Catalytic Upgrading of Ethanol to n-Butanol: Progress in Catalyst Development

State-of-the-art advances in homogeneous molecular catalysis for the Guerbet upgrading of bio-ethanol to fuel-grade bio-butanol

The upgrading of ethanol to n-butanol marks a major breakthrough in the field of biofuel technology, offering the advantages of compatibility with existing infrastructure while simultaneously offering potential benefits in terms of transport efficiency and energy density. With its lower vapour pressure and reduced corrosiveness compared to ethanol, n-butanol is easier not only to manage but also to transport, eliminating the need for costly infrastructure changes. This leads to improved fuel efficiency and reduced fuel consumption. These features position n-butanol as a promising alternative to ethanol in the future of biodiesel. This review article delves into the cutting-edge advancements in upgrading ethanol to butanol, highlighting the critical importance of this transformation in enhancing the value and practical application of biofuels. While traditional methods for making butanol rely heavily on fossil fuels, those that employ ethanol as a starting material are dominated by heterogeneous catalysis, which is limited by the requirement of high temperatures and a lack of selectivity. Homogeneous catalysts have been pivotal in enhancing the efficiency and selectivity of this conversion, owing to their unique mode of operation at the molecular level. A comprehensive review of the various homogeneous catalytic processes employed in the transformation of feedstock-agnostic bio-ethanol to fuel-grade bio-n-butanol is provided here, with a major focus on the key advancements in catalyst design, reaction conditions and mechanisms that have significantly improved the efficiency and selectivity of these Guerbet reactions.

Effect of the ZrO2 Crystal Phase on Performance over a CuCeZrO Catalyst for Dehydrogenative Condensation of Ethanol to Ethyl Acetate

Ethyl acetate is an important chemical, and ethanol dehydrogenative condensation with 95.6% atomic economy is a promising synthetic route. CuZrO-based catalysts are widely applied in this reaction; however, the effect of the ZrO2 crystal phase in the CuCeZrO catalyst upon reaction deserves to be explored further. Herein, the ZrO2 crystal phase in the CuCeZrO catalyst was regulated by controlling the calcination temperature, and a high temperature (≥600 °C) is conducive to the transformation of the tetragonal phase to the monoclinic phase. Additionally, monoclinic ZrO2 (m-ZrO2) with limited density of the strong base is found to be more beneficial to the selective production of ethyl acetate from ethanol, while tetragonal ZrO2 (t-ZrO2) with abundant strongly basic sites is more inclined to the formation of butanol and its downstream esters. This work not only improves our understanding of the crystal phase effect in a CuCeZrO catalytic system but also paves the way for the development of more efficient catalysts for ethyl acetate production.

Utilizing Undissolved Portion (UNP) of Cement Kiln Dust as a Versatile Multicomponent Catalyst for Bioethylene Production from Bioethanol: An Innovative Approach to Address the Energy Crisis

This study focuses on upcycling cement kiln dust (CKD) as an industrial waste by utilizing the undissolved portion (UNP) as a multicomponent catalyst for bioethylene production from bioethanol, offering an environmentally sustainable solution. To maximize UNP utilization, CKD was dissolved in nitric acid, followed by calcination at 500 °C for 3 h in an oxygen atmosphere. Various characterization techniques confirmed that UNP comprises five different compounds with nanocrystalline particles exhibiting an average crystal size of 47.53 nm. The UNP catalyst exhibited a promising bioethylene yield (77.1%) and selectivity (92%) at 400 °C, showcasing its effectiveness in converting bioethanol to bioethylene with outstanding properties. This exceptional performance can be attributed to its distinctive structural characteristics, including a high surface area and multiple-strength acidic sites that facilitate the reaction mechanism. Moreover, the UNP catalyst displayed remarkable stability and durability, positioning it as a strong candidate for industrial applications in bioethylene production. This research underscores the importance of waste reduction in the cement industry and offers a sustainable path toward a greener future.

Ni-Based Hydrotalcite (HT)-Derived Cu Catalysts for Catalytic Conversion of Bioethanol to Butanol

Catalytic conversion of biomass-derived ethanol into n-butanol through Guerbet coupling reaction has become one of the key reactions in biomass valorization, thus attracting significant attention recently. Herein, a series of supported Cu catalysts derived from Ni-based hydrotalcite (HT) were prepared and performed in the continuous catalytic conversion of ethanol into butanol. Among the prepared catalysts, Cu/NiAlOx shows the best performance in terms of butanol selectivity and catalyst stability, with a sustained ethanol conversion of ~35% and butanol selectivity of 25% in a time-on-stream (TOS) of 110 h at 280 °C. While for the Cu/NiFeOx and Cu/NiCoOx, obvious catalyst deactivation and/or low butanol selectivity were obtained. Extensive characterization studies of the fresh and spent catalysts, i.e., X-ray diffraction (XRD), Transmission electron microscopy (TEM), X-ray photoelectron spectroscopy (XPS) and Hydrogen temperature-programmed reduction (H2-TPR), reveal that the catalysts' deactivation is mainly caused by the support deconstruction during catalysis, which is highly dependent on the reducibility. Additionally, an appropriate acid-base property is pivotal for enhancing the product selectivity, which is beneficial for the key process of aldol-condensation to produce butanol.

Design Strategies for Hydroxyapatite-Based Materials to Enhance Their Catalytic Performance and Applicability

Hydroxyapatite (HAP) is a green catalyst that has a wide range of applications in catalysis due to its high flexibility and multifunctionality. These properties allow HAP to accommodate a large number of catalyst modifications that can selectively improve the catalytic performance in target reactions. To date, many studies have been conducted to elucidate the effect of HAP modification on the catalytic activities for various reactions. However, systematic design strategies for HAP catalysts are not established yet due to an incomplete understanding of underlying structure-activity relationships. In this review, tuning methods of HAP for improving the catalytic performance are discussed: 1) ionic composition change, 2) morphology control, 3) incorporation of other metal species, and 4) catalytic support engineering. Detailed mechanisms and effects of structural modulations on the catalytic performances for attaining the design insights of HAP catalysts are investigated. In addition, computational studies to understand catalytic reactions on HAP materials are also introduced. Finally, important areas for future research are highlighted.

Effect of Strontium Modification in Mg-Al Mixed Oxide Catalysts on Product Distribution toward Catalytic Reaction of Ethanol

The aim of this research was to examine the effect of strontium content in the MgAlO catalyst for the catalytic ethanol reaction on the product distribution. The structure of the catalysts and the actual amount of strontium on the catalysts were verified using XRD and ICP techniques, respectively. The acid and basic strength characteristics of catalysts were examined using NH3-TPD and CO2-TPD techniques, respectively. The strontium content was found to influence the textural properties and the acidic and basic characteristics of the catalysts, leading to differences in product selectivity and ethanol conversion. The MgAlO catalyst with 1.9 wt % strontium provided the maximum ethylene and butanol selectivity, probably due to the presence of appropriate medium acidic and strong basic sites. All catalysts can efficiently produce ethylene by a dehydration reaction and acetaldehyde by a dehydrogenation reaction. Acetaldehyde selectivity was dominant with increased strontium loading.

Highly Selective and Stable Cu Catalysts Based on Ni-Al Catalytic Systems for Bioethanol Upgrading to n-Butanol

The catalytic upgrading of ethanol into butanol through the Guerbet coupling reaction has received increasing attention recently due to the sufficient supply of bioethanol and the versatile applications of butanol. In this work, four different supported Cu catalysts, i.e., Cu/Al2O3, Cu/NiO, Cu/Ni3AlOx, and Cu/Ni1AlOx (Ni2+/Al3+ molar ratios of 3 and 1), were applied to investigate the catalytic performances for ethanol conversion. From the results, Ni-containing catalysts exhibit better reactivity; Al-containing catalysts exhibit better stability; but in terms of ethanol conversion, butanol selectivity, and catalyst stability, a corporative effect between Ni-Al catalytic systems can be clearly observed. Combined characterizations such as XRD, TEM, XPS, H2-TPR, and CO2/NH3-TPD were applied to analyze the properties of different catalysts. Based on the results, Cu species provide the active sites for ethanol dehydrogenation/hydrogenation, and the support derived from Ni-Al-LDH supplies appropriate acid-base sites for the aldol condensation, contributing to the high butanol selectivity. In addition, catalysts with strong reducibility (i.e., Cu/NiO) may be easily deconstructed during catalysis, leading to fast deactivation of the catalysts in the Guerbet coupling process.

Transition Metal-Promoted Mg-Fe Mixed Oxides for Conversion of Ethanol to Valuable Products

The conversion of ethanol into petrochemicals, such as ethyl and butyl acetate, butanol, hexanol, and so forth was studied. The conversion was catalyzed by Mg-Fe mixed oxide modified with a second transition metal (Ni, Cu, Co, Mn, or Cr). The main aim was to describe the influence of second transition metal on (i) the catalyst itself and (ii) reaction products such as ethyl acetate, butanol, hexanol, acetone, and ethanal. Moreover, the results were compared with the results of pure Mg-Fe. The reaction was carried out in the gas phase in a flow reactor with a weight hour space velocity of 4.5 h^-1 for 32 h at three reaction temperatures (280, 300, and 350 °C). The metals Ni and Cu in Mg-Fe oxide enhanced the ethanol conversion due to the population of active dehydrogenation sites. Despite the lower acido-basicity, Cu, Co, and Ni supported the yield of ethyl acetate, and Cu and Ni also promoted the yield of higher alcohols. Ni was related to the extent of the gasification reactions. Moreover, long-term stability (by leaching of metals) test was carried out for all catalysts (128 h).

Ethanol Coupling Reactions over MgO-Al2O3 Mixed Oxide-Based Catalysts for Producing Biofuel Additives

Catalytic conversion of ethanol to 1-butanol was studied over MgO-Al₂O₃ mixed oxide-based catalysts. Relationships between acid-base and catalytic properties and the effect of active metal on the hydrogen transfer reaction steps were investigated. The acid-base properties were studied by temperature-programmed desorption of CO₂ and NH₃ and by the FT-IR spectroscopic examination of adsorbed pyridine. Dispersion of the metal promoter (Pd, Pt, Ru, Ni) was determined by CO pulse chemisorption. The ethanol coupling reaction was studied using a flow-through microreactor system, He or H₂ carrier gas, WHSV = 1 gEtOH·gcat.-1·h-1, at 21 bar, and 200-350 °C. Formation and transformation of surface species under catalytic conditions were studied by DRIFT spectroscopy. The highest butanol selectivity and yield was observed when the MgO-Al₂O₃ catalyst contained a relatively high amount of strong-base and medium-strong Lewis acid sites. The presence of metal improved the activity both in He and H₂; however, the butanol selectivity significantly decreased at temperatures ≥ 300 °C due to acceleration of undesired side reactions. DRIFT spectroscopic results showed that the active metal promoted H-transfer from H₂ over the narrow temperature range of 200-250 °C, where the equilibrium allowed significant concentrations of both dehydrogenated and hydrogenated products.

Optimal Conditions for Butanol Production from Ethanol over MgAlO Catalyst Derived from Mg-Al Layer Double Hydroxides

The MgAlO catalyst was obtained from thermal decomposition of the MgAl-LDH catalyst having Mg/Al molar ratio of 5. The catalytic Guerbet reaction of ethanol was investigated to determine the effect of WHSV and nitrogen flow rate on butanol production and product distribution. It was performed in a fixed-bed microreactor under continuous flow of vaporized ethanol mixed with N₂. The MgAlO catalyst had high total basic sites and high total acid sites that were crucial for ethanol Guerbet reaction. The MgAlO catalyst showed the highest butanol selectivity at 300℃ under WHSV = 3.10 h^-1 and nitrogen flow rate = 3,600 mL/h, and the highest butanol yield at 400℃ under WHSV = 3.10 h^-1 and nitrogen flow rate = 900 mL/h. It can be summarized that in order to enhance the butanol yield, the low WHSV is preferred to increase the contact time of ethanol and catalyst under moderate temperature.

Structural Evolution of MOF-Derived RuCo, A General Catalyst for the Guerbet Reaction

Guerbet alcohols, a class of β-branched terminal alcohols, find widespread application because of their low melting points and excellent fluidity. Because of the limitations in the activity and selectivity of existing Guerbet catalysts, Guerbet alcohols are not currently produced via the Guerbet reaction but via hydroformylation of oil-derived alkenes followed by aldol condensation. In pursuit of a one-step synthesis of Guerbet alcohols from simple linear alcohol precursors, we show that MOF-derived RuCo alloys achieve over a million turnovers in the Guerbet reaction of 1-propanol, 1-butanol, and 1-pentanol. The active catalyst is formed in situ from ruthenium-impregnated metal-organic framework MFU-1. XPS and XAS studies indicate that the precatalyst is composed of Ru precursor trapped inside the MOF pores with no change in the oxidation state or coordination environment of Ru upon MOF incorporation. The significantly higher reactivity of Ru-impregnated MOF versus a physical mixture of Ru precursor and MOF suggests that the MOF plays an important role in templating the formation of the active catalyst and/or its stabilization. XPS reveals partial reduction of both ruthenium and MOF-derived cobalt under the Guerbet reaction conditions, and TEM/EDX imaging shows that Ru is decorated on the edges of dense nanoparticles, as well as thin nanoplates of CoOx. The use of ethanol rather than higher alcohols as a substrate results in lower turnover frequencies, and RuCo recovered from ethanol upgrading lacks nanostructures with plate-like morphology and does not exhibit Ru-enrichment on the surface and edge sites. Notably, 1H and 31P NMR studies show that through use of K3PO4 as a base promoter in the RuCo-catalyzed alcohol upgrading, the formation of carboxylate salts, a common side product in the Guerbet reaction, was effectively eliminated.

Interfacial Sites in Ag Supported Layered Double Oxide for Dehydrogenation Coupling of Ethanol to n-Butanol

Upgrading of ethanol to n-butanol through dehydrogenation coupling has received increasing attention due to the wide application of n-butanol. But the enhancement of ethanol dehydrogenation and followed coupling to produce high selectivity to n-butanol is still highly desired. Our previous work has reported an acid-base-Ag synergistic catalysis, with Ag particles supported on Mg and Al-containing layered double oxides (Ag/MgAl-LDO). Here, Ag-LDO interfaces have been manipulated for dehydrogenation coupling of ethanol to n-butanol by tailoring the size of Ag particles and the interactions between Ag and LDO. It has been revealed that increasing the population of surface Ag sites at Ag-LDO interfaces promotes not only the dehydrogenation of ethanol to acetaldehyde but also the subsequent aldol condensation of generated acetaldehyde. A selectivity of up to 76 % to n-butanol with an ethanol conversion of 44 % has been achieved on Ag/LDO with abundant interfacial Ag sites, much superior to the state-of-the-art catalysts.

Development of a New Ternary Al2O3-HAP-Pd Catalyst for Diethyl Ether and Ethylene Production Using the Preferential Dehydration of Ethanol

This study aims to convert ethanol to higher value-added products, particularly diethyl ether and ethylene using the catalytic dehydration of ethanol. Hence, the gas-phase dehydration of ethanol over Al2O3-HAP catalysts as such and modified by addition of palladium (Pd) in a microreactor was evaluated. The commercial Al2O3-HAP catalyst was first prepared by the physical mixing method, and then, the optimal ratio of the Al2O3-HAP catalyst (2:8 by wt %) was impregnated with Pd to develop a new functional catalyst to alter surface acidity. Based on the results, the combination of Al2O3 and HAP catalysts generated significant quantities of weak acid sites which demonstrates an enhancement in catalytic activity. In addition, Pd modification in the optimal composition ratio of the Al2O3-HAP catalyst extremely increased the amount of weak acid sites as well as weak acid density due to the synergistic effect between the Pd and Al2O3-HAP catalyst that are supposed to suggest the active sites in the reaction. Among all catalysts, the Al20-HAP80-Pd catalyst displayed brilliant catalytic performance in the course of diethyl ether yield (ca. 51.0%) at a reaction temperature of 350 °C and ethylene yield (ca. 75.0%) at a reaction temperature of 400 °C having an outstanding stability under time-on-stream for 10 h. This is recognized to the combination of the effects of weak acid sites (Lewis acidity), small amount of strong acid sites, and structural characteristics of the catalytic materials used.

Eco-Friendly and Sustainable Process for Converting Hydrous Bioethanol to Butanol

The purpose of the study was the development of water-resistant catalyst and catalytic processes for the conversion of hydrous ethanol to 1-butanol. Water, in hydrous ethanol, strongly inhibits conversion to 1-butanol on solid catalysts. In this study, the nonstoichiometric P-deficient hydroxyapatite containing carbonate anions (C-HAP), Ca10−x/2(PO4)6−x(CO3)x(OH)2, displayed good performance in the Guerbet condensation of hydrated ethanol to 1-butanol, after proper stabilization of reaction conditions. Hydrous ethanol (96 wt%) was converted on C-HAP formed as extrudates with silica binder at 400 °C and weight hour space velocity (WHSV) = 0.5–1.0 h−1 to yield 21–23% 1-butanol and 73–74% selectivity. It displayed stable operation for up to 170 h on streams conducted in bench and mini-pilot rigs with catalyst loadings of 2 and 50 cm3, respectively. The process simulation employed the recycling of ethanol without laboratory verification to reach 68% theoretical yield of 1-butanol. The techno-economic analysis demonstrated the feasibility of this process, showing that it may be profitable depending on the prices of hydrated ethanol and 1-butanol.

Elucidating the Influence of the d-Band Center on the Synthesis of Isobutanol

As the search for carbon-efficient synthesis pathways for green alternatives to fossil fuels continues, an expanding class of catalysts have been developed for the upgrading of lower alcohols. Understanding of the acid base functionalities has greatly influenced the search for new materials, but the influence of the metal used in catalysts cannot be explained in a broader sense. We address this herein and correlate our findings with the most fundamental understanding of chemistry to date by applying it to d-band theory as part of an experimental investigation. The commercial catalysts of Pt, Rh, Ru, Cu, Pd, and Ir on carbon as a support have been characterized by means of SEM, EDX-mapping, STEM, XRD, N2-physisorption, and H2-chemisorption. Their catalytic activity has been established by means of c-methylation of ethanol with methanol. For all catalysts, the TOF with respect to i-butanol was examined. The Pt/C reached the highest TOF with a selectivity towards i-butanol of 89%. The trend for the TOFs could be well correlated with the d-band centers of the metal, which formed a volcano curve. Therefore, this study is another step towards the rationalization of catalyst design for the upgrading of alcohols into carbon-neutral fuels or chemical feedstock.

Improvement of n-butanol Guerbet condensation: a reaction integration of n-butanol Guerbet condensation and 1,1-dibutoxybutane hydrolysis

n-Butanol Guerbet condensation is a green route to 2-ethylhexanol (2EHO).

Role of Lewis Acids of MIL-101(Cr) in the Upgrading of Ethanol to n-Butanol

The upgrading of bioethanol to n-butanol has recently been a focus of considerable attention due to the advantages of n-butanol over bioethanol as a sustainable fuel. The efficiency of this reaction is highly dependent on the development of catalysts, where understanding how catalysts perform is essential. However, traditional catalysts are normally composed of several kinds of active sites that work together synergistically in reactions, making it challenging to identify the role that individual active sites play. Herein, we synthesized three chromium-based MOFs ((MIL-101(Cr), where MIL stands for Matériaux Institut Lavoisier) with different Lewis acidities but without any basic sites. The linear relationship between Lewis acidities and their dehydration and condensation abilities suggests that there is a competition between the ethanol dehydration to diethyl ether and acetaldehyde condensation on Lewis acids. Upon the introduction of Pd, the Lewis acidity also dominates the particle size of Pd and then the dehydrogenation and hydrogenating abilities of catalysts.

Condensed Phase Guerbet Reactions of Ethanol/Isoamyl Alcohol Mixtures

The self-condensation and cross-condensation reactions of ethanol and isoamyl alcohol are examined to better understand the potential routes to value-added byproducts from fuel ethanol production. Reactions have been carried out in both batch autoclave and continuous condensed-phase reactors using a lanthanum-promoted, alumina-supported nickel catalyst at near-critical condensed phase conditions. Analysis of multiple candidate kinetic models led to a Langmuir–Hinshelwood rate expression that is first-order in alcohol with water as the strongly adsorbed species. This model provides the best fit of data from both batch and continuous reactor experiments. Activation energies for primary condensation reactions increase as carbon chain lengths increase. Selectivities to higher alcohols of 94% and 87% for ethanol and isoamyl alcohol, respectively, were observed at different operating conditions.

Catalyst Performance Studies on the Guerbet Reaction in a Continuous Flow Reactor Using Mono- and Bi-Metallic Cu-Ni Porous Metal Oxides

Higher alcohols like 1-butanol are considered important biofuels with superior properties compared to the more readily available bio-ethanol. An attractive route to prepare 1-butanol from ethanol is the Guerbet reaction. We here report the use of hydrotalcite-derived mono- (Cu-PMO or Ni-PMO) and bi-metallic (CuNi-PMO) porous metal oxide catalysts for the Guerbet coupling of ethanol to 1-butanol in a continuous flow reactor (320 °C, 0.1 MPa, LHSV = 15 mL g−1 h−1) at extended times on stream (~160 h). Two distinct regimes with different product distributions were observed for the Cu-PMO and CuNi-PMO catalyst with time on stream. At the start of the run, the initial conversion of ethanol dropped from about 85% to less than 20% after 60 h and acetaldehyde was the main product (regime 1). At prolonged times on stream (60–160 h), fairly constant low conversions of ethanol (14%) were observed and 1-butanol was the main product (regime 2). Performance of the monometallic Cu-PMO catalyst in terms of 1-butanol yield and stability was lower compared to the bi-metallic CuNi-PMO. Detailed catalyst characterization studies (XRD, H2-TPR, sorption of acrylic acid, TGA, TEM, HAADF-STEM, and EDS mapping) on both fresh and spent CuNi-PMO taken at various times on stream was performed to determine the changes in catalyst morphology and composition during a run, and particularly to obtain information on changes in catalyst structure operating in regime 1 or 2. The change in chemoselectivity is in line with an increase in basicity of the catalyst at extended runtimes.

Phosphine-free pincer-ruthenium catalyzed biofuel production: high rates, yields and turnovers of solventless alcohol alkylation

High TONs and TOFs are observed for the β-alkylation of alcohols using phosphine-free pincer-ruthenium catalysts at a very low base loading. Kinetic studies and DFT calculations were complementary and provide a clear understanding on the mechanism.

Yttria-Stabilized Zirconia as a High-Performance Catalyst for Ethanol to n-Butanol Guerbet Coupling

It has been shown that yttria-stabilized zirconia is an effective catalyst for ethanol to n-butanol Guerbet coupling. The variation of the calcination temperature allows an improvement in the catalytic characteristics of this material via stabilization of the tetragonal phase of zirconia, having higher basicity than the monoclinic one. The treatment of yttria-stabilized zirconia at an optimal calcination temperature of 500 °C induces the increase in surface basicity required for the aldol condensation step, along with a decrease in surface acidity, which is responsible for the side reaction such as ethylene formation. The catalyst obtained significantly exceeds in selectivity and n-butanol yield than individual zirconia and other oxide systems which have been studied in this reaction.