Efficient Electrocatalytic Reduction of Furfural to Furfuryl Alcohol in a Microchannel Flow Reactor

Enhancing electrochemical reactions in organic synthesis: the impact of flow chemistry

Utilizing electrons directly offers significant potential for advancing organic synthesis by facilitating novel reactivity and enhancing selectivity under mild conditions. As a result, an increasing number of organic chemists are exploring electrosynthesis. However, the efficacy of electrochemical transformations depends critically on the design of the electrochemical cell. Batch cells often suffer from limitations such as large inter-electrode distances and poor mass transfer, making flow cells a promising alternative. Implementing flow cells, however, requires a foundational understanding of microreactor technology. In this review, we briefly outline the applications of flow electrosynthesis before providing a comprehensive examination of existing flow reactor technologies. Our goal is to equip organic chemists with the insights needed to tailor their electrochemical flow cells to meet specific reactivity requirements effectively. We also highlight the application of reactor designs in scaling up electrochemical processes and integrating high-throughput experimentation and automation. These advancements not only enhance the potential of flow electrosynthesis for the synthetic community but also hold promise for both academia and industry.

Efficient Electrochemical Hydrogenation of Furfural to Furfuryl Alcohol Using an Anion-Exchange Membrane Electrolysis Cell

The electrochemical hydrogenation (ECH) of furfural (FF) offers a promising pathway for the production of furfuryl alcohol (FA) while aligning with sustainability and environmental considerations. However, this technology has primarily been studied in half-cell configurations operating at high cell voltages and low current densities. Herein, we employ a membrane electrode assembly (MEA) system with an anion-exchange membrane for the ECH of FF and systematically investigate various parameters, including the ionomer content in the cathode catalyst, electrolyte type, electrolyte concentration, and flow rate. Under optimal conditions, our MEA system with non-noble metal-based catalysts exhibits a current density of 30 mA cm-2 with a Faradaic efficiency for FA production of 66% at a cell voltage of 2 V, maintaining operational durability for 5 h. This study highlights the potential of electrochemical FA production for practical applications to realize the decarbonization of the hydrogenation industry.

Developing electrochemical hydrogenation towards industrial application

Electrochemical hydrogenation reactions gained significant attention as a sustainable and efficient alternative to conventional thermocatalytic hydrogenations. This tutorial review provides a comprehensive overview of the basic principles, the practical application, and recent advances of electrochemical hydrogenation reactions, with a particular emphasis on the translation of these reactions from lab-scale to industrial applications. Giving an overview on the vast amount of conceivable organic substrates and tested catalysts, we highlight the challenges associated with upscaling electrochemical hydrogenations, such as mass transfer limitations and reactor design. Strategies and techniques for addressing these challenges are discussed, including the development of novel catalysts and the implementation of scalable and innovative cell concepts. We furthermore present an outlook on current challenges, future prospects, and research directions for achieving widespread industrial implementation of electrochemical hydrogenation reactions. This work aims to provide beginners as well as experienced electrochemists with a starting point into the potential future transformation of electrochemical hydrogenations from a laboratory curiosity to a viable technology for sustainable chemical synthesis on an industrial scale.

Electroenzymatic Reduction of Furfural to Furfuryl Alcohol by an Electron Mediator and Enzyme Orderly Assembled Biocathode

The electroenzymatic valorization of biomass derivatives into valuable biochemicals has a promising outlook. However, bottlenecks including poor electron transfer between the electrode surface and oxidoreductase, inefficient regeneration of cofactors, and high cost of enzymes and electron mediators hindered the realistic applications of the technique. Herein, to address the above technical barriers, a novel bio-electrocatalytic system that integrates the electrochemical NADH regeneration and enzymatic reaction was constructed, using an orderly assembled composite bioelectrode consisting of an outer immobilized enzyme layer and a sandwiched redox mediator rhodium complex layer. The as-prepared composite bioelectrode was further applied for the highly selective hydrogenation of furfural into furfural alcohol. Results indicated that the enzyme activity was significantly improved, while the furfural valorization was promoted by effective interfacial electron transition and co-factor regeneration on the composite bioelectrode. Considerable high furfural conversion (96.4%) can be achieved accompanied by a furfural alcohol selectivity of 90.0% at -1.2 V (vs Ag/AgCl). The novel composite bioelectrode also showed good stability and reusability. Up to 85.1% of the original furfural alcohol selectivity can be preserved after 10 times of recycling. This work presents a promising green alternative for the valorization of furfural, which also shows great potential extending to the valorization of other biomass compounds.

Advances in Selective Electrochemical Oxidation of 5-Hydroxymethylfurfural to Produce High-Value Chemicals

The conversion of biomass is a favorable alternative to the fossil energy route to solve the energy crisis and environmental pollution. As one of the most versatile platform compounds, 5-hydroxymethylfural (HMF) can be transformed to various value-added chemicals via electrolysis combining with renewable energy. Here, the recent advances in electrochemical oxidation of HMF, from reaction mechanism to reactor design are reviewed. First, the reaction mechanism and pathway are summarized systematically. Second, the parameters easy to be ignored are emphasized and discussed. Then, the electrocatalysts are reviewed comprehensively for different products and the reactors are introduced. Finally, future efforts on exploring reaction mechanism, electrocatalysts, and reactor are prospected. This review provides a deeper understanding of mechanism for electrochemical oxidation of HMF, the design of electrocatalyst and reactor, which is expected to promote the economical and efficient electrochemical conversion of biomass for industrial applications.

Selective Furfuryl Alcohol Production from Furfural via Bio-Electrocatalysis

The catalytic reduction of renewable furfural into furfuryl alcohol for various applications is in the ascendant. Nonetheless, the conventional chemo-catalysis hydrogenation of furfural always suffers from poor selectivity, harsh conditions, and expensive catalysts. Herein, to overcome the serious technical barriers of conventional furfuryl alcohol production, an alternative bio-electrocatalytic hydrogenation system was established under mild and neutral conditions, where the dissolved cofactor (NADH) and the alcohol dehydrogenase (ADH) participated in a tandem reaction driven by the electron from a novel Rh (III) complex fixed cathode. Under the optimized conditions, 81.5% of furfural alcohol selectivity can be realized at −0.43 V vs. RHE. This contribution presents a ‘green’ and promising route for the valorization of furfural and other biomass compounds.

Direct Synthesis of α-Sulfenylated Ketones under Electrochemical Conditions

We investigated the electrochemical sulfenylation reaction in both batch and continuous flow regimes, involving thiophenols/thiols and enol-acetates to yield α-sulfenylated ketones, without using additional oxidants or catalysts. Studies with different electrolytes were also performed, revealing that quaternary ammonium salts are the best mediators for this reaction. Notably, during the study of the reaction scope, a Boc-cysteine proved to be extremely tolerant to our protocol, thus increasing its relevance. The methodology also proved to be scalable in both batch and continuous flow conditions, opening up possibilities for further studies since these relevant functional groups are important moieties in organic synthesis.

Flash Synthesis and Continuous Production of C-Arylglycosides in a Flow Electrochemical Reactor

Electrochemistry provides a green and atom-efficient route to synthesize pharmaceutical and useful functional molecules, as it eliminates the need for the harsh chemical oxidants and reductants commonly used in traditional chemical reactions. To promote the implementation of electrochemical processes in the industry, there is a strong demand for the development of technologies that would allow for scale-up and a shortened reaction process time. Herein, we report that electrolysis was successfully accomplished using a flow-divided-electrochemical reactor within a few seconds, enabling the desired chemical conversion in a short period of time. Moreover, the narrow electrode gap of the flow reactor, which offers greener conditions than the conventional batch reactor, resulted in the continuous flash synthesis of C-arylglycosides.

Bifunctional Pt/Au Janus electrocatalysts for simultaneous oxidation/reduction of furfural with bipolar electrochemistry

The sustainable conversion of biomass-derived compounds into high added-value products is a very important contemporary scientific challenge. In this context, we report here the simultaneous electro-oxidation/-reduction of a biomass-derived compound in a one-pot approach using bipolar electrochemistry. Bifunctional Pt/Au Janus electrocatalysts are employed for a selective conversion of furfural into both, furfuryl alcohol and furoic acid, which can't be achieved when using non-Janus particles. The results emphasize the benefits of bipolar electrochemistry in the frame of electrosynthesis processes.

High-Grade Biofuel Synthesis from Paired Electrohydrogenation and Electrooxidation of Furfural Using Symmetric Ru/Reduced Graphene Oxide Electrodes

Electrochemical hydrogenation is a challenging technoeconomic process for sustainable liquid fuel production from biomass-derived compounds. In general, half-cell hydrogenation is paired with water oxidation to generate the low economic value of O₂ at the anode. Herein, a new strategy for the rational design of Ru/reduced graphene oxide (Ru/RGO) nanocomposites through a cost-effective and straightforward microwave irradiation technique is reported for the first time. The Ru nanoparticles with an average size of 3.5 nm are well anchored into the RGO frameworks with attractive nanostructures to enhance the furfural's paired electrohydrogenation (ECH) and electrooxidation (ECO) process to achieve high-grade biofuel. Furfural is used as a reactant with the paired electrolyzer to produce furfuryl alcohol and 2-methylfuran at the cathode side. Simultaneously, 2-furic acid and 5-hydroxyfuroic acid along with plenty of H⁺ and e^- are generated at the anode side. Most impressively, the paired electrolyzer induces an extraordinary ECH and ECO of furfural, with the desired production of 2-methylfuran (yield = 91% and faradic efficiency (FE) of 95%) at X_FF = 97%, outperforming the ECH half-cell reaction. The mechanisms of the half-cell reaction and paired cell reaction are discussed. Exquisite control of the reaction parameters, optimized strategies, and the yield of individual products are demonstrated. These results show that the Ru/RuO nanocomposite is a potential candidate for biofuel production in industrial sectors.

Probing electrosynthetic reactions with furfural on copper surfaces

This work entails the integrated use of electrochemistry and operando Raman spectroscopy to probe the reduction of a biomass platform, furfural, to value-added chemicals on Cu electrodes. The results reveal key structural differences of the Cu that dictate selectivity for furfuryl alcohol or 2-methylfuran.

Hybrid Process Models in Electrochemical Syntheses under Deep Uncertainty

Chemical process engineering and machine learning are merging rapidly, and hybrid process models have shown promising results in process analysis and process design. However, uncertainties in first-principles process models have an adverse effect on extrapolations and inferences based on hybrid process models. Parameter sensitivities are an essential tool to understand better the underlying uncertainty propagation and hybrid system identification challenges. Still, standard parameter sensitivity concepts may fail to address comprehensive parameter uncertainty problems, i.e., deep uncertainty with aleatoric and epistemic contributions. This work shows a highly effective and reproducible sampling strategy to calculate simulation uncertainties and global parameter sensitivities for hybrid process models under deep uncertainty. We demonstrate the workflow with two electrochemical synthesis simulation studies, including the synthesis of furfuryl alcohol and 4-aminophenol. Compared with Monte Carlo reference simulations, the CPU-time was significantly reduced. The general findings of the hybrid model sensitivity studies under deep uncertainty are twofold. First, epistemic uncertainty has a significant effect on uncertainty analysis. Second, the predicted parameter sensitivities of the hybrid process models add value to the interpretation and analysis of the hybrid models themselves but are not suitable for predicting the real process/full first-principles process model’s sensitivities.

Electrocatalytic reduction of furfural with high selectivity to furfuryl alcohol using AgPd alloy nanoparticles

AgPd alloy nanoparticles were applied for the electrocatalytic reduction of furfural (2-furfuraldehyde). Constant potential electrolysis experiments were carried out and furfural conversions and product selectivities to furfuryl alcohol were systematically investigated to elucidate the alloy composition-catalytic property relationship. AgPd catalysts exhibited faradaic efficiencies to furfuryl alcohol over 95% for Ag60Pd40 at low overpotentials in neutral, aqueous electrolyte.

Recent catalytic routes for the preparation and the upgrading of biomass derived furfural and 5-hydroxymethylfurfural

Furans represent one of the most important classes of intermediates in the conversion of non-edible lignocellulosic biomass into bio-based chemicals and fuels. At present, bio-furan derivatives are generally obtained from cellulose and hemicellulose fractions of biomass via the acid-catalyzed dehydration of their relative C6-C5 sugars and then converted into a wide range of products. Furfural (FUR) and 5-hydroxymethylfurfural (HMF) are surely the most used furan-based feedstocks since their chemical structure allows the preparation of various high-value-added chemicals. Among several well-established catalytic approaches, hydrogenation and oxygenation processes have been efficiently adopted for upgrading furans; however, harsh reaction conditions are generally required. In this review, we aim to discuss the conversion of biomass derived FUR and HMF through unconventional (transfer hydrogenation, photocatalytic and electrocatalytic) catalytic processes promoted by heterogeneous catalytic systems. The reaction conditions adopted, the chemical nature and the physico-chemical properties of the most employed heterogeneous systems in enhancing the catalytic activity and in driving the selectivity to desired products are presented and compared. At the same time, the latest results in the production of FUR and HMF through novel environmental friendly processes starting from lignocellulose as well as from wastes and by-products obtained in the processing of biomass are also overviewed.

A Divergent Paired Electrochemical Process for the Conversion of Furfural Using a Divided-Cell Flow Microreactor

Furfural is a prominent, non-petroleum-based chemical feedstock material, derived from abundantly available hemicellulose. Hence, its derivatization into other useful biobased chemicals is a subject of high interest in contemporary academic and industrial research activities. While most strategies to convert furfural require energy-intensive reaction routes, the use of electrochemical activation allows to provide a sustainable and green alternative. Herein, a disparate approach for the conversion of furfural is reported based on a divergent paired electrochemical conversion, enabling the simultaneous production of 2(5H)-furanone via an anodic oxidation, and the generation of furfuryl alcohol and/or hydrofuroin via a cathodic reduction. Using water as solvent and NaBr as supporting electrolyte and electron-mediator, a green and sustainable process was developed, which maximizes productive use of electricity and minimizes byproduct formation.

A one-step electrochemically reduced graphene oxide based sensor for sensitive voltammetric determination of furfural in milk products

Designing of fast, inexpensive and sensitive furfural determination methods for dairy milk is crucial in analytical and food chemistry. In this study, an electrochemical sensor was developed for the cathodic determination of furfural using a one-step electrochemically reduced graphene oxide (ErGO) modified glassy carbon electrode (GCE). The morphology and chemical constituents of the obtained ErGO/GCE were characterized by scanning electron microscopy (SEM), transmission electron microscopy (TEM), X-ray diffraction (XRD), and Raman and X-ray photoelectron spectroscopy (XPS). The results showed that the fast and green electrochemical reduction process effectively eliminated the oxygen-containing groups in GO and produced reduced graphene with a high surface area and improved electron transfer kinetics. In addition, the ErGO based sensor displayed excellent responses for furfural in a Na₂HPO₄-NaH₂PO₄ solution (pH = 9.18) with a wide linear range from 2 to 2015 μM and a low detection limit of 0.4 μM (S/N = 3). The reduction mechanism of furfural was also discussed. Furthermore, the feasibility of the sensor was confirmed by the determination of furfural in three milk samples which generated acceptable outputs.

Kinetics of furfural electrochemical hydrogenation and hydrogenolysis in acidic media on copper

This article reports the competing kinetics and insights into the mechanisms of the electrochemical hydrogenation and hydrogenolysis of furfural to furfuryl alcohol and 2-methylfuran.

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.

Electro-organic synthesis - a 21st century technique

The severe limitations of fossil fuels and finite resources influence the scientific community to reconsider chemical synthesis and establish sustainable techniques. Several promising methods have emerged, and electro-organic conversion has attracted particular attention from international academia and industry as an environmentally benign and cost-effective technique. The easy application, precise control, and safe conversion of substrates with intermediates only accessible by this method reveal novel pathways in synthetic organic chemistry. The popularity of electricity as a reagent is accompanied by the feasible conversion of bio-based feedstocks to limit the carbon footprint. Several milestones have been achieved in electro-organic conversion at rapid frequency, which have opened up various perspectives for forthcoming processes.

Accelerating sulfonyl fluoride synthesis through electrochemical oxidative coupling of thiols and potassium fluoride in flow

Sulfonyl fluorides are valuable synthetic motifs which are currently of high interest due to the popularity of the sulfur (VI) fluoride exchange (SuFEx) click chemistry concept. Herein, we describe a flow chemistry approach to enable their synthesis through an electrochemical oxidative coupling of thiols and potassium fluoride. The reaction can be carried out at room temperature and atmospheric pressure and the yield of the targeted sulfonyl fluoride, by virtue of the short inter-electrode distance between a graphite anode and a stainless-steel cathode, reached up to 92% in only 5 min residence time compared to 6 to 36 h in batch. A diverse set of thiols (7 examples) was subsequently converted in flow. Finally, a fully telescoped process was developed which combines the electrochemical sulfonyl fluoride synthesis with a follow-up SuFEx reaction.

Stability of the ketyl radical as a descriptor in the electrochemical coupling of benzaldehyde

Electroreductive coupling is an emerging pathway for the renewable upgrading of biomass derived oxygenates. This work investigates electrochemical benzaldehyde reduction on Au, Cu, Pt and Pd using reactivity testing and in situ spectroscopy.

Electroorganic Synthesis under Flow Conditions

Despite the long history of electroorganic synthesis, it did not participate in the mainstream of chemical research for a long time. This is probably due to the lack of equipment and standardized protocols. However, nowadays organic electrochemistry is witnessing a renaissance, and a wide range of interesting electrochemical transformations and methodologies have been developed, not only for academic purposes but also for large scale industrial production. Depending on the source of electricity, electrochemical methods can be inherently green and environmentally benign and can be easily controlled to achieve high levels of selectivity. In addition, the generation and consumption of reactive or unstable intermediates and hazardous reagents can be achieved in a safe way. Limitations of traditional batch-type electrochemical methods such as the restricted electrode surface, the necessity of supporting electrolytes, and the difficulties in scaling up can be alleviated using electrochemical flow cells. Microreactors offer high surface-to-volume ratios and enable precise control over temperature, residence time, flow rate, and pressure. In addition, efficient mixing, enhanced mass and heat transfer, and handling of small volumes lead to simpler scaling-up protocols and minimize safety concerns. Electrolysis under flow conditions reduces the possibility of overoxidation as the reaction mixture is flown continuously out of the reactor in contrast to traditional batch-type electrolysis cells. In this Account, we highlight our contributions in the area of electroorganic synthesis under flow conditions over the past decade. We have designed and manufactured different generations of electrochemical flow cells. The first-generation reactor was effectively used in developing a simple one-step synthesis of diaryliodonium salts and used in proof-of-concept reactions such as the trifluoromethylation of electron-deficient alkenes via Kolbe electrolysis of trifluoroacetic acid in addition to the selective deprotection of the isonicotinyloxycarbonyl (iNoc) group from carbonates and thiocarbonates. The improved second-generation flow cell enabled the development of efficient synthesis of isoindolinones, benzothiazoles, and thiazolopyridines, achieving gram-scale for some of the products easily without changing the reactor design or reoptimizing the reaction parameters. In addition, the same reactor was used in the development of an efficient continuous flow electrochemical synthesis of hypervalent iodine reagents. The generated unstable hypervalent iodine reagents were easily used without isolation in various oxidative transformations in a coupled flow/flow manner and could be easily transformed into bench-stable reagents via quantitative ligand exchange with the appropriate acids. Our second-generation reactor was further improved and commercialized by Vapourtec Ltd. We have demonstrated the power of online analysis in accelerating optimizations and methodology development. Online mass spectrometry enabled fast screening of the charge needed for the cyclization of amides to isoindolinones. The power of online 2D-HPLC combined with a Design of Experiments approach empowered the rapid optimization of stereoselective electrochemical alkoxylations of amino acid derivatives.

Flow Rhodaelectro-Catalyzed Alkyne Annulations by Versatile C-H Activation: Mechanistic Support for Rhodium(III/IV)

A flow-metallaelectro-catalyzed C-H activation was realized in terms of robust rhodaelectro-catalyzed alkyne annulations. To this end, a modular electro-flow cell with a porous graphite felt anode was designed to ensure efficient turnover. Thereby, a variety of C-H/N-H functionalizations proved amenable for alkyne annulations with high levels of regioselectivity and functional group tolerance, viable in both an inter- or intramolecular manner. The electro-flow C-H activation allowed easy scale up, while in-operando kinetic analysis was accomplished by online flow-NMR spectroscopy. Mechanistic studies suggest an oxidatively induced reductive elimination pathway on rhodium(III) in an electrocatalytic regime.

The Fundamentals Behind the Use of Flow Reactors in Electrochemistry

In the past decade, research into continuous-flow chemistry has gained a lot of traction among researchers in both academia and industry. Especially, microreactors have received a plethora of attention due to the increased mass and heat transfer characteristics, the possibility to increase process safety, and the potential to implement automation protocols and process analytical technology. Taking advantage of these aspects, chemists and chemical engineers have capitalized on expanding the chemical space available to synthetic organic chemists using this technology. Electrochemistry has recently witnessed a renaissance in research interests as it provides chemists unique and tunable synthetic opportunities to carry out redox chemistry using electrons as traceless reagents, thus effectively avoiding the use of hazardous and toxic reductants and oxidants. The popularity of electrochemistry stems also from the potential to harvest sustainable electricity, derived from solar and wind energy. Hence, the electrification of the chemical industry offers an opportunity to locally produce commodity chemicals, effectively reducing inefficiencies with regard to transportation and storage of hazardous chemicals. The combination of flow technology and electrochemistry provides practitioners with great control over the reaction conditions, effectively improving the reproducibility of electrochemistry. However, carrying out electrochemical reactions in flow is more complicated than just pumping the chemicals through a narrow-gap electrolytic cell. Understanding the engineering principles behind the observations can help researchers to exploit the full potential of the technology. Thus, the prime objective of this Account is to provide readers with an overview of the underlying engineering aspects which are associated with continuous-flow electrochemistry. This includes a discussion of relevant mass and heat transport phenomena encountered in electrochemical flow reactors. Next, we discuss the possibility to integrate several reaction steps in a single streamlined process and the potential to carry out challenging multiphase electrochemical transformations in flow. Due to the high control over mass and heat transfer, electrochemical reactions can be carried out with great precision and reproducibility which provide opportunities to enhance and tune the reaction selectivity. Finally, we detail on the scale-up potential of flow electrochemistry and the importance of small interelectrode gaps on pilot and industrial-scale electrochemical processes. Each principle has been illustrated with a relevant organic synthetic example. In general, we have aimed to describe the underlying engineering principles in simple words and with a minimum of equations to attract and engage readers from both a synthetic organic chemistry and a chemical engineering background. Hence, we anticipate that this Account will serve as a useful guide through the fascinating world of flow electrochemistry.