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ARTICLE
This journal is © The Royal Society of Chemistry 2017 Green Chem., 2017, 00, 1-3 | 1
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.
2 | Green Chem., 2017, 00, 1-3 This journal is © The Royal Society of Chemistry 2017
This journal is © The Royal Society of Chemistry 2017 Green Chem., 2017, 00, 1-3 | 3
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
4 | Green Chem., 2017, 00, 1-3 This journal is © The Royal Society of Chemistry 2017
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
Table 1. Characterisation data of the HTlcs and the mixed metal oxides thereof derived.
This journal is © The Royal Society of Chemistry 2017 Green Chem., 2017, 00, 1-3 | 5
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
6 | Green Chem., 2017, 00, 1-3 This journal is © The Royal Society of Chemistry 2017
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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This journal is © The Royal Society of Chemistry 2017 Green Chem., 2017, 00, 1-3 | 7
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
8 | Green Chem., 2017, 00, 1-3 This journal is © The Royal Society of Chemistry 2017
This journal is © The Royal Society of Chemistry 2017 Green Chem., 2017, 00, 1-3 | 9
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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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.
10 | Green Chem., 2017, 00, 1-3 This journal is © The Royal Society of Chemistry 2017
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
This journal is © The Royal Society of Chemistry 2017 Green Chem., 2017, 00, 1-3 | 11
12 | Green Chem., 2017, 00, 1-3 This journal is © The Royal Society of Chemistry 2017
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
This journal is © The Royal Society of Chemistry 2017 Green Chem., 2017, 00, 1-3 | 13
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.
14 | Green Chem., 2017, 00, 1-3 This journal is © The Royal Society of Chemistry 2017