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Cutting-edge research for a greener sustainable future
Accepted Manuscript

This article can be cited before page numbers have been issued, to do this please use: G. M. Lari, G.
Pastore, C. Mondelli and J. Perez-Ramirez, Green Chem., 2017, DOI: 10.1039/C7GC02610B.

Volume 18 Number 7 7 April 2016 Pages 1821–2242 This is an Accepted Manuscript, which has been through the

Green Royal Society of Chemistry peer review process and has been
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Towards sustainable manufacture of epichlorohydrin from


Published on 16 October 2017. Downloaded by Freie Universitaet Berlin on 17/10/2017 07:22:08.

glycerol using hydrotalcite-derived basic oxides

Green Chemistry Accepted Manuscript


Received 00th January 20xx,
Accepted 00th January 20xx Giacomo M. Lari, Giorgio Pastore, Cecilia Mondelli* and Javier Pérez-Ramírez*
DOI: 10.1039/x0xx00000x Commercial two-step processes to convert glycerol into epichlorohydrin are more benign compared to the predominant
industrial route starting from propene in terms of materials requirements and CO2 emissions. Still, the use of alkali
www.rsc.org/
hydroxides in stoichiometric amounts in the second reaction, i.e., the dehydrochlorination of the dichloropropanol
intermediate, leads to the formation of large amounts of salt wastes, thus limiting the greenness of the technology. Here,
we show for the first time that the latter transformation can be selectively conducted in the gas phase in the presence of a
heterogeneous hydrotalcite-derived mixed oxide of Al and Mg. Upon reaction, the lamellar solid is rehydrated to a
hydrotalcite-like compound, which can effectively activate the alcoholic group of dichloropropanol owing to its strong
Brønsted basic character and moderately high surface area. In-depth characterisation of the porous, compositional,
structural and acid/base properties demonstrates that the HCl formed during the reaction causes the progressive
exchange of interlayer OH groups by Cl atoms, thus gradually diminishing the reactivity of the material. Facile calcination
restores the original mixed oxide structure and is shown to enable three equivalent consecutive reaction runs. Since the
HCl evolved along with water upon regeneration can be recycled in the first step of the process, i.e., glycerol
hydrochlorination, our approach paves the way for a waste-free and more atom efficient biobased epichlorohydrin
production process.

i.e. a facility where the triol is valorised into higher-value


[3]
Introduction chemicals. Many conversion paths have been proposed to
The upgrading of vegetable oils, which substantially comprises obtain compounds retaining the C3 backbone, such as lactic
their transesterification to produce biodiesel, has a low acid and lactates, diols, carbonates, ethers, esters and
[4]
profitability compared to the conventional refining of epichlorohydrin. The latter, which is conventionally
[5]
petroleum to fuels and base chemicals.[1] This is not merely produced starting from propene, has a world market of ca.
–1
due to the small difference between the price of the product 2 Mt y and a very broad application range. Before the
and the cost of the feedstock, but relates to the fact that biodiesel production introduced burgeoning amounts of cheap
glycerol, the main by-product of the transesterification glycerol in the market, this molecule was the key intermediate
[6]
process, is obtained in greater quantities than the cosmetic, in the most relevant industrial route to the triol. Nowadays,
food and pharmaceutical industries are able to absorb and epichlorohydrin is mainly used as a (co-)monomer in the
must, largely, be disposed of as a waste.[2] Thus, the economic preparation of epoxy resins and as an intermediate in the
and environmental footprint of a biodiesel plant would benefit manufacture of other polymers (e.g., polyesters), explosives
[7]
from the establishment of an associated glycerol biorefinery, and commodities.

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Scheme 1. Preparation of epichlorohydrin from glycerol by hydrochlorination to dichloropropanols followed by hydroxide-mediated epoxide formation and undesired thermally-
induced isomerisation of epichlorohydrin to chloroacetone.

[8]
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The processes proposed for the synthesis of this epoxide halides, which were transformed into metal halides during the
[19]
from glycerol are based on two reaction steps (Scheme 1) and reaction but could be regenerated by calcination at 823 K.

Green Chemistry Accepted Manuscript


some of them have been industrially applied up to a scale of In this work, mixed oxides of magnesium and aluminum
−1 [9]
100 kt y , as, for example, the Solvay’s Epicerol process. obtained by thermal activation of hydrotalcite-like compounds
Notably, this company highlighted the milder ecologic impact (HTlcs) are introduced as efficient solids for the gas-phase
of their technology compared to the fossil fuel-based route in conversion of dichloropropanols to epichlorohydrin. The
view of the inferior requirement for materials and CO2 superiority of these basic solids is identified by evaluation of
[8]
emissions. The first transformation comprises the acid and basic compounds with variable strength. The
chlorination of liquid glycerol with HCl gas, which is bubbled selectivity towards epichlorohydrin is maximised by tuning the
through the reactor, in the presence of a catalyst, typically an temperature as well as the concentration and strength of the
[10]
organic carboxylic acid. After reaction, the mixture mostly basic sites through variation of the Mg/Al ratio and the
contains various isomers of monochlorinated and activation conditions of the HTlc, which offers insights into
dichlorinated species. Upon separation, the first class of structure-mechanism-activity relations. Since the testing of the
molecules is recycled back to the hydrochlorination reactor best performer over prolonged reaction times evidences
along with unconverted glycerol, while the second is fed to a pronounced decrease in activity, the origins of this decay are
second reactor, typically a reactive-distillation unit, where an unraveled and a facile strategy to restore the original level is
inorganic base is added to deprotonate the residual hydroxyl demonstrated. Lastly, qualitative conclusions are drawn on the
group. This induces ring closure, which forms the epoxide and environmental and economic advantages of using a
is associated with the elimination of HCl. The catalyst applied heterogeneous rather than a homogeneous base in a glycerol-
in the first step can be recovered easily by distillation or to-epichlorohydrin process.
[9,10]
filtration, depending on its physical state. In contrast, the
conventional stoichiometric bases, like aqueous solutions of
[9]
NaOH, KOH or Ca(OH)2, used in the second reaction lead to
the formation of salt by-products. Furthermore, based on the
nature of the alkaline compound, the salt can be soluble in the
product feed, hence increasing the difficulty and the cost of its
[11]
separation as well as posing serious corrosion issues to the
[12]
units downstream of the reactor. Accordingly, to attain a
greener glycerol-based production of epichlorohydrin further
developments are required to meet to principles of waste
reduction, atom economy and use of regenerable chemicals.
Highly instrumental to this purpose would be the introduction
[13]
of a heterogeneous reactant.
Based on the mechanism and the nature of the homogeneous
[14]
alkaline compounds, solid bases such as alkali oxides,
[15] [16]
hydrotalcites or basic zeolites are expected to be most
suited for the reaction. Nevertheless, it cannot be excluded
that this transformation can proceed through different
pathways, in analogy to the dehydrochlorination-
oligomerisation of alkyl chlorides, which is mediated by acid
sites.[17] While a catalytic material is preferable, the
identification of a suitable system appears as a challenging
endeavor. Indeed, hydrochloric acid is generated, which,
obviously, interacts with basic sites in a strong manner,[18]
likely leading to activity loss by poisoning. Focusing on a solid
reactant, reusability would be a highly relevant parameter.
This property has been demonstrated for basic metal oxides
(CaO, MgO) applied to the dehydrohalogenation of alkyl

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X'Pert PRO-MPD diffractometer with Ni-filtered Cu Kα


radiation (λ = 0.1541 nm), acquiring data in the 10-60° 2θ
Experimental range with an angular step size of 0.05° and a counting time of
2 s per step. Al magic angle spinning nuclear magnetic
Materials 27
resonance ( Al MAS NMR) spectroscopy was conducted in a
γ-Al2O3 (Alfa Aesar, 99.997% metals basis), MgO (Strem Bruker Avance 700 spectrometer operated at 182.4 MHz using
Chemicals, 99.5%), a USY zeolite in protonic form with a bulk 4-mm ZrO2 rotors spun at 10 kHz. Spectra were acquired
Si/Al ratio of 405 (Zeolyst, USY) and a Y zeolite in sodium form accumulating 512 scans using a pulse length of 1 ms, a recycle
with a bulk Si/Al ratio of 2.6 (Zeolyst, CBV100) were used as delay of 1 s and solid (NH4)Al(SO4)2 as a reference
received.
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(δ = 0.00 ppm). Temperature-programmed desorption of


Two Mg- and Al-based HTlcs with a nominal Mg/Al ratio of carbon dioxide (CO2-TPD) and temperature programmed

Green Chemistry Accepted Manuscript


x = 2 and 4 (coded as HTx) were prepared by co-precipitation oxidation with O2 (TPO) were carried out using a Micromeritics
3
at pH 10. 500 cm of a x·0.25 M and 0.25 M aqueous solution Autochem II chemisorption analyser coupled with a MKS Cirrus
of Mg(NO3)3·6H2O (Riedel-de Haen, >99%) and Al(NO3)3·9H2O 2 quadrupole mass spectrometer. For the first measurements,
3 −1
(Sigma-Aldrich, >98%), respectively, were added dropwise to the samples (0.05 g) were treated in a He flow (20 cm min )
3 3
600 cm of 2 M aqueous Na2CO3 (Sigma-Aldrich, >99.5%) at a at 373 K for 2 h. Afterwards, CO2 (50 pulses, 1 cm each pulse)
3 −1 3 −1
rate of 3.5 cm min while magnetically stirring (500 rpm) at carried by He (10 cm min ) was adsorbed at 323 K, followed
ambient temperature. A 40 wt.% NaOH (Sigma-Aldrich, 97%) by He purging at the same temperature for 1 h. CO2 desorption
3 −1
solution was simultaneously added dropwise to keep the pH at was performed using a He flow of 10 cm min and monitored
−1
10. The obtained slurry was aged at 333 K for 6 h under in the 323-973 K range (10 K min ). The concentration of basic
3
stirring. After filtering and washing (3 times, 200 cm of sites (CB), expressed as mmol of CO2 per gram, was obtained
deionised water each time), the precipitate was dried at 333 K by multiplying the area of the desorption curve by a calibration
for 18 h. Mixed metal oxides were obtained by calcination of factor obtained from the decomposition of known amounts of
−1
the HTlcs at 673-973 K (ramp rate = 5 K min ) for 5 h. These Na2CO3 (Sigma-Aldrich, >99.5%) and dividing it by the mass of
samples were labelled as HTx-cy, where y is the calcination the sample. Upon TPO, the samples (0.05 g) were treated in a
3 −1
temperature expressed in K. He flow (20 cm min ) at 373 K for 2 h. Thereafter, the
An alkaline-activated USY zeolite with basic character (USY-AT) temperature was lowered to 323 K and the flow composition
3 −1
was synthesised by adding 3.3 g of a high-silica USY zeolite and rate modified to 10 vol.% O2 in He and 10 cm min ,
3 −1
(Si/Al = 405, Zeolyst) to 100 cm of a 0.1 M methanolic (Sigma- respectively. The sample was heated up to 973 K (10 K min )
Aldrich, 99.8%) solution of NaOH. After stirring for 10 min at while monitoring the gases evolved. The chlorine and the
room temperature, the solid was filtered and washed with carbon contents of the used solids were determined by
3 [20]
methanol (3 times, 100 cm each time). elemental analysis using a LECO CHN-9000 instrument.
An alkali-activated Y zeolite (Y-AT) was prepared in two steps. Transmission electron micrographs (TEM) were acquired using
Firstly, a zeolite Y (Zeolyst, CBV100) was dealuminated at 373 K a FEI Talos F200A instrument operated at 200 kV.
3
in a 0.15 M solution of H4EDTA (Fluka, >99%, 15 cm per gram
of zeolite) for 24 h, recovered by filtration, washed with Testing
3
deionised water (3 times, 30 cm per gram of zeolite) and dried The gas-phase dehydrochlorination (Aldrich-Fine Chemicals,
at 338 K for 16 h. Thereafter, the solid obtained was treated in 98%) was studied at ambient pressure using a continuous-flow
3
0.05-0.2 M aqueous NaOH (30 cm per gram of zeolite) at fixed-bed reactor setup (Microactivity Reference, PID
338 K for 30 min, using an Easymax 102 setup (Mettler Eng&Tech) comprising: (i) a syringe pump for the admission of
Toledo). After quenching in an ice bath and filtering, the the 10 wt.% aqueous solution of the reactant, (ii) a mass flow
3
zeolite was washed with deionised water (3 times, 30 cm per controller for feeding N2 (PanGas, 99.99%), (iii) a tubular
[21]
gram of zeolite) and dried at 338 K for 16 h. quartz reactor (12 mm internal diameter) equipped with a frit
3
MgO/USY was prepared by dry impregnation. 4 cm of a to support the heterogeneous bed and a thermocouple to
0.25 M aqueous solution of Mg(NO3)2·6H2O (Fluka, 99%) were monitor its temperature and heated in an oven and (iv) a
added dropwise to 4 g of the USY zeolite at room temperature. condenser kept at 273 K. 0.1-0.5 g of material (0.2-0.5 mm
The sample was dried at 338 K overnight and calcined at 823 K particle size, 3-12 mm bed thickness) were loaded into the
−1 [18]
(5 K min ) for 5 h. reactor and the system was heated to the desired temperature
3 −1
(403-673 K) under a N2 flow of 100 cm min . Thereafter, an
Characterisation
aqueous dichloropropanol solution (5-10 wt.%) was admitted
The elemental composition of the materials was determined for 0.5-3 h. In order to verify the theoretical possibility to
by X-ray fluorescence spectroscopy (XRF) using an Orbis Micro vaporise dichloropropanol under the reaction conditions, the
XRF instrument equipped with a Rh source operated at 35 kV physical state of the dichloropropanol-water mixture was
and 500 mA. N2 sorption at 77 K was conducted using a calculated for solute concentrations ranging from 0 to 100
Micromeritics TriStar analyser. Prior to the measurements, the wt.% and between 273-473 K based on the UNIFAC model and
solids were degassed at 573 K under vacuum for 3 h. Powder using the RGibbs function in Aspen Plus V8.6.
X-ray diffraction (XRD) was performed using a PANalytical

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Fig. 1. Dichloropropanol conversion and epichlorohydrin selectivity in the presence of different materials. T = 473 K, P = 1 bar, t = 0.5 h and WHSV = 6 h−1.

Liquid samples were collected from the condenser every calcined at 823 K, HT2-c823). These materials have a strong
15 min, which were analysed using an HP 6890 gas Lewis-, strong Brønsted-, weak Brønsted- and strong Lewis-
chromatograph equipped with an HP-5 capillary column and a basic character, respectively. γ-Al2O3 and a zeolite Y in its
flame ionisation detector. Quantification was achieved based sodium form with a bulk nominal Si/Al ratio of 2.6 were chosen
on the absolute peak areas. Calibration curves were measured as representative strong and weak Lewis acids, in this order.
in the 0.5-10, 0.5-7 and 0.5-3 wt.% ranges for 1,3-dichloro-2- Strong Brønsted acidity was featured in an ultra-stable Y
propanol, epichlorohydrin and chloroacetone, respectively. zeolite in protonic form with a bulk nominal Si/Al ratio of 405
The calibration response factor of unknown compounds was (H-USY). Finally, to assess the relevance of the co-presence of
assumed to be the same as that of epichlorohydrin. acidity and basicity, 1.1 wt.% of MgO was supported on the H-
The conversion of the substrate was calculated as the number USY zeolite (MgO/USY) and the zeolite Y was modified by an
of moles of substrate reacted divided by number of moles of alkaline treatment in 0.15 M NaOH (Y-AT). The porous and
substrate fed and the selectivity towards the product i as the acid/base properties of these solids are in line with those
number of moles of product formed divided by the total reported in the literature for analogous materials (Table 1 and
number of moles of products, according to the following Table S1 in the ESI).[15,18,20,21] All of the systems were tested in
equations, where the subscripts 0/1 refer to the reactor a continuous-flow fixed-bed reactor kept at 473 K by feeding
inlet/outlet mixture: an aqueous dichloropropanol solution (5 wt.%) along with an
Xdichloropropanol = (ndichloropropanol,0 - ndichloropropanol,1) / ndichloropropanol,0 inert carrier for 0.5 h (Fig. 1 and Table S2). Solids possessing
Si = ni,1 / (ndichloropropanol,0 - ndichloropropanol,1) Brønsted and Lewis acidity generally displayed very low
The carbon balance was calculated as the ratio between the activity (<1% dichloropropanol conversion) and selectivity
number of moles of products and the number of moles of towards epichlorohydrin (<15%). This behaviour was
glycerol fed and was always higher than 90%. The rationalised by the capability of acid sites to catalyse
experimental error, determined by three repetitions of dehydration and oligomerisation reactions, leading to
selected runs, was within 5%, which allowed excluding the fouling,[22] which was evidenced by the black colour assumed
occurrence of bypass phenomena in the experiments applying by the white powders upon the test and confirmed by CHN
the thinner beds analysis (up to 8 wt.% C, Table S1). In addition to the
generation of carbonaceous species, chloroacetone was
formed as a by-product with a selectivity up to 25%. The poor
Results and discussion performance of solid acids improved through the
incorporation of basic sites. In fact, the dichloropropanol
Evaluation of solid acids and bases
conversion increased from 0.5 and 1.0% to 2.2 and 3.8% over
Since the identification of a suitable solid for the Y-AT and MgO/USY, respectively, and the epichlorohydrin
dehydrochlorination of dichloropropanol to epichlorohydrin is selectivity raised to ca. 50% over both solids. However, coke
here tackled for the first time, a diverse set of materials was was still produced in a significant amount in these two cases
selected for assessement. In analogy with the stoichiometric (4-5 wt.% C), due to the marked acidity retained by the zeolites
homogeneous reactants commonly used in the established upon their modification. Superior epichlorohydrin yields were
liquid-phase processes, part of the compounds comprised solid attained over purely basic solids, except for USY-AT. Indeed,
bases of different nature and strength. Specifically, they MgO, the HTlc and the mixed Mg-Al oxide displayed a
included earth-alkali oxides (MgO), alkali-activated zeolites conversion of 5, 6 and 8% and an epichlorohydrin selectivity of
[20]
(USY-AT) and HTlc in as-synthesised form, i.e., layered ca. 30, 70 and 80%, respectively. Notably, coke formation was
double hydroxides with formula limited over these materials (<3 wt.% C).
2+ 3+ m+ 2+
[Mg nAl m(OH)2(n+m)] [CO3 ]m/2·H2O (here with n = 4 and m =
2, HT2), or in calcined state, i.e., Mg-Al mixed oxides (here Design of Mg-Al mixed oxides

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Based on its remarkable performance, the Mg-Al oxide was in agreement with previous literature (Table 1). The XRD
selected for further development. Since such compound was patterns of the solids show the typical reflections of a
obtained from a hydrotalcite-like precursor, it was conceived rhombohedral (3R) layered double hydroxide structure
to vary its properties by altering the composition of the (Fig. 2a), which are shifted to lower 2θ values due to the
starting double layered hydroxide. Thus, an additional sample expansion of the unit cell size caused by the higher Mg
[24]
was prepared with a Mg/Al ratios of 4 (HT4). A ratio lower than content. TEM confirmed the platelet-like structure of the
2 was excluded, since for this value it is not feasible to attain a crystals (Fig. 3a), which exhibit extensive intergrowth and are
27
solid with pure hydrotalcite structure, while a ratio higher than oriented in a random fashion. All of the Al MAS NMR spectra
4 was irrelevant, since it leads to materials with limited ion- display a signal centred at 10 ppm, indicating the octahedral
[23] [15a]
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exchange properties. The actual metal ratio in the as- (Oh) symmetry of the Al centres (Fig. 2b). The basicity of
synthesised samples was close to the nominal value and, in all the HTlcs was probed by CO2-TPD (Fig. 2c). For all samples, the

Green Chemistry Accepted Manuscript


2 −1
cases, the surface area was comprised between 70-80 m g ,

Table 1. Characterisation data of the HTlcs and the mixed metal oxides thereof derived.

Sample Molar Mg/Ala Crystalline Vporec SBETd CBe Tdesf Tdecf Cg


- phase(s)b cm3 g−1 m2 g−1 µmol g−1 K K wt.%
HT2 1.97 HT 0.47 81 85 404 623 0.9
HT4 3.52 HT 0.42 65 89 395 595 0.4
HT2-c823 1.82 MMO 0.58 197 600 532 - 1.0
HT4-c673 3.31 HT+MMO 0.45 148 412 473 650 0.3
HT4-c823 3.50 MMO 0.60 223 482 573 - 1.0
HT4-c973 3.52 MMO 0.58 203 355 536 - 1.1
a
XRF. b XRD. HT = hydrotalcite, MMO = mixed metal oxide. c Volume of N2 adsorbed at p/p0 = 0.98. d Total surface area, BET method. e Concentration of basic sites,
CO2-TPD. f Temperature corresponding to the maximum of the desorption (des) and decomposition (dec) peaks in the CO2-TPD profiles. g Carbon content of the used
materials, elemental analysis.

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Fig. 2. (a,d) XRD, (b,e) 27Al MAS NMR and (c,f) CO2-TPD profiles of the (a,b,c) as-synthesised HTx and (d,e,f) calcined HTx-cy materials. JCPDS 22-700 and 87-0653 comprise the
reference diffractograms used for the assignment of the HTlc and the mixed metal oxide phases, respectively.

curves evidence a low-intensity peak with maximum at third of the Al atoms changed their environment upon
−1
ca. 400 K, indicating the presence of few (<80 mmol g ) weak calcination attaining a tetrahedral geometry (Td) (Fig. 2e),
basic sites, which is accompanied by a second, very which is generally quite distorted considering the broad shape
pronounced signal peaking between 600-700 K, which was of the resonance at 80 ppm, and that, based on the
produced by the decomposition of interlayer carbonates. The appearance of a peak at 18 ppm, about half of the remaining
area of this second contribution is larger for HT2 than for HT4, octahedral sites became highly distorted (C3v). The density of
in line with the greater Al substitution and, thus, capacity of basic centres of the calcined samples underwent a ca. 8-fold
accommodating interlayer anions. After calcination at 823 K, increase (Fig. 2f and Table 1) and was maximal for HT2-c823.
the two samples possessed the same Mg/Al ratios as the Still, although preserving sites of mild and moderate strength,
corresponding starting HTlcs (Table 1) and ca. 2.5-3.5 times HT4-c823 possessed the strongest centres (Tdes > 773 K).
2 −1
higher surface area (150-220 m g ). Their diffractograms To modify the characteristics of the mixed oxide, we also
almost exclusively comprise two relatively broad reflections at considered the thermal treatment of the starting HTlcs, tuning
43 and 62° 2θ (Fig. 2d), which indicate the transformation of its temperature. Thus, HT4 was additionally calcined at 673
the double layered hydroxide into a mixed oxide retaining the and 973 K. The use of milder conditions led to an only partial
[15]
layered structure (Scheme 2). Platelet-like crystals were decomposition of the hydrotalcite to the mixed oxide, as
visualised by TEM (Fig. 3b), which also highlighted an increased demonstrated by the surface area, which was intermediate
disorder, i.e., an augmentation of intercrystalline between that of the precursor and that of the mixed oxide
mesoporosity. The latter is in line with the higher surface area obtained upon calcination at 823 K, by the detection of
27
(Table 1). Al MAS NMR spectroscopy revealed that about one unconverted precursor by XRD (Fig. 2d) and by the coexistence

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of octahedral and distorted octa- and tetrahedral species diffractogram, which featured sharper peaks than those for
27
according to Al MAS NMR spectroscopy. After calcination at the other two samples, suggesting a moderate increase of the
973 K, only a mixed oxide phase was evidenced in the crystallite size due to sintering at high temperatures.
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Scheme 2. Generation of the Mg-Al mixed oxide by calcination of a HTlc, its modification upon use in the dichloropropanol-to-epichlorohydrin reaction and its subsequent
regeneration by calcination.

The two new sets of samples were tested in the vapour at this temperature and at 403 K, which is the mildest
dehydrochlorination of dichloropropanol under the same condition applied in the testing in this study. For the
conditions applied in the initial evaluation of materials except concentration employed, the plot (Fig. S1 in the ESI) suggests
for the temperature, which was decreased to 423 K with the that this is fulfilled, since both mixture components are in the
purpose of boosting the selectivity towards epichlorohydrin. gas phase above 373 K. With respect to the HTlcs, HT4 showed
Since the boiling point of dichloropropanol is 450 K, a phase
diagram for the dichloropropanol-water mixture was
calculated to verify that the reactant would be present as a

Fig. 4. (a) Yield of epichlorohydrin, chloroacetone and other by-products upon


conversion of dichloropropanol in the presence of HTx and HTx-cy materials. (b)
Fig. 3. TEM images of the HT4 precursor and of the calcined HT4-c823 material in its Epichlorohydrin yield as a function of their specific surface area. T = 423 K, P = 1 bar, t =
fresh, used and regenerated forms. 0.5 h and WHSV = 6 h−1.

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Experiments conducted heating the latter at 673 K confirmed


the formation of the ketonic product with a yield of 78%.
Minor quantities of coke were found on all the solids after
reaction (Table 1). Since no dependence of these amounts on
acid/base or textural properties was observed, thermal
mechanisms might be held responsible for its formation.
Comparison of the dichloropropanol conversion over the
various mixed oxides with the type of their basic sites did not
unveil any correlation, while their surface area appeared as a
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better descriptor for activity (Fig. 4b), hinting at the active-site


accessibility, rather than its nature, as the most relevant

Green Chemistry Accepted Manuscript


parameter.

Optimisation of the reaction conditions


In view of the superior epichlorohydrin yield obtained in the
presence of HT4-c823, the influence of the reaction
parameters on the performance was investigated using this
sample. In the 403-673 K range, the dichloropropanol
conversion increased monotonously with the temperature
(Fig. 5a). The only exception was observed at 403 K, since an
unexpectedly high conversion was observed. This was
explained by the occurrence of capillary condensation in the
micropores (vide infra) of the material and to the consequently
altered diffusion and reaction kinetics. In contrast, the
Fig. 5. Dichloropropanol conversion and selectivity towards epichlorohydrin and selectivity towards the desired product, epichlorohydrin, was
chloroacetone in the presence of HT4-c823 as a function of (a) temperature and (b) comprised between 80 and 100% below 423 K and rapidly
weight hourly space velocity. T = 423 K, P = 1 bar, t = 0.5 h and WHSV = 6 h−1. decreased between 423-573 K, approaching 0% at the highest
temperature. In line with these results, the reactant was
an only slightly lower conversion and epichlorohydrin thermally decomposed in blank tests in an amount that
selectivity than the newly evaluated HT2 (5 versus 6% and 70 corresponds to only 2 and up to 20% in the 403-423 K and 423-
versus 75%, respectively, Fig. 4a and Table S2). A noticeable 673 K ranges, respectively (Fig. S2). The selectivity trend for
boost in activity and selectivity was observed over all calcined chloroacetone was exactly opposite to that of epichlorohydrin,
solids, which were maximised over HT4-c823 (20% i.e., the formation of the ketonic compound was negligible at
dichloropropanol conversion, 90% epichlorohydrin selectivity). low temperatures and almost exclusive at high temperatures.
It should be noted that these two parameters are linked, i.e., a These results indicate that a temperature of 423 K, as applied
higher selectivity is achieved at a higher conversion level. This in the evaluation of Mg-Al-based solids, was optimal to
was explained by the fact that the concentration of maximise the selectivity towards the desired product.
chloroacetone, the main by-product, was equal in all tests, An increase of the space velocity through the application of a
suggesting that its rate of formation is not influenced by the lower mass of solid base led to a pronounced decrease in the
nature of the solid and is likely generated through a thermally- conversion and a slight drop of the selectivity towards
driven pathway. By analogy with the decomposition of other epichlorohydrin (Fig. 5b). The latter observation is in
epoxides,[25] it was hypothesised that this by-product arises agreement
from the thermal isomerisation of epichlorohydrin.

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Table 2. Characterisation data of used and regenerated HT4-c823 samples upon three consecutive reaction cycles.

HT4-c823 sample Molar Mg/Ala Crystalline Vporec SBETd CBe Tdesf Clg Cg
- phase(s)b cm3 g−1 m2 g−1 µmol g−1 K wt.% wt.%
Fresh 3.50 MMO 0.60 223 482 573 - -
Used #1* 3.25 HT+MMO 0.47 125 6 - 10.7 0.9
Calcined #1 3.41 MMO 0.51 205 425 540 0.9 0.0
Used #2* 3.38 HT+MMO 0.42 110 8 - 10.0 1.1
Calcined #2 3.45 MMO 0.52 199 409 545 1.1 0.0
Used #3* 3.32 HT+MMO 0.44 112 5 - 11.3 0.9
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Calcined #3 3.38 MMO 0.50 195 397 500 0.8 0.0


Used+ 1.81 HT+MMO+others 0.41 89 2 - 12.1 0.6

Green Chemistry Accepted Manuscript


Calcined 1.75 MMO+others 0.47 145 227 473 6.2 0.0
a
XRF. b XRD. HT = hydrotalcite, MMO = mixed metal oxide. c Volume of N2 adsorbed at p/p0 = 0.98. d Total surface area, BET method e Concentration of basic sites, CO2-
TPD. f Temperature corresponding to the maximum of the desorption (des) and decomposition (dec) peaks in the CO2-TPD profiles. g Carbon content of the used
materials, elemental analysis. * T = 423 K, P = 1 bar and WHSV = 6 h−1. + T = 398 K, P = 1 bar and WHSV = 6 h−1.

with the fact that, since the residence time in the heated In order to gain insights into the fate of the solid in the
section of the reactor was unaltered, the thermally-driven reaction, the used HT4-c823 was characterised thoroughly.
generation of by-products was not affected. Elemental analysis indicated a high chlorine content (10.7
The best performing material, HT4-c823, was tested over a wt.%, Table 2), which was comparable to the amount
prolonged reaction time under the best conditions (423 K and effectively released upon formation of the epichlorohydrin and
1.2 h−1). The initially high (ca. 60%) dichloropropanol chloroacetone products, which confirms the exclusive
conversion was found to rapidly decrease to 15% during the participation of the mixed oxide as a solid reactant in the
first hour (Fig. 6a). Similarly, the high epichlorohydrin conversion of dichloropropanol. From a structural viewpoint, a
selectivity observed portion of the material re-assumed the hydrotalcite structure
in the first stage of the test diminished, in line with the fact that characterised the precursor (Fig. 7a). It is well known that
that chloroacetone and coke were generated at a constant upon contacting layered double hydroxide-derived oxides with
yield. liquid water or with its vapour at 303-423 K the material
converts back into a HTlc featuring hydroxide instead of
Characterisation of the used solid carbonate anions.[26] Due to the smaller size of OH−, the

Fig. 6. Dichloropropanol conversion and selectivity towards epichlorohydrin in three consecutive reaction cycles with intermediate regeneration of HT4-c823at (a) T = 423 K,
P = 1 bar and WHSV = 1.2 h−1 and (b) T = 403 K, P = 1 bar and WHSV = 6 h−1.

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interlayer spacing is lower than for the original material and determined for HT4 and HT4-c823 in fresh forms (Tables 1 and
the reflections in the XRD pattern appear at slightly higher 2θ. 2). TEM analysis evidenced that the layered organisation of the
The presence of water in the reaction, the comparable solid was retained, although the morphology of the platelets
conditions and the shift in peak position (ca. 1.0 2θ) in the became less defined (Fig. 3c). In agreement with the
diffractogram are consistent with the hydration of the mixed conversion of part of the aluminium sites from a tetrahedral or
oxide. Still, in view of the fact that HT2-c823 acquires chlorine distorted octahedral into an octahedral geometry, the signal at
27
upon use, no metal chlorides are formed and the chlorine 18 ppm in the Al MAS NMR spectrum exhibited a
− −
anion has a comparable size to OH , Cl species shall occupy comparatively higher intensity (Fig. 7b). The CO2-TPD profile
interlayer positions. Actually, it is supposed that the mixed indicated a small amount of residual basic sites (Fig. 7c). This

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oxide is firstly converted into a rehydrated hydrotalcite, in corroborates the predominance of neutral Cl anion over basic
− −
which the OH species serve as basic sites for the reaction with OH species in the interlayer spaces (Scheme 2) and hints that

Green Chemistry Accepted Manuscript



dichloropropanol and are progressively substituted by Cl ions the residual mixed oxide phase is located in the interior of the
(Scheme 2). In analogy to these considerations, it is speculated particles. The difficulty of the reactant to reach the core of the
that carbonate species might have been at least partly material explains the gradual loss in activity. Indeed, at the
replaced by hydroxide species in HT2 and HT4 upon use and beginning of the reaction, dichloropropanol can easily access
that their inferior conversion level compared to mixed oxides the basic sites present at the external surface, while, at later
is likely due to the milder basicity of residual carbonates and stages, it has to diffuse into the pores to find unreacted sites. If
their lower surface area (Fig. 4 and Table 1). In line with the the reactant freely diffused in the solid, the conversion level
structural changes, the surface area of HT4-c823 after reaction would stay at 100% and the reaction would last 1.15 h over
diminished to an intermediate value between those HT2-c823 under the conditions applied.

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Green Chemistry Accepted Manuscript


27 27
Fig. 7. (a) XRD, (b) Al MAS NMR and (c) CO2-TPD profiles of the HT4-c823 material used at 423 K. (d) XRD, (e) Al MAS NMR and (f) CO2-TPD profiles of the HT4-c823 material
used at 403 K. JCPDS 22-700, 87-0653 and 01-1133 comprise the reference diffractograms used for the assignment of the HTlc, the mixed metal oxide and AlCl3 phases,
respectively.

(Fig. 7a). Accordingly, the surface area increased back to an only


Regeneration studies slightly lower value than for the fresh HT4-c823 sample (Table 2)
27
In order to recover the original mixed oxide structure, the used and Al MAS NMR indicated that the proportion between
sample was subjected to calcination at 823 K, which was aluminium sites with tetrahedral and octahedral geometry was
effective in reducing the chlorine content to only less than similar to that of the original material (Fig. 7b). Moreover, CO2-TPD
[19]
1 wt.%. Based on the chemical behaviour of metal chlorides, evidenced that the solid regained basicity (Fig. 7c). Notably, the
it is put forward that the elimination of chlorine from the HTlc concentration of basic sites of the regenerated oxide is almost
generated in the reaction could follow two main mechanisms equal to that of the starting material when relating the values to
involving molecular oxygen provided in the treatment or water their surface areas (Table 2). In addition, the mass and Mg/Al ratio
released by the solid upon heating: of the calcined sample were equivalent to the data measured for
[Mg8Al2(OH)20]Cl2.nH2O + 0.5O2 → Mg8Al2O11 + Cl2+(n+10)H2O the fresh solid, considering the amount of chlorine that remained in
[Mg8Al2(OH)20]Cl2.nH2O → Mg8Al2O11 + 2HCl + (n+9)H2O the material, indicating that metals leaching was negligible.
In the first case, the chloride ion is oxidised to elemental Testing of the calcined sample produced analogous results to those
chlorine, while along the second path HCl is produced through obtained in the first run (Fig. 6a), except for the slightly inferior
an acid-base reaction. Since only HCl was detected by MS initial activity, which is in line with the moderately lower surface
analysis upon TPO of the used material (Fig. S3), the second area and basicity and the small amount of residual chorine
route was predominant. XRD confirmed the disappearance of the contained. Remarkably, calcination of the re-used material was
hydrotalcite-like phase and the restoration of the mixed oxide equally effective in regenerating the mixed oxide as the treatment

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of HT4-c823 (Fig. S4). The presence of water greatly facilitates ion


migration within the solid, which helped the formation of more
[27]
thermodynamically-stable phases, i.e. aluminium chloride.
Calcination of this material converted the hydrotalcite phase into
the mixed oxide, but the latter produced very sharp reflections,
which is indicative of a severe increase of the particle size. XRD also
evidenced that AlCl3 remained in the material, in line with its
[27]
decomposition temperature in excess of 900 K. These findings
are in agreement with the only partial restoration of the surface
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area and the still high Cl content in the sample (Table 2). The
basicity of the calcined solid was strongly inferior to that of the

Green Chemistry Accepted Manuscript


fresh mixed oxide in view of the enrichment in Mg of the system. In
line with the characterisation data, the initial activity of the calcined
Scheme 3. Simplified flow sheet for (a) the conventional glycerol-to-epichlorohydrin
process and (b) the process herein introduced based on HTlc-derived oxides for the
solid was remarkably lower than that of the freshly prepared mixed
second reaction, showing the reaction-regeneration units as well as the chlorine oxide. A subsequent regeneration-reaction cycle showed a further
recycling loop. deterioration of the performance. Accordingly, operation of the
mixed oxide in the gas phase is a prerequisite to attain stable
conducted after the first reaction (Table 2) and, accordingly, the reaction-regeneration cycles. For this purpose, the well-known
reaction data collected in the third test were comparable to those memory effect of layered double hydroxides is another crucial
of the second run (Fig. 6a). factor, since it enables the interconversion between hydrotalcite
Finally, since the epichlorohydrin selectivity was 15% higher at and mixed oxide forms with minimal modification of their basic and
403 K, HT4-c823 was assessed also at this 20-K lower temperature. textural properties.[15] From a practical viewpoint, a continuous
Under these conditions, the dichloropropanol conversion production of epichlorohydrin can be realised operating two
progressively decreased reaching a similar level to that attained at reactors simultaneously, one dedicated to the desired
the end of the run at 423 K (Fig. 6b). In contrast, the selectivity transformation and one to the regeneration of the solid base.
towards epichlorohydrin remained almost unperturbed at ca. 95%. Overall, the use of a solid base in the gas phase in place of
This is rationalised by the minor occurrence of the thermal homogeneous alkaline solutions allows the compliance of the
decomposition of the product to chloroacetone at 403 K. Analysis of glycerol-to-epichlorohydrin process with three main green
the used material uncovered substantial differences with respect to chemistry principles. Firstly, the generation of a salt byproduct is
the sample retrieved after the reaction at 423 K. In this case, the avoided, simplifying downstream purification and reducing waste
mixed oxide phase was fully converted into a hydrotalcite-like treatment efforts. Secondly, the solid reactant is regenerable,
− reducing the material needs. Thirdly, the HCl evolved upon its
phase as well as AlCl3 (Fig. 7d). Thus, Cl ions formed upon reaction
− regeneration could be easily recycled in the dehalogenation of
not only exchanged OH species at interlayer positions but also
27 glycerol to dichloropropanols (Scheme 3), maximising the atom
generated a metal salt. Al MAS NMR spectroscopy only detected
hexacoordinated Al sites (Fig. 7e), in line with the octahedral economy and the cost-related performance of the overall glycerol-
geometry of this metal in the hydrotalcite and in AlCl3, and CO2-TPD to-epichlorohydrin route. Additionally, it is worth noting that the
indicated a full depletion on the basicity (Fig. 7f), as expected from solid base shares an equivalent non-toxic nature to the
the neutral nature of OH-free hydrotalcite and the metal chloride. homogeneous counterpart.
The distinct alterations underwent by the sample at 403 K are likely
due to the pronounced condensation observed on the solid
reactant at this temperature, suggesting that the transformation Conclusions
took place in a liquid phase. Although the equilibrium diagram In this study, a solid and recyclable base is introduced as
indicates that a pure vapour phase should be present, capillary alternative to alkali hydroxides for the dehydrochlorination of
condensation might have been induced by the surface rugosity glycerol-derived dichloropropanol to epichlorohydrin. Upon
and/or the liquid mixture might not have fully vaporised due to testing of compounds with variable acid/base properties,
insufficient heat transfer rates during the short residence time in Lewis-basic mixed oxides obtained from hydrotalcite-like
the heated zone of the reactor. The first hypothesis is supported by materials emerged as the best-performing solids. Their
the application of the Kelvin equation. selectivity pattern was found to be strongly influenced by
௉ ିଶఊ௏೘ ௖௢௦ሺఏሻ temperature, since total selectivity towards epichlorohydrin
݈݊ ቀ௉ ቁ ൌ ௥ோ்
బ was achieved below 423 K, while the product thermally
When using the values typical of pure water in view of the diluted decomposed to chloroacetone under harsher conditions.
nature of the system (i.e., a surface tension γ of 6·10−2 N m−1, a Optimisation of the space velocity enabled epichlorohydrin
molar volume Vm of 1.8·10−5 m3 mol−1, a contact angle θ of yields as high as 60%. Thorough characterisation enabled the
0 degrees and a condensation pressure P0 of 2.2 bar), a liquid phase elucidation of the reaction mechanism. The latter involves the
is expected to form in pores with a diameter r smaller than ca. initial formation of the actual active phase from the lamellar
6 nm, which are responsible for a significant fraction of the porosity mixed oxide, a rehydrated hydrotalcite, and the subsequent
progressive replacement of the hydroxide ions at the

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interlayer positions by chlorine ions. Simple calcination Franchini, M. Laura Dieuzeide, A. M. Duarte de Farias, N.
appeared effective in restoring a mixed oxide phase with Amadeo, M. A. Fraga, Chem. Eng. J., 2015, 272, 108-118.
16 D. Verboekend, T.C. Keller, S. Mitchell, J. Pérez-Ramírez, Adv.
equivalent porous, structural and basic properties and, thus, Funct. Mater. 2013, 23, 1923-1934.
reactivity to the starting solid after a first and second reuse. 17 M. Ibáñez, M. Gamero, J. Ruiz-Martínez, B. M. Weckhuysen,
Since this treatment releases HCl, a closed chlorine loop within A. T. Aguayo, J. Bilbao and P. Castaño, Catal. Sci. Technol.,
the whole glycerol-to-epichlorohydrin process was envisaged 2016, 6, 296-306.
when reutilising hydrochloric acid for the dehalogenation of 18 B. Puértolas, T. C. Keller, S. Mitchell and J. Pérez-Ramírez,
Appl. Catal., B, 2016, 184, 77-86.
the triol (Scheme 3). Based on the absence of salt by-products 19 G. Huang, G. Lu, J. Wang and J. Yu, J. Anal. Appl. Pyrolysis,
and the enhancement of the atom economy through HCl 2011, 91, 159-164; (b) N. C. Christensen, US Pat. 2413292,
Published on 16 October 2017. Downloaded by Freie Universitaet Berlin on 17/10/2017 07:22:08.

recycling, the new approach shown in this work holds potential 1946.
toward a greener preparation of epichlorohydrin from 20 G.M. Lari, K. Desai, C. Mondelli and J. Pérez-Ramírez, Catal.

Green Chemistry Accepted Manuscript


renewable resources. Sci. Technol., 2016, 6, 2706-2714.
21 G.M. Lari, B. Puértolas, M.S. Frei, C. Mondelli and J. Pérez-
Ramírez, ChemCatChem, 2016, 8, 1507-1514.
22 A. Aho, N. Kumar, K. Eränen, T. Salmi, M. Hupa and D. Y.
Acknowledgements Murzin, Process Saf. Environ. Prot., 2007, 85, 473-480.
This work was supported by the Swiss National Science 23 F. Cavani, F. Trifirò and A.Vaccari, Catal. Today, 1991, 11,
273-301.
Foundation (Project Number 200020-159760). Dr. S. Mitchell is 24 D. G. Cantrell, L. J. Gillie, A. F. Lee and K. Wilson, Appl. Catal.,
thanked for the TEM analyses and the microscopy centre of A, 2005, 287, 183–190.
ETH Zurich (ScopeM) is acknowledged for providing access to 25 R. R. Baldwin, A. Keen, R. W. Walker, J. Chem. Soc., Faraday
its faciliƟes. Trans. 1, 1984, 80, 435-456.
26 J. Pérez-Ramírez, S. Abelló, N. M. van der Pers, Chem. Eur. J.,
2007, 13, 870-878.
27 L. Catoire and M. T. Swihart, J. Electrochem. Soc., 2002, 149,
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Table of Contents Entry


Towards sustainable manufacture of epichlorohydrin from glycerol
using hydrotalcite-derived basic oxides
Giacomo M. Lari, Giorgio Pastore, Cecilia Mondelli and Javier Pérez-Ramírez
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Green Chemistry Accepted Manuscript


Regenerable hydrotalcite-derived Mg-Al oxide is an effective heterogeneous base to avoid waste
formation and enable halogen recycling in the glycerol-to-epichlorohydrin process.

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