010/038422 WO2010144873A1 (en) | 2009-06-13 | 2010-06-11 | Production of adipic acid and derivatives from carbohydrate-containing materials |
AU2010259937A AU2010259937B2 (en) | 2009-06-13 | 2010-06-11 | Production of adipic acid and derivatives from carbohydrate-containing materials |
CA2763777A CA2763777C (en) | 2009-06-13 | 2010-06-11 | Production of adipic acid and derivatives from carbohydrate-containing materials |
EP10726398.0A EP2440515B1 (en) | 2009-06-13 | 2010-06-11 | Production of adipic acid and derivatives from carbohydrate-containing materials |
US12/814,240 US8501989B2 (en) | 2009-06-13 | 2010-06-11 | Production of adipic acid and derivatives from carbohydrate-containing materials |
NZ596975A NZ596975A (en) | 2009-06-13 | 2010-06-11 | Production of adipic acid and derivatives from carbohydrate-containing materials |
CN201080026096.9A CN102803196B (en) | 2009-06-13 | 2010-06-11 | By the material production adipic acid of carbohydrate containing and derivant |
BRPI1010708-8A BRPI1010708B1 (en) | 2009-06-13 | 2010-06-11 | "PROCESSES FOR PREPARING ADPICIC ACID PRODUCT, AND ADDIC ACID OR DERIVATIVE THEREOF" |
ZA2011/08808A ZA201108808B (en) | 2009-06-13 | 2011-11-30 | Production of adipic acid and derivatives from carbohydrate-containing materials |
US13/932,413 US8927768B2 (en) | 2009-06-13 | 2013-07-01 | Production of adipic acid and derivatives from carbohydrate-containing materials |
PH12014500727A PH12014500727A1 (en) | 2009-06-13 | 2014-04-02 | Production of adipic acid and derivatives from carbohydrate-containing materials |
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EP (1) | EP2440515B1 (en) |
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BR (1) | BRPI1010708B1 (en) |
CA (1) | CA2763777C (en) |
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