Microflow chemistry and its electrification for sustainable chemical manufacturing

Sustainability is vital in solving global societal problems. Still, it requires a holistic view by considering renewable energy and carbon sources, recycling waste streams, environmentally friendly resource extraction and handling, and green manufacturing. Flow chemistry at the microscale can enable continuous sustainable manufacturing by opening up new operating windows, precise residence time control, enhanced mixing and transport, improved yield and productivity, and inherent safety. Furthermore, integrating microfluidic systems with alternative energy sources, such as microwaves and plasmas, offers tremendous promise for electrifying and intensifying modular and distributed chemical processing. This review provides an overview of microflow chemistry, electrification, their integration toward sustainable manufacturing, and their application to biomass upgrade (a select number of other processes are also touched upon). Finally, we identify critical areas for future research, such as matching technology to the scale of the application, techno-economic analysis, and life cycle assessment.

Sulfuric Acid-Catalyzed Dehydratization of Carbohydrates for the Production of Adhesive Precursors

Carbohydrates and hexose-derived 5-hydroxymethylfurfural (5-HMF) are platform chemicals for the synthesis of sustainable binders. New, greener approaches aim at the development of production systems, which minimize process steps and avoid organic solvents or other auxiliaries that could interfere with subsequent resin synthesis. In our work, carbohydrate solutions rich in 5-hydroxymethylfurfural (5-HMF) were produced using a continuous-flow microreactor and diluted H₂SO₄ as the catalyst. After optimization of the process conditions (temperature, reaction time, catalyst content), a 5-HMF yield of 49% was obtained at a low reaction time of 0.6 min and a catalyst concentration of 1% at 175 °C and 17 bar pressure. Extensive rehydration of the product was avoided by efficient immediate cooling of the reaction solution. The stability of the reaction system was improved by increasing the inner diameter of the capillary in the flow reactor to 2 mm. Advantageously, the obtained reaction mixtures are used directly as precursors in the development of sustainable binder systems, without the need of additional purification, filtration, or extraction steps.

Mesoporous Porphyrin-Silica Nanocomposite as Solid Acid Catalyst for High Yield Synthesis of HMF in Water

Solid acid catalysts occupy a special class in heterogeneous catalysis for their efficiency in eco-friendly conversion of biomass into demanding chemicals. We synthesized porphyrin containing porous organic polymers (PorPOPs) using colloidal silica as a support. Post-modification with chlorosulfonic acid enabled sulfonic acid functionalization, and the resulting material (PorPOPS) showed excellent activity and durability for the conversion of fructose to 5-hydroxymethyl furfural (HMF) in green solvent water. PorPOPS composite was characterized by N2 sorption, FTIR, TGA, CHNS, FESEM, TEM and XPS techniques, justifying the successful synthesis of organic networks and the grafting of sulfonic acid sites (5 wt%). Furthermore, a high surface area (260 m2/g) and the presence of distinct mesopores of ~15 nm were distinctly different from the porphyrin containing sulfonated porous organic polymer (FePOP-1S). Surprisingly the hybrid PorPOPS showed an excellent yield of HMF (85%) and high selectivity (>90%) in water as compared to microporous pristine-FePOP-1S (yield of HMF = 35%). This research demonstrates the requirement of organic modification on silica surfaces to tailor the activity and selectivity of the catalysts. We foresee that this research may inspire further applications of biomass conversion in water in future environmental research.

Fast microflow kinetics and acid catalyst deactivation in glucose conversion to 5-hydroxymethylfurfural

Continuous flow microreactors operating at short residence times and high temperatures can give high HMF productivity and contribute to process intensification of biorefineries.

Current Situation of the Challenging Scale-Up Development of Hydroxymethylfurfural Production

Hydroxymethylfurfural (HMF) is a high-value platform chemical derived from renewable resources. In recent years, considerable efforts have been made to produce HMF also at industrial scale, which still faces some challenges regarding yield as well as sustainable and economic process designs. This critical Review evaluates the industrial process development of sustainable biomass conversion to HMF. Qualitative and quantitative guidelines are defined for the technological assessment of the processes described in patent literature. The formation of side products, difficulties in the separation and purification of HMF as well as catalyst regeneration were identified as major challenges in the HMF production. A first small-scale, commercial HMF production plant with a capacity of 300 tHMF per year has been operating in Switzerland since 2014.

Continuous Flow Upgrading of Selected C2-C6 Platform Chemicals Derived from Biomass

The ever increasing industrial production of commodity and specialty chemicals inexorably depletes the finite primary fossil resources available on Earth. The forecast of population growth over the next 3 decades is a very strong incentive for the identification of alternative primary resources other than petro-based ones. In contrast with fossil resources, renewable biomass is a virtually inexhaustible reservoir of chemical building blocks. Shifting the current industrial paradigm from almost exclusively petro-based resources to alternative bio-based raw materials requires more than vibrant political messages; it requires a profound revision of the concepts and technologies on which industrial chemical processes rely. Only a small fraction of molecules extracted from biomass bears significant chemical and commercial potentials to be considered as ubiquitous chemical platforms upon which a new, bio-based industry can thrive. Owing to its inherent assets in terms of unique process experience, scalability, and reduced environmental footprint, flow chemistry arguably has a major role to play in this context. This review covers a selection of C₂ to C₆ bio-based chemical platforms with existing commercial markets including polyols (ethylene glycol, 1,2-propanediol, 1,3-propanediol, glycerol, 1,4-butanediol, xylitol, and sorbitol), furanoids (furfural and 5-hydroxymethylfurfural) and carboxylic acids (lactic acid, succinic acid, fumaric acid, malic acid, itaconic acid, and levulinic acid). The aim of this review is to illustrate the various aspects of upgrading bio-based platform molecules toward commodity or specialty chemicals using new process concepts that fall under the umbrella of continuous flow technology and that could change the future perspectives of biorefineries.

Rapid, High-Yield Fructose Dehydration to 5-Hydroxymethylfurfural in Mixtures of Water and the Noncoordinating Ionic Liquid [bmim][OTf]

The noncoordinating ionic liquid [bmim][OTf] (bmim=1-butyl-3-methylimidazolium) is an effective and versatile solvent for the high-yield dehydration of fructose to the platform chemical 5-hydroxymethylfurfural (HMF) over short reaction times. In contrast to prior studies in which low yields were obtained for this transformation in ionic liquids (ILs) with noncoordinating anions, this contribution reveals that the water content is an essential parameter for an efficient reaction in ILs. Achieving the optimum amount of water can increase the yield dramatically by regulating the acidity of the catalyst and partially suppressing the side reaction caused by self-condensation of HMF. Using acid catalysis in [bmim][OTf] with 3.5 % water content, yields above 80 % can be achieved at 100 °C in only 10 min, even at high (14 %) fructose loading. These results also suggest that [bmim][OTf] represents a superior medium for solvent extraction of HMF compared to halide-based ILs, allowing the option of isolation or further valorization of the HMF formed.

High-Yield 5-Hydroxymethylfurfural Synthesis from Crude Sugar Beet Juice in a Biphasic Microreactor

5-Hydroxymethylfurfural (HMF) is an important biobased platform chemical obtainable in high selectivity by the hydrolysis of fructose (FRC). However, FRC is expensive, making the production of HMF at a competitive market price highly challenging. Here, it is shown that sugar beet thick juice, a crude, sucrose-rich intermediate in sugar refining, is an excellent feedstock for HMF synthesis. Unprecedented high selectivities and yields of >90 % for HMF were achieved in a biphasic reactor setup at 150 °C using salted diluted thick juice with H2 SO4 as catalyst and 2-methyltetrahydrofuran as a bioderived extraction solvent. The conversion of glucose, obtained by sucrose inversion, could be limited to <10 mol %, allowing its recovery for further use. Interestingly, purified sucrose led to significantly lower HMF selectivity and yields, showing advantages from both an economic and chemical selectivity perspective. This opens new avenues for more cost-effective HMF production.

Conversion of Fructose to HMF in a Continuous Fixed Bed Reactor with Outstanding Selectivity

5-Hydroxymethylfurfural (HMF) is a very promising component for bio-based plastics. Efficient synthesis of HMF from biomass is still challenging because of fast degradation of HMF to by-products under formation conditions. Therefore, different studies, conducted mainly in monophasic and biphasic batch systems with and without water addition have been published and are still under investigation. However, to produce HMF at a large scale, a continuous process is preferable. Until now, only a few studies have been published in this context. In this work, it is shown that fluorous alcohol hexafluoroisopropanol (HFIP) can act as superior reaction solvent for HMF synthesis from fructose in a fixed bed reactor. Very high yields of 76% HMF can be achieved in this system under optimized conditions, whilst the catalyst is very stable over several days. Such high yields are only described elsewhere with high boiling reaction solvents like dimethylsulfoxide (DMSO), whereas HFIP with a boiling point of 58 °C is very easy to separate from HMF.

Characterization of Pseudo-Lignin from Steam Exploded Birch

There is a growing interest in a more wholesome utilization of biomass as the need for greener chemistry and non-mineral oil-based products increases. Lignin is the largest renewable resource for aromatic chemicals, which is found in all types of lignocellulosic biomass. Steam-explosion of lignocellulosic biomass is a useful pretreatment technique to make the polymeric material more available for processing. However, this heat-based pretreatment is known to result in the formation of pseudo-lignin, a lignin-like polymer made from carbohydrate degradation products. In this work, we have analyzed steam-exploded birch with a varying severity factor (3.1-5.0) by pyrolysis-gas chromatography-mass spectrometry, 2D-NMR, and Fourier transform infrared spectroscopy. The main results reveal a consumption of acetic acid at higher temperatures, with the increase of furan components in the pyrolyzate. The IR and NMR spectral data support these results, and there is a reason to believe that the conditions for humin formation are accomplished under steam explosion. Pseudo-lignin seems to be a humin-like compound.

Organic Carbonates: Efficient Extraction Solvents for the Synthesis of HMF in Aqueous Media with Cerium Phosphates as Catalysts

We describe a process for the selective conversion of C6 -polyols into 5-hydroxymethylfurfural (5-HMF) in biphasic systems of organic carbonate/water (OC/W), with cerium(IV) phosphates as catalysts. Different reaction parameters such as the OC/W ratio, catalyst loading, reaction time, and temperature, were investigated for the dehydration of fructose. Under the best reaction conditions, a yield of 67.7 % with a selectivity of 93.2 % was achieved at 423 K after 6 h of reaction using [(Ce(PO4)1.5 (H2 O)(H3 O)0.5 (H2 O)0.5)] as the catalyst. A maximum yield of 70 % with the same selectivity was achieved after 12 h. At the end of the reaction, the catalyst was removed by centrifugation, the organic phase was separated from water and evaporated in vacuo (with solvent recovery), and solid 5-HMF was isolated (purity >99 %). The recovery and reuse of the catalyst and the relationship between the structure of the OC and the efficiency of the extraction are discussed. The OC/W system influences the lifetime of the catalysts positively compared to only water.

One-pot conversions of raffinose into furfural derivatives and sugar alcohols by using heterogeneous catalysts

Inedible and/or waste biomass reserves are being strongly focused upon as a suitable new energy and chemical source. Raffinose, which is an indigestible trisaccharide composed of glucose, galactose, and fructose, is found abundantly in beet molasses, sugar cane, and seeds of many leguminous plants. Herein, we demonstrate the one-pot synthesis of furan derivatives and sugar alcohols from raffinose by using heterogeneous acid, base, and/or metal-supported catalysts. The combination of Amberlyst-15 and hydrotalcite (HT) showed a high activity (37% yield) for 5-hydroxymethyl-2-furaldehyde (HMF) through continuous hydrolysis, isomerization, and dehydration reactions. In addition, the use of a hydrotalcite-supported ruthenium catalyst (Ru/HT) successfully afforded 2,5-diformylfuran (DFF, 27% yield) from HMF produced by raffinose, directly. Moreover, the hydrogenation of hexoses obtained by raffinose hydrolysis into sugar alcohols (galactitol, mannitol, sorbitol) was also achieved in a high yield (91%) with Amberlyst-15 and Ru/HT catalysts. Thus, we suggest that raffinose has great potential for the synthesis of important industrial intermediates under mild reaction conditions.

Condition screening and process investigation of aldose transformation in borate-containing acidic phosphate buffer system under microwave irradiation

The aldose transformation process in borate-containing acidic phosphate buffer system is systematically studied under microwave irradiation.

Catalytic dehydration of carbohydrates on in situ exfoliatable layered niobic acid in an aqueous system under microwave irradiation

A simple and efficient microwave-assisted HNb(3)O(8) catalytic process is proposed for the dehydration of carbohydrates in the aqueous phase. A 5-hydroxymethylfurfural (HMF) yield of 55.9 % was achieved at a high substrate/catalyst weight ratio of 50 from a 10 wt % fructose solution, which is close to the yield achieved by homogeneous aqueous systems. The critical factor for this performance is the fast in situ exfoliation of layered HNb(3)O(8) with the aid of microwave irradiation, which leads to quasi-homogeneous catalytic behavior. Importantly, the catalytic system is also applicable for the one-pot production of HMF from di- and polysaccharides, such as inulin, through a consecutive hydrolysis-dehydration reaction. Additionally, the unique restacking feature of the exfoliated HNb(3)O(8) ensures the good reusability of the catalyst.

Production of hybrid diesel fuel precursors from carbohydrates and petrochemicals using formic acid as a reactive solvent

We report the one-pot alkylation of mesitylene with carbohydrate-derived 5-(hydroxymethyl)furfural (HMF) as a step toward diesel-range liquids. Using FeCl(3) as a catalyst, HMF is shown to alkylate toluene, xylene, and mesitylene in high yields in CH(2)Cl(2) and MeNO(2) solvents. Efforts to extend this reaction to greener or safer solvents showed that most ether-based solvents are unsatisfactory. Acid catalysts (e.g, p-TsOH) also proved to be ineffective. Using formic acid as a reactive solvent, mesitylene could be alkylated to give mesitylmethylfurfural (MMF) starting from fructose with yields up to approximately 70 %. The reaction of fructose with formic acid in the absence of mesitylene gave rise to low yields of the formate ester of HMF, which indicates the stabilizing effect of replacing the hydroxyl substituent with mesityl. The arene also serves as a second phase into which the product is extracted. Even by using formic acid, the mesitylation of less expensive precursors such as glucose and cellulose proceeded only in modest yields (ca. 20 %). These simpler substrates were found to undergo mesitylation by using hydrogen chloride/formic acid via the intermediate chloromethylfurfural.