U.S. patent application number 16/229341 was filed with the patent office on 2019-04-25 for processes for preparing 2,5-furandicarboxylic acid and esters thereof.
The applicant listed for this patent is E I DU PONT DE NEMOURS AND COMPANY. Invention is credited to PRANIT S. METKAR, Ronnie Ozer, Bhuma Rajagopalan.
Application Number | 20190119238 16/229341 |
Document ID | / |
Family ID | 56611578 |
Filed Date | 2019-04-25 |
United States Patent
Application |
20190119238 |
Kind Code |
A1 |
METKAR; PRANIT S. ; et
al. |
April 25, 2019 |
PROCESSES FOR PREPARING 2,5-FURANDICARBOXYLIC ACID AND ESTERS
THEREOF
Abstract
A process for producing furan dicarboxylic acid or an ester
thereof from a feedstock comprising hydroxymethyl furfural (HMF)
and humins is disclosed. Humins are a byproduct from reactions
forming HMF from sugars and are typically removed from the HMF
prior to any further processing. A humins-containing HMF feedstock
is utilized to produce furan dicarboxylic acids and ester
substantially free from humins.
Inventors: |
METKAR; PRANIT S.; (Houston,
TX) ; Ozer; Ronnie; (Arden, DE) ; Rajagopalan;
Bhuma; (Wilmington, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
E I DU PONT DE NEMOURS AND COMPANY |
Wilmington |
DE |
US |
|
|
Family ID: |
56611578 |
Appl. No.: |
16/229341 |
Filed: |
December 21, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15743015 |
Jan 9, 2018 |
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PCT/US2016/043296 |
Jul 21, 2016 |
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16229341 |
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62196808 |
Jul 24, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C07D 307/68
20130101 |
International
Class: |
C07D 307/68 20060101
C07D307/68 |
Claims
1. A process comprising: a) oxidizing a feedstock comprising
hydroxymethyl furfural and humins to produce a mixture comprising
crude humins-containing 2,5-furan dicarboxylic acid; b) separating
the mixture to obtain a solid 2,5-furan dicarboxylic acid/humins
composition; c) esterifying the solid 2,5-furan dicarboxylic
acid/humins composition with an alcohol to produce a crude ester of
2,5-furan dicarboxylic acid; and d) purifying the crude ester of
2,5-furan dicarboxylic acid obtained in step c) by distillation or
by sublimation to produce a purified ester of 2,5-furan
dicarboxylic acid substantially free of humins.
2. The process of claim 1 wherein the purified ester of 2,5-furan
dicarboxylic acid is 2,5-furan dicarboxylic acid dimethyl
ester.
3. A process comprising: i) oxidizing a feedstock comprising
hydroxymethyl furfural and humins in a solvent to produce a mixture
comprising crude humins-containing 2,5-furan dicarboxylic acid; and
ii) filtering the mixture under high temperature to obtain a
filtrate comprising 2,5-furan dicarboxylic acid substantially free
of humins, wherein the filtration temperature is sufficiently high
to keep the 2,5-furan dicarboxylic acid soluble in the solvent.
4. The process of claim 3, wherein the high temperature of the
filtering step ii) is in the range of from 50.degree. C. to
200.degree. C.
5. The process of claim 3, further comprising a step iii)
crystallizing the 2,5-furan dicarboxylic acid substantially free of
humins to obtain further purified 2,5-furan dicarboxylic acid.
6. The process of claim 3 wherein the solvent is acetic acid or a
mixture of acetic acid and water.
7. A process comprising: i) oxidizing a feedstock comprising
hydroxymethyl furfural and humins in a solvent to produce a mixture
comprising crude humins-containing 2,5-furan dicarboxylic acid; ii)
filtering the mixture under high temperature to obtain a filtrate
comprising 2,5-furan dicarboxylic acid substantially free of
humins, wherein the filtration temperature is sufficiently high to
keep the 2,5-furan dicarboxylic acid soluble in the solvent; iii)
esterifying the 2,5-furan dicarboxylic acid substantially free of
humins with an alcohol to produce a crude ester of 2,5-furan
dicarboxylic acid; and iv) purifying the crude ester of 2,5-furan
dicarboxylic acid obtained in step iii) by distillation or
sublimation to obtain a purified ester.
8. The process of claim 7 wherein the ester of 2,5-furan
dicarboxylic acid is 2,5-furan dicarboxylic acid dimethyl
ester.
9. The process of claim 7 wherein the high temperature of the
filtration step ii) is in the range of from 50.degree. C. to
200.degree. C.
10. The process of claim 7 wherein the solvent is acetic acid or
acetic acid and water.
11. The process of claim 7 wherein the purified ester of 2,5-furan
dicarboxylic acid comprises less than 100 ppm humins as determined
by size exclusion chromatography, a b* value of less than 3 as
determined by LAB color measurement, and greater than 99 percent by
weight of the diester of 2,5-furan dicarboxylic acid, based on the
total weight of the purified ester of 2,5-furan dicarboxylic
acid.
12. The process of claim 7, wherein at least a portion of the
alcohol is replaced with an alcohol source.
13. The process of claim 1 wherein the purified ester of 2,5-furan
dicarboxylic acid comprises less than 100 ppm humins as determined
by size exclusion chromatography, a b* value of less than 3 as
determined by LAB color measurement, and greater than 99 percent by
weight of the diester of 2,5-furan dicarboxylic acid, based on the
total weight of the purified ester of 2,5-furan dicarboxylic
acid.
14. The process of claim 1, wherein at least a portion of the
alcohol is replaced with an alcohol source.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. Non Provisional
application Ser. No. 15/743,015 filed on Jan. 9, 2018, which is a
371 of PCT/US2016/043296 filed Jul. 21, 2016 which claims benefit
of priority from U.S. Provisional Application No. 62/196,808 filed
on Jul. 24, 2015, which is incorporated herein by reference in its
entirety.
FIELD OF THE DISCLOSURE
[0002] The present disclosure is directed towards processes for
preparing 2,5-furandicarboxylic acid and esters thereof, especially
diesters thereof, from mixtures comprising 5-hydroxymethyl furfural
and humins.
BACKGROUND OF THE DISCLOSURE
[0003] Poly (trimethylene furandicarboxylate (PTF) is a renewable
polyester and can be synthesized via the polycondensation reaction
of 2,5-furandicarboxylic acid or 2,5-furandicarboxylic acid diester
with 1,3-propane diol. Compared with polyethylene terephthalate
(PET), PTF demonstrates improved oxygen and carbon dioxide barrier
properties that are very important for the carbonated beverage and
food packaging industry.
[0004] The quality of the 2,5-furandicarboxylic acid diester,
especially the color of the monomer is important for obtaining the
high quality, colorless PTF that is required for the beverage, food
and packaging industries. The process for producing
2,5-furandicarboxylic acid and its diesters in a renewable manner
proceeds via the oxidation of hydroxymethyl furfural (HMF). HMF
from renewable resources is often contaminated with highly colored
polymeric impurities called humins. The removal of humins from
processes producing furandicarboxylic acid and its diesters
continues to be a problem.
[0005] The present disclosure relates to efficient processes for
producing both furan dicarboxylic acid and its diesters that are
substantially free from humins, from hydroxymethyl furfural
contaminated with humins.
SUMMARY OF THE DISCLOSURE
[0006] The present disclosure relates to a process comprising:
[0007] a) oxidizing a feedstock comprising HMF and humins to
produce a mixture comprising crude humins-containing FDCA; [0008]
b) separating the mixture to obtain a solid FDCA/humins
composition; [0009] c) esterifying the solid FDCA/humins
composition with an alcohol to produce a crude ester of FDCA; and
[0010] d) purifying the crude ester of FDCA obtained in step c) by
distillation or by sublimation to produce a purified ester of FDCA
substantially free of humins
[0011] In other embodiments, the process comprises: [0012] i)
oxidizing a feedstock comprising HMF and humins in a solvent to
produce a mixture comprising crude humins-containing FDCA; and
[0013] ii) filtering the mixture under high temperature to obtain a
filtrate comprising FDCA substantially free of humins, wherein the
filtration temperature is sufficiently high to keep the FDCA
soluble in the solvent.
[0014] In still further embodiments, the process comprises: [0015]
i) oxidizing a feedstock comprising HMF and humins in a solvent to
produce a mixture comprising crude humins-containing FDCA; [0016]
ii) filtering the mixture under high temperature to obtain a
filtrate comprising FDCA substantially free of humins, wherein the
filtration temperature is sufficiently high to keep the FDCA
soluble in the solvent; [0017] iii) esterifying the FDCA
substantially free of humins with an alcohol to produce a crude
ester of FDCA; and [0018] iv) purifying the crude ester of FDCA
obtained in step iii) by distillation or sublimation.
DETAILED DESCRIPTION OF THE DISCLOSURE
[0019] The disclosures of all cited patent and non-patent
literature are incorporated herein by reference in their
entirety.
[0020] As used herein, the term "embodiment" or "disclosure" is not
meant to be limiting, but applies generally to any of the
embodiments defined in the claims or described herein. These terms
are used interchangeably herein.
[0021] Unless otherwise disclosed, the terms "a" and "an" as used
herein are intended to encompass one or more (i.e., at least one)
of a referenced feature.
[0022] The features and advantages of the present disclosure will
be more readily understood by those of ordinary skill in the art
from reading the following detailed description. It is to be
appreciated that certain features of the disclosure, which are, for
clarity, described above and below in the context of separate
embodiments, may also be provided in combination in a single
element. Conversely, various features of the disclosure that are,
for brevity, described in the context of a single embodiment, may
also be provided separately or in any sub-combination. In addition,
references to the singular may also include the plural (for
example, "a" and "an" may refer to one or more) unless the context
specifically states otherwise.
[0023] The use of numerical values in the various ranges specified
in this application, unless expressly indicated otherwise, are
stated as approximations as though the minimum and maximum values
within the stated ranges were both proceeded by the word "about".
In this manner, slight variations above and below the stated ranges
can be used to achieve substantially the same results as values
within the ranges. Also, the disclosure of these ranges is intended
as a continuous range including each and every value between the
minimum and maximum values.
[0024] As used herein:
[0025] The acronym FDCA means 2,5-furan dicarboxylic acid.
[0026] The acronym FFCA means 5-formylfuran-2-carboxylic acid.
[0027] The acronym FDME means 2,5-furan dicarboxylic acid dimethyl
ester.
[0028] The acronym FDMME means the monomethyl ester of 2,5-furan
dicarboxylic acid.
[0029] The acronym FFME means the methyl ester of
5-formylfuran-2-carboxylic acid.
[0030] The acronym HMF means 5-hydroxymethyl furfural.
[0031] The acronym AcMF means 5-acetoxymethyl-2-furaldehyde.
[0032] The term HMF means hydroxymethyl furfural and should also be
understood to include derivatives of HMF wherein HMF has reacted
with the solvent or with another HMF molecule or derivative to form
directly related derivatives of HMF. Examples of HMF derivatives
can include ethers when the solvent includes an alcohol and esters
when the solvent includes a carboxylic acid.
[0033] The term HMF dimer refers to the product of etherification
of two molecules of HMF to form
5,5'-oxy(bismethylene)-2-furaldehyde.
[0034] The term "humins" means a highly colored, generally brown to
black, amorphous or non-crystalline polymers resulting from the
dehydration of sugars. Humins are generally insoluble in water.
[0035] The phrase "substantially free of humins" means a
composition that contains less than 100 parts per million of humins
as measured by HPLC or SEC analytical methods. In other
embodiments, the composition contains less than 75 ppm of humins,
or less than 50 ppm of humins or less than 25 ppm humins or less
than 20 ppm humins or less than 15 ppm humins or less than 10 ppm
humins, as measured by HPLC/SEC.
[0036] The phrase "ester of FDCA" means a composition comprising
greater than 50 percent by weight of the diester of
2,5-furandicarboxylic acid, based on the total weight of the ester
of FDCA. The remainder of the composition can be the monoester of
2,5-furandicarboxylic acid, the ester of
5-formylfuran-2-carboxylate, 5-formylfuran-2-carboxylic acid,
2,5-furandicarboxylic acid or a combination thereof. In other
embodiments, the diester can comprise greater than 90 percent or
greater than 95 percent or greater than 96 percent or greater than
97 percent or greater than 98 percent or greater than 99 percent by
weight of the ester of FDCA, with the other furan compounds making
up the remainder of the composition. Furthermore, the percentage by
weight is based on the dry composition, for example, a composition
dried for at least 8 hours in a vacuum oven at a temperature in the
range of from 40.degree. C. to 100.degree. C. and at a pressure of
less than or equal to 0.5 bar.
[0037] The phrase "at a temperature sufficiently high to keep the
FDCA soluble in the solvent" means a temperature in the range of
from 50.degree. C. to 275.degree. C., so that at least 95 percent
by weight of the FDCA is dissolved in the solvent, based on the
total amount of FDCA in the mixture.
[0038] The phrase "alcohol source" means a molecule which, in the
presence of water and optionally an acid, forms an alcohol.
[0039] In some embodiments, the disclosure relates to a process
comprising: [0040] a) oxidizing a feedstock comprising HMF and
humins to produce a mixture comprising crude humins-containing
FDCA; [0041] b) separating the mixture to obtain a solid
FDCA/humins composition; [0042] c) esterifying the solid
FDCA/humins composition to produce a crude ester of FDCA; and
[0043] d) purifying the crude ester of FDCA obtained in step c) by
distillation or by sublimation to produce a purified ester of FDCA
substantially free of humins.
[0044] In other embodiments, the process comprises: [0045] i)
oxidizing a feedstock comprising HMF and humins in a solvent to
produce a mixture comprising crude humins-containing FDCA mixture;
and [0046] ii) filtering the mixture under high temperature to
obtain a filtrate comprising FDCA substantially free from humins,
wherein the filtration temperature is sufficiently high to keep the
FDCA soluble in the solvent.
[0047] In still further embodiments, the process comprises: [0048]
i) oxidizing a feedstock comprising HMF and humins in a solvent to
produce a mixture comprising crude humins-containing FDCA mixture;
[0049] ii) filtering the mixture under high temperature to obtain a
filtrate comprising FDCA substantially free from humins, wherein
the filtration temperature is sufficiently high to keep the FDCA
soluble in the solvent; [0050] iii) esterifying the FDCA
substantially free of humins to produce a crude ester of FDCA; and
[0051] iv) purifying the crude ester of FDCA obtained in step c) by
distillation or sublimation.
[0052] The feedstock comprising HMF and humins can be produced by
the dehydration of hexose sugars, starch, amylose, galactose,
cellulose, hemicellulose, inulin, fructan, glucose, fructose,
sucrose, maltose, cellobiose, lactose, and/or sugar oligomers.
Depending upon the dehydration process conditions, the feedstock
can comprise HMF and humins, optionally further comprising one or
more of an HMF ether or an HMF ester, for example,
5-acetoxymethyl-2-furaldehyde. The amount of humins in the
feedstock can vary depending upon the process conditions used to
form the HMF. In some embodiments, the amount of humins in the
feedstock comprising HMF and humins can be in the range of from
greater than or equal to 10 parts per million (ppm) to up to
500,000 ppm, based on the total weight of HMF and humins in the
feedstock. In other embodiments, the amounts of humins can be in
the range of from 100 ppm to 500,000 ppm or from 2500 ppm to
250,000 ppm or from 10,000 to 200,000 ppm or from 50,000 to 200,000
ppm, based on the total weight of HMF and humins.
[0053] The oxidation step a) can be conducted by contacting a
feedstock comprising 5-hydroxymethyl furfural (HMF) and humins with
an oxidant in the presence of an oxidation catalyst to produce a
crude humins-containing FDCA. The oxidation step is typically
carried out in a solvent, for example, acetic acid or a mixture of
acetic acid and water. The oxidation catalyst can be a homogeneous
oxidation catalyst.
[0054] Any suitable homogeneous oxidation catalyst which is
effective for oxidizing HMF, HMF esters, or HMF ethers to FDCA
and/or derivatives of FDCA can be used. The homogeneous oxidation
catalysts can include, for example, metal catalysts comprising one
or more transition metals. In some embodiments, the metal catalyst
comprises cobalt, manganese or a combination thereof. In other
embodiments, the metal catalyst further comprises zirconium or
cerium. The oxidation catalyst may further include bromine. In some
embodiments, the metal catalyst may react with the bromine and form
in-situ metal bromides. In some embodiments, the metal catalyst
comprises or consists essentially of from 59 to 5900 parts per
million of Co, from 55 to 5500 parts per million of Mn, and from
203 to 20000 parts per million of Br. All of the parts per million
of the catalyst are based on the total weight of the oxidation
reaction mixture. Still other metals have previously been found
useful for combining with Co/Mn/Br, for example, Zr and/or Ce and
may be included.
[0055] Each of the metal components can be provided in any of their
known ionic forms. Preferably the metal or metals are in a form
that is soluble in the oxidation solvent. Examples of suitable
counterions for cobalt and manganese include, but are not limited
to, carbonate, acetate, acetate tetrahydrate and halide. In some
embodiments, the bromine can be in the form of the bromide, for
example, hydrogen bromide, sodium bromide, ammonium bromide or
potassium bromide. In some embodiments, cobalt acetate, cobalt
acetate tetrahydrate, manganese acetate and/or manganese acetate
tetrahydrate can be used.
[0056] The oxidation step can be performed at a temperature in the
range of from 120.degree. C. to 250.degree. C. In other
embodiments, the oxidation step can be performed at a temperature
in the range of from 125.degree. C. to 250.degree. C. or
130.degree. C. to 240.degree. C. The oxidation step further
comprises an oxidant, for example, oxygen gas or an
oxygen-containing gas. As an oxygen-containing gas, air or a
mixture of oxygen and nitrogen can be used. In some embodiments,
the pressure of the oxidant in step a) is such that an oxygen
partial pressure of from 0.2 to 100 bar is provided. In other
embodiments, the oxygen partial pressure can be in the range of
from 0.2 to 50 bar or from 0.2 to 30 bar or from 0.2 to 21 bar.
[0057] The oxidation step a) produces a mixture comprising crude
humins-containing FDCA. Step b) comprises separating the mixture to
obtain a solid FDCA/humins composition. The solid FDCA/humins
composition can be separated by filtration or by centrifugation.
The separation can be conducted at a temperature at or below the
temperature of the oxidation temperature of step a). In some
embodiments, the separation step is conducted at a temperature
below the oxidation temperature, for example, a temperature in the
range of from 20.degree. C. to 200.degree. C. In other embodiments,
the separation temperature is in the range of from 30.degree. C. to
175.degree. C. or from 40.degree. C. to 150.degree. C. The
oxidation mixture comprising the crude humins-containing FDCA from
step a) can be cooled in the oxidation vessel, in a separate vessel
or in a series of vessels that gradually cool the reaction
temperature to the desired separation temperature. In some
embodiments, the crude humins-containing FDCA is cooled via
evaporative cooling via a series of evaporative cooling
vessels.
[0058] Separation of the mixture yields a solid FDCA/humins
composition and a mother liquor composition. In some embodiments,
the solid FDCA/humins composition comprises in the range of from
greater than or equal to 10 ppm to 100,000 ppm of humins, based on
the total weight of the FDCA and the humins. In other embodiments,
the solids FDCA/humins composition comprises in the range of from
100 ppm to 50,000 ppm, or from 500 ppm to 25,000 ppm, or from 1,000
to 20,000 ppm, or from 10,000 to 20,000 ppm of humins, based on the
total weight of FDCA and humins. The solid FDCA/humins composition
obtained from the separation step can be used as is, without a
further purification step.
[0059] In step c), the solid FDCA/humins composition obtained in
step b) can be esterified to produce a crude ester of FDCA. The
solid FDCA/humins can be used, as is from step b), and can be in
the form of a dry solid or a wet cake. The esterification can be
accomplished by heating the solids FDCA/humins composition with an
excess of an alcohol having in the range of from 1 to 12 carbon
atoms, especially alkyl alcohols. Suitable alcohols can include,
for example methanol, ethanol, propanol, butanol, pentanol,
hexanol, heptanol, octanol, nonanol, decanol, undecanol, dodecanol
or isomers thereof. In some embodiments, the alcohol is in the
range of from 1 to 6 carbon atoms or in the range of from 1 to 4
carbon atoms or in the range of from 1 to 2 carbon atoms. In some
embodiments, the alcohol is methanol and the ester of FDCA is
FDME.
[0060] In some embodiments, the percentage of FDCA and alcohol that
can be fed to the reactor can be expressed as a weight percentage
of the FDCA based on the total amount of FDCA and the alcohol. For
example, the weight of FDCA can be in the range of from 1 to 70
percent by weight, based on the total weight of the FDCA and the
alcohol. Correspondingly, the alcohol can be present at a weight
percentage of about 30 to 99 percent by weight, based on the total
amount of FDCA and the alcohol. In other embodiments, the FDCA can
be present in the range of from 2 to 60 percent, or from 5 to 50
percent, or from 10 to 50 percent, or from 15 to 50 percent, or
from 20 to 50 percent by weight, wherein all percentages by weight
are based on the total amount of FDCA and the alcohol.
[0061] In other embodiments, the ratio of alcohol to the FDCA can
be expressed in a molar ratio wherein the molar ratio of the
alcohol to the FDCA can be in the range of from 2.01:1 to 40:1. In
other embodiments, the molar ratio of the alcohol to FDCA can be in
the range of from 2.2:1 to 40:1, or 2.5:1 to 40:1, or 3:1 to 40:1,
or 4:1 to 40:1, or 8:1 to 40:1, or 10:1 to 40:1, or 15:1 to 40:1,
or 20:1 to 40:1, or 25:1 to 40:1, or 30:1 to 40:1.
[0062] At least a portion of the alcohol can be replaced with an
alcohol source. The alcohol source is a molecule which, in the
presence of water and optionally an acid forms an alcohol. In some
embodiments, the alcohol source is an acetal, an orthoformate, an
alkyl carbonate, a trialkyl borate, a cyclic ether comprising 3 or
4 atoms in the ring or a combination thereof. Suitable acetals can
include, for example, dialkyl acetals, wherein the alkyl portion of
the acetal comprises in the range of from 1 to 12 carbon atoms. In
some embodiments, the acetal can be 1,1-dimethoxyethane
(acetaldehyde dimethyl acetal), 2,2 dimethoxypropane (acetone
dimethyl acetal), 1,1-diethoxyethane (acetaldehyde diethyl acetal)
or 2,2 diethoxypropane (acetone diethyl acetal). Suitable
orthoformates can be, for example, trialkyl orthoformate wherein
the alkyl group comprises in the range of from 1 to 12 carbon
atoms. In some embodiments, the orthoester is trimethyl
orthoformate or triethyl orthoformate. Suitable alkyl carbonates
can be dialkyl carbonates wherein the alkyl portion comprises in
the range of from 1 to 12 carbon atoms. In some embodiments, the
dialkyl carbonate is dimethyl carbonate or diethyl carbonate.
Suitable trialkyl borates can be, for example, trialkyl borates
wherein the alkyl portion comprises in the range of from 1 to 12
carbon atoms. In some embodiments, the trialkyl borate is trimethyl
borate or triethyl borate. A cyclic ether can also be used wherein
the cyclic ether has 3 or 4 carbon atoms in the ring. In some
embodiments, the cyclic ether is ethylene oxide or oxetane. If
used, the alcohol source can be used to replace in the range of
from 0.1 percent to 100 percent of the alcohol, based on the total
weight of the alcohol in the process.
[0063] In further embodiments, combinations of the alcohol and the
alcohol source can also be used. In some embodiments, the
percentage by weight of the alcohol can be in the range of from
0.001 percent to 99.999 percent by weight, based on the total
weight of the alcohol and the alcohol source. In other embodiments,
the alcohol can be present at a percentage by weight in the range
of from 1 to 99 percent, or from 5 to 95 percent, or from 10 to 90
percent, or from 20 to 80 percent, or from 30 to 70 percent, or
from 40 to 60 percent, wherein the percentages by weight are based
on the total weight of the alcohol and the alcohol source.
[0064] The solid FDCA/humins mixture is fed to a reactor and is
contacted with an excess of alcohol, optionally with an
esterification catalyst. The esterification reaction can be
conducted at elevated temperatures, for example, in the range of
from 50.degree. C. to 325.degree. C. and at a pressure in the range
of from 1 bar and 140 bar for a sufficient time to produce the
desired ester of FDCA. In other embodiments, the temperature can be
in the range of from 75.degree. C. to 325.degree. C., or from
100.degree. C. to 325.degree. C., or from 125.degree. C. to
325.degree. C., or from 150.degree. C. to 320.degree. C., or from
160.degree. C. to 315.degree. C., or from 170 to 310.degree. C. In
other embodiments, the temperature can be in the range of from
50.degree. C. to 150.degree. C., or from 65.degree. C. to
140.degree. C., or from 75.degree. C. to 130.degree. C. In still
further embodiments, the temperature can be in the range of from
250.degree. C. to 325.degree. C., or from 260.degree. C. to
320.degree. C., or from 270.degree. C. to 315.degree. C., or from
275.degree. C. to 310.degree. C., or from 280.degree. C. to
310.degree. C. In some embodiments, the pressure can be in the
range of from 5 bar to 130 bar, or from 15 bar to 120 bar, or from
20 bar to 120 bar. In other embodiments, the pressure can be in the
range of from 1 bar to 5 bar, or 1 bar to 10 bar, or 1 bar to 20
bar. The pressure and temperature of the step c) are chosen so that
contents of the reactor comprise a liquid phase and at least a
portion of the contents are in the gas phase.
[0065] Step c) can optionally be conducted in the presence of an
esterification catalyst, for example, the catalyst can be cobalt
(II) acetate, iron (II) chloride, iron (III) chloride, iron (II)
sulfate, iron (III) sulfate, iron (II) nitrate, iron (III) nitrate,
iron (II) oxide, iron (III) oxide, iron (II) sulfide, iron (III)
sulfide, iron (II) acetate, iron (III) acetate, magnesium (II)
acetate, magnesium (II) hydroxide, manganese (II) acetate,
phosphoric acid, sulfuric acid, zinc (II) acetate, zinc stearate, a
solid acid catalyst, a zeolite solid catalyst, or a combination
thereof. The metal acetates, chlorides and hydroxides can be used
as the hydrated salts. In some embodiments, the catalyst can be
cobalt (II) acetate, iron (II) chloride, iron (III) chloride,
magnesium (II) acetate, magnesium hydroxide, zinc (II) acetate, or
a hydrate thereof. In still further embodiments, the catalyst can
be iron (II) chloride, iron (III) chloride, or a combination
thereof. In other embodiments, the catalyst can be cobalt acetate.
In some embodiments, the catalyst can be sulfuric acid, hydrobromic
acid, hydrochloric acid, boric acid, or another suitable Bronsted
acid. Combinations of any of the above catalysts may also be
useful. If present, a catalyst can be used at a rate of 0.01 to 5.0
percent by weight, based on the total weight of the FDCA, alcohol
and optionally the alcohol source, and the catalyst. In other
embodiments, the amount of catalyst present can be in the range of
from 0.2 to 4.0, or from 0.5 to 3.0, or from 0.75 to 2.0, or from
1.0 to 1.5 percent by weight, wherein the percentages by weight are
based on the total amount of FDCA, methanol and the catalyst.
[0066] The catalyst can also be a solid acid catalyst having the
thermal stability required to survive reaction conditions. The
solid acid catalyst may be supported on at least one catalyst
support. Examples of suitable solid acids include without
limitation the following categories: 1) heterogeneous
heteropolyacids (HPAs) and their salts, 2) natural or synthetic
minerals (including both clays and zeolites), such as those
containing alumina and/or silica, 3) cation exchange resins, 4)
metal oxides, 5) mixed metal oxides, 6) metal salts such as metal
sulfides, metal sulfates, metal sulfonates, metal nitrates, metal
phosphates, metal phosphonates, metal molybdates, metal tungstates,
metal borates or combinations thereof. The metal components of
categories 4 to 6 may be selected from elements from Groups 1
through 12 of the Periodic Table of the Elements, as well as
aluminum, chromium, tin, titanium, and zirconium. Examples include,
without limitation, sulfated zirconia and sulfated titania.
[0067] Suitable HPAs include compounds of the general formula
X.sub.aM.sub.bO.sub.c.sup.q-, where X is a heteroatom such as
phosphorus, silicon, boron, aluminum, germanium, titanium,
zirconium, cerium, cobalt or chromium, M is at least one transition
metal such as tungsten, molybdenum, niobium, vanadium, or tantalum,
and q, a, b, and c are individually selected whole numbers or
fractions thereof. Nonlimiting examples of salts of HPAs include,
for example, lithium, sodium, potassium, cesium, magnesium, barium,
copper, gold and gallium, and ammonium salts. Examples of HPAs
suitable for the disclosed process include, but are not limited to,
tungstosilicic acid (H.sub.4[SIW.sub.12O.sub.40].xH.sub.2O),
tungstophosphoric acid (H.sub.3[PW.sub.12O.sub.40].xH.sub.2O),
molybdophosphoric acid (H.sub.3[PMo.sub.12O.sub.40].xH.sub.2O),
molybdosilicic acid (H.sub.4[SiMo.sub.12O.sub.40].xH.sub.2O),
vanadotungstosilicic acid
(H.sub.4+n[SiV.sub.nW.sub.12-nO.sub.40].xH.sub.2O),
vanadotungstophosphoric acid
(H.sub.3+n[PV.sub.nW.sub.12-nO.sub.40].xH.sub.2O),
vanadomolybdophosphoric acid
(H.sub.3+n[PV.sub.nMo.sub.12-nO.sub.40].xH.sub.2O),
vanadomolybdosilicic acid
(H.sub.4+n[SiV.sub.nMo.sub.12-nO.sub.40].xH.sub.2O),
molybdotungstosilicic acid
(H.sub.4[SiMo.sub.nW.sub.12-nO.sub.40].xH.sub.2O),
molybdotungstophosphoric acid
(H.sub.3[PMo.sub.nW.sub.12-nO.sub.40].xH.sub.2O), wherein n in the
formulas is an integer from 1 to 11 and x is an integer of 1 or
more.
[0068] Natural clay minerals are well known in the art and include,
without limitation, kaolinite, bentonite, attapulgite, and
montmorillonite.
[0069] In an embodiment, the solid acid catalyst is a cation
exchange resin that is a sulfonic acid functionalized polymer.
Suitable cation exchange resins include, but are not limited to the
following: styrene divinylbenzene copolymer-based strong cation
exchange resins such as AMBERLYST.TM. and DOWEX.RTM. available from
Dow Chemicals (Midland, Mich.) (for example, DOWEX.RTM. Monosphere
M-31, AMBERLYST.TM. 15, AMBERLITE.TM. 120); CG resins available
from Resintech, Inc. (West Berlin, N.J.); Lewatit resins such as
MONOPLUS.TM. S 100H available from Sybron Chemicals Inc.
(Birmingham, N.J.); fluorinated sulfonic acid polymers (these acids
are partially or totally fluorinated hydrocarbon polymers
containing pendant sulfonic acid groups, which may be partially or
totally converted to the salt form) such as NAFION.RTM.
perfluorinated sulfonic acid polymer, NAFION.RTM. Super Acid
Catalyst (a bead-form strongly acidic resin which is a copolymer of
tetrafluoroethylene and perfluoro-3,6-dioxa-4-methyl-7-octene
sulfonyl fluoride, converted to either the proton (H+), or the
metal salt form) available from DuPont Company (Wilmington,
Del.).
[0070] In an embodiment, the solid acid catalyst is a supported
acid catalyst. The support for the solid acid catalyst can be any
solid substance that is inert under the reaction conditions
including, but not limited to, oxides such as silica, alumina,
titania, sulfated titania, and compounds thereof and combinations
thereof; barium sulfate; calcium carbonate; zirconia; carbons,
particularly acid washed carbon; and combinations thereof. Acid
washed carbon is a carbon that has been washed with an acid, such
as nitric acid, sulfuric acid or acetic acid, to remove impurities.
The support can be in the form of powder, granules, pellets, or the
like. The supported acid catalyst can be prepared by depositing the
acid catalyst on the support by any number of methods well known to
those skilled in the art of catalysis, such as spraying, soaking or
physical mixing, followed by drying, calcination, and if necessary,
activation through methods such as reduction or oxidation. The
loading of the at least one acid catalyst on the at least one
support is in the range of 0.1-20 weight percent based on the
combined weights of the at least one acid catalyst and the at least
one support. Certain acid catalysts perform better at low loadings
such as 0.1-5%, whereas other acid catalysts are more likely to be
useful at higher loadings such as 10-20%. In an embodiment, the
acid catalyst is an unsupported catalyst having 100% acid catalyst
with no support such as, pure zeolites and acidic ion exchange
resins.
[0071] Examples of supported solid acid catalysts include, but are
not limited to, phosphoric acid on silica, NAFION.RTM., a
sulfonated perfluorinated polymer, HPAs on silica, sulfated
zirconia, and sulfated titania. In the case of NAFION.RTM. on
silica, a loading of 12.5% is typical of commercial examples.
[0072] In another embodiment, the solid acid catalyst comprises a
sulfonated divinylbenzene/styrene copolymer, such as AMBERLYST.TM.
70.
[0073] In one embodiment, the solid acid catalyst comprises a
sulfonated perfluorinated polymer, such as NAFION.RTM. supported on
silica (SiO.sub.2).
[0074] In one embodiment, the solid acid catalyst comprises natural
or synthetic minerals (including both clays and zeolites), such as
those containing alumina and/or silica.
[0075] Zeolites suitable for use herein can be generally
represented by the following formula
M.sub.2/nO.Al.sub.2O.sub.3.xSiO.sub.2.yH.sub.2O wherein M is a
cation of valence n, x is greater than or equal to about 2, and y
is a number determined by the porosity and the hydration state of
the zeolite, generally from about 2 to about 8. In naturally
occurring zeolites, M is principally represented by Na, Ca, K, Mg
and Ba in proportions usually reflecting their approximate
geochemical abundance. The cations M are loosely bound to the
structure and can frequently be completely or partially replaced
with other cations by conventional ion exchange.
[0076] The zeolite framework structure has corner-linked tetrahedra
with Al or Si atoms at centers of the tetrahedra and oxygen atoms
at the corners. Such tetrahedra are combined in a well-defined
repeating structure comprising various combinations of 4-, 6-, 8-,
10-, and 12-membered rings. The resulting framework structure is a
pore network of regular channels and cages that is useful for
separation. Pore dimensions are determined by the geometry of the
aluminosilicate tetrahedra forming the zeolite channels or cages,
with nominal openings of about 0.26 nm for 6-member rings, about
0.40 nm for 8-member rings, about 0.55 nm for 10-member rings, and
about 0.74 nm for 12-member rings (these numbers assume the ionic
radii for oxygen). Zeolites with the largest pores, being 8-member
rings, 10-member rings, and 12-member rings, are frequently
considered small, medium and large pore zeolites, respectively.
[0077] In a zeolite, the term "silicon to aluminum ratio" or,
equivalently, "Si/Al ratio" means the ratio of silicon atoms to
aluminum atoms. Pore dimensions are critical to the performance of
these materials in catalytic and separation applications, since
this characteristic determines whether molecules of certain size
can enter and exit the zeolite framework.
[0078] In practice, it has been observed that very slight decreases
in ring dimensions can effectively hinder or block movement of
particular molecular species through the zeolite structure. The
effective pore dimensions that control access to the interior of
the zeolites are determined not only by the geometric dimensions of
the tetrahedra forming the pore opening, but also by the presence
or absence of ions in or near the pore. For example, in the case of
zeolite type A, access can be restricted by monovalent ions, such
as Na.sup.+ or K.sup.+, which are situated in or near 8-member ring
openings as well as 6-member ring openings. Access can be enhanced
by divalent ions, such as Ca.sup.2+, which are situated only in or
near 6-member ring openings. Thus, the potassium and sodium salts
of zeolite A exhibit effective pore openings of about 0.3 nm and
about 0.4 nm respectively, whereas the calcium salt of zeolite A
has an effective pore opening of about 0.5 nm.
[0079] The presence or absence of ions in or near the pores,
channels and/or cages can also significantly modify the accessible
pore volume of the zeolite for sorbing materials. Representative
examples of zeolites are (i) small pore zeolites such as NaA (LTA),
CaA (LTA), Erionite (ERI), Rho (RHO), ZK-5 (KFI) and chabazite
(CHA); (ii) medium pore zeolites such as ZSM-5 (MFI), ZSM-11 (MEL),
ZSM-22 (TON), and ZSM-48 (*MRE); and (iii) large pore zeolites such
as zeolite beta (BEA), faujasite (FAU), mordenite (MOR), zeolite L
(LTL), NaX (FAU), NaY (FAU), DA-Y (FAU) and CaY (FAU). The letters
in parentheses give the framework structure type of the
zeolite.
[0080] Zeolites suitable for use herein include medium or large
pore, acidic, hydrophobic zeolites, including without limitation
ZSM-5, faujasites, beta, mordenite zeolites or mixtures thereof,
having a high silicon to aluminum ratio, such as in the range of
5:1 to 400:1 or 5:1 to 200:1. Medium pore zeolites have a framework
structure consisting of 10-membered rings with a pore size of about
0.5-0.6 nm. Large pore zeolites have a framework structure
consisting of 12-membered rings with a pore size of about 0.65 to
about 0.75 nm. Hydrophobic zeolites generally have Si/Al ratios
greater than or equal to about 5, and the hydrophobicity generally
increases with increasing Si/Al ratios. Other suitable zeolites
include without limitation acidic large pore zeolites such as H--Y
with Si/Al in the range of about 2.25 to 5.
[0081] The esterification step can produce a crude ester of FDCA
comprising the desired diester of FDCA and optionally, further
comprising the mono ester of FDCA, the alkyl ester of
5-formylfuran-2-carboxylic acid, 5-formylfuran-2-carboxylic acid,
and unreacted FDCA. In some embodiments, the product of the
esterification can be removed from the reactor by removing a vapor
component, wherein the vapor component comprises water, the alcohol
and the crude ester of FDCA. If the crude ester of FDCA is removed
via the vapor phase, humins remain in the liquid phase and the
crude ester of FDCA comprises very little if any humins. Other
impurities may be present, but humins generally are not contained
in the vapor phase. In other embodiments, the contents of the
esterification reactor can be cooled and the crude ester of FDCA
can be removed via a solid liquid separation step. The cooling
step, if present, can be performed in the esterification reactor,
in a separate cooling vessel or in a series of separate cooling
vessels, wherein each successive vessel further cools the mixture
when compared to the previous cooling vessel. The cooling of the
contents of the esterification step c) can cause the ester of FDCA
to crystallize. If the crude ester of FDCA is crystallized, then
humins will be present in the solids phase. The crude ester of FDCA
can then be separated by filtration or centrifugation. Separation
of the solids comprising the crude ester of FDCA also yields a
mother liquor. The mother liquor can comprise the alcohol and
water. If an alcohol source is used, then the mother liquor can
also comprise one or more of the by-products from the hydrolysis of
the alcohol source. For example, in the presence of water,
trimethyl orthoformate is known to form methanol and methyl
formate. Other hydrolysis products of the disclosed alcohol sources
are well-known in the art and can be present in the mother
liquor.
[0082] The process further comprises a step d), purifying the crude
ester of FDCA obtained in step c) by crystallization, distillation
or sublimation to produce a purified ester of FDCA substantially
free of humins. In some embodiments, the purification step d) is a
distillation step, wherein the distillation is performed at low
pressure, for example, in the range of from less than 1 bar to
0.0001 bar. In other embodiments, the pressure can be in the range
of from 0.75 bar to 0.001 bar or from 0.5 bar to 0.01 bar. In other
embodiments, the purification step d) is a sublimation step wherein
the solid crude ester of FDCA is sublimed to provide the purified
ester of FDCA substantially free of humins.
[0083] In some embodiments, the amount of humins in the purified
ester of FDCA is less than 100 ppm as determined by size exclusion
chromatography. In still further embodiments, the purified ester of
FDCA has a b* color value of less than 3, or less than 2, as
determined by LAB color measurement. In other embodiments, the
purified ester of FDCA comprises greater than or equal to 99% by
weight of the ester of FDCA, wherein the percentage by weight is
based on the total amount of a sample of the dried ester of
FDCA.
[0084] In other embodiments, the disclosure relates to a process
comprising: [0085] i) oxidizing a feedstock comprising HMF and
humins in a solvent to produce a mixture comprising crude
humins-containing FDCA; and [0086] ii) filtering the mixture under
high temperature to obtain a filtrate comprising FDCA substantially
free of humins, wherein the filtration temperature is sufficiently
high to keep the FDCA soluble in the solvent.
[0087] The oxidation step can be conducted under the same oxidation
conditions as was given above for step a), with the exception that,
in some embodiments, the concentration of the FDCA in the solvent
is in the range of from 0.1 percent to 15 percent by weight, based
on the total weight of the solvent. In other embodiments, the
concentration of the FDCA can be in the range of from 0.1 to 12.0
percent by weight. In some embodiments, the solvent for step i) is
acetic acid, or mixture of acetic acid and water.
[0088] Following the oxidation step, the process further comprises
a step ii), filtering the mixture under high temperature to obtain
a filtrate comprising FDCA substantially free of humins, wherein
the filtration temperature is sufficiently high to keep the FDCA
soluble in the solvent. Temperatures sufficiently high to keep the
FDCA soluble in the solvent are dependent on the concentration of
the FDCA in the solvent, and can easily be determined. For example,
in a solvent containing 93 wt. % acetic acid and 7 wt. % water,
FDCA is typically soluble up to about 10 percent by weight at a
temperature of between 180.degree. C. and 275.degree. C. At lower
temperature, for example, temperatures as low as 50.degree. C.,
lesser amounts of FDCA are soluble in acetic acid or a mixture of
acetic acid and water. In some embodiments, the high temperature of
the filtration step ii) can be in the range of from 50.degree. C.
to 275.degree. C. In other embodiments, the filtration step ii) can
be conducted at a temperature in the range of from 75.degree. C. to
250.degree. C. or from 100.degree. C. to 225.degree. C. or from
120.degree. C. to 200.degree. C. It has been found that the
solubility of the humins is dependent at least on the solvent
composition, for example, the amount of water in the acetic acid.
Therefore, the filtration step ii) can provide a filtrate wherein
the filtrate comprises FDCA substantially free from humins.
[0089] In some embodiments, the filtrate comprising FDCA
substantially free of humins can be evaporated or distilled to
provide solid impure FDCA substantially free of humins. The FDCA
substantially free of humins can be purified by any of the known
methods, for example, using at least one crystallization step.
Suitable crystallization solvents can include for example, acetic
acid, a mixture of acetic acid and water or water.
[0090] In still further embodiments, the disclosure relates to a
process comprising: [0091] i) oxidizing a feedstock comprising HMF
and humins in a solvent to produce a mixture comprising crude
humins-containing FDCA, wherein the concentration of the FDCA in
the solvent is in the range of from 0.1 percent to 15 percent by
weight, based on the total weight of the solvent; [0092] ii)
filtering the mixture under high temperature to obtain a filtrate
comprising FDCA substantially free of humins, wherein the
filtration temperature is sufficiently high to keep the FDCA
soluble in the solvent; [0093] iii) esterifying the FDCA
substantially free of humins to produce a crude ester of FDCA; and
[0094] iv) purifying the crude ester of FDCA obtained in step
c).
[0095] Process steps i) and ii) are identical to steps i) and ii)
described above. The process further provides steps iii) and iv).
The step iii) of esterifying the FDCA substantially free of humins
can be further comprises a step of removing at least a portion of
the solvent to provide solid FDCA substantially free of humins. The
esterification step iii) can utilize dry solids or a wet cake of
the FDCA substantially free of humins. The esterifying step can use
the same conditions as described above for the esterification step
c). The product of step iii) is a crude ester of FDCA. In some
embodiments, the ester of FDCA is a methyl ester of FDCA.
[0096] The crude ester of FDCA can be purified in step iv) by
crystallization, distillation or sublimation. The process steps for
the sublimation are identical to those given for the purification
step d).
[0097] The described processes can provide a purified ester of FDCA
substantially free of humins or FDCA substantially free of humins.
The purified ester of FDCA comprises less than 100 ppm humins, a b*
value of less than 3 and greater than 99 percent by weight of the
diester of FDCA, based on the total weight of the purified ester of
FDCA.
[0098] Non-limiting examples of the processes disclosed herein
include:
1. A process comprising: [0099] a) oxidizing a feedstock comprising
HMF and humins to produce a mixture comprising crude
humins-containing FDCA; [0100] b) separating the mixture to obtain
a solid FDCA/humins composition; [0101] c) esterifying the solid
FDCA/humins composition with an alcohol to produce a crude ester of
FDCA; and [0102] d) purifying the crude ester of FDCA obtained in
step c) to produce a purified ester of FDCA substantially free of
humins. 2. The process of embodiment 1 wherein the purified ester
of FDCA is 2,5-furan dicarboxylic acid dimethyl ester. 3. A process
comprising: [0103] i) oxidizing a feedstock comprising HMF and
humins in a solvent to produce a mixture comprising crude
humins-containing FDCA; and [0104] ii) filtering the mixture under
high temperature to obtain a filtrate comprising FDCA substantially
free of humins, wherein the filtration temperature is sufficiently
high to keep the FDCA soluble in the solvent. 4. The process of
embodiment 3 wherein the high temperature of the filtration step
ii) is in the range of from 50.degree. C. to 275.degree. C. 5. The
process of embodiment 3, further comprising a step iii)
crystallizing the 2,5-furan dicarboxylic acid substantially free of
humins to obtain further purified 2,5-furan dicarboxylic acid. 6.
The process of embodiment 3 wherein the solvent is acetic acid or a
mixture of acetic acid and water. 7. A process comprising: [0105]
i) oxidizing a feedstock comprising HMF and humins in a solvent to
produce a mixture comprising crude humins-containing FDCA; [0106]
ii) filtering the mixture under high temperature to obtain a
filtrate comprising FDCA substantially free of humins, wherein the
filtration temperature is sufficiently high to keep the FDCA
soluble in the solvent; [0107] iii) esterifying the FDCA
substantially free of humins with an alcohol to produce a crude
ester of FDCA; and [0108] iv) purifying the crude ester of FDCA
obtained in step iii) by distillation or sublimation to obtain a
purified ester. 8. The process of embodiment 7 wherein the ester of
FDCA is a methyl ester of FDCA. 9. The process of embodiment 7
wherein the high temperature of the filtration step ii) is in the
range of from 50.degree. C. to 275.degree. C. 10. The process of
embodiment 7 wherein the solvent is acetic acid or acetic acid and
water. 11. The process of any one of embodiments 1, 3 or 7 wherein
the purified ester of FDCA comprises less than 100 ppm humins as
determined by size exclusion chromatography, a b* value of less
than 3 as determined by LAB color measurement, and greater than 99
percent by weight of the diester of FDCA, based on the total weight
of the purified ester of FDCA. 12. The process of any one of
embodiments 1 or 7, wherein at least a portion of the alcohol is
replaced with an alcohol source.
EXAMPLES
[0109] Unless otherwise noted, all chemicals and reagents are
available from the Sigma-Aldrich Company, St. Louis, Mo.
[0110] ACS grade glacial acetic acid was obtained from Fisher
Scientific.
[0111] The HMF feed was provided by Archer Daniels Midland (ADM)
Company, Decatur, Ill.
[0112] Methanol was obtained from EMD Millipore (catalog #
MX-0472-6).
[0113] Acetonitrile was obtained from Fisher Scientific (catalog #
A955-1).
[0114] Isopropanol was also obtained from Fisher Scientific
(catalog # A4641L1).
[0115] The following abbreviations are used in the examples:
".degree. C." means degrees Celsius; "wt %" means weight percent;
"g" means gram; "min" means minute(s); ".mu.L" means microliter;
"ppm" means microgram per gram, ".mu.m" means micrometer; "mL"
means milliliter; "mm" means millimeter and "mL/min" means
milliliter per minute; "slpm" means standard liters per minute;
"HMF" means 5-(hydroxymethyl)furfural, "AcMF" means
5-(acetoxymethyl)furfural, "DMF" means dimethylformamide, "FFCA"
means 5-formyl-2-furancarboxlyic acid, "FDCA" means
2,5-furandicarboxylic acid, "FDME" means
dimethyl-furan-2,5-dicarboxylate, "FFME" means formyl furan methyl
ester, "FDMME" means furan dicarboxylic acid mono methyl ester.
Test/General Methods
HPLC Analysis
[0116] HPLC analysis was used as one means to measure the FDCA,
FDMME & FDME contents of the product mixture. An Agilent 1200
series HPLC equipped with a ZORBAX.TM. SB-Aq column (4.6
mm.times.250 mm, 5 .mu.m) and photodiode array detector was used
for the analysis of the reaction samples. The wavelength used to
monitor the reaction was 280 nm. The HPLC separation of FDME, FDCA
and FDMME was achieved using a gradient method with a 1.0 mL/min
flow rate combining two mobile phases: Mobile Phase A: 0.5% v/v
trifluoroacetic acid (TFA) in water and Mobile Phase B:
acetonitrile. The column was held at 60.degree. C. and 2 .mu.L
injections of samples were performed. Analyzed samples were diluted
to <0.1 wt % for components of interest in a 50:50 (v/v)
acetonitrile/isopropanol solvent. The solvent composition and flow
rates used for the gradient method is given in Table 1 with linear
changes occurring over the corresponding step whenever the
composition changes.
TABLE-US-00001 TABLE 1 Table 1: Gradient program for HPLC Start
Volume % Mobile Volume % Mobile time Phase B, at Phase B, at End of
Step (min) Beginning of Step Step 1 0.0 0 0 2 6.0 0 80 3 20.0 80 80
4 25.0 80 0 5 25.1 0 0 6 30.0 0 0
[0117] Retention times were obtained by injecting analytical
standards of each component onto the HPLC. The amount of the
analyte in weight percent was typically determined by injection of
two or more injections from a given prepared solution and averaging
the area measured for the component using the OpenLAB CDS C.01.05
software. The solution analyzed by HPLC was generated by dilution
of a measured mass of the reaction sample with a quantified mass of
50:50 (v/v) acetonitrile/isopropanol solvent. Quantification was
performed by comparing the areas determined in the OpenLAB software
to a linear external calibration curve at five or more starting
material concentrations. Typical R.sup.2 values for the fit of such
linear calibration curves was in excess of 0.9997.
[0118] While the presented HPLC method was used for this analysis,
it should be understood that any HPLC method that can discriminate
between products, starting materials, intermediates, impurities,
and solvent can be used for this analysis. It should also be
understood that while HPLC was used as a method of analysis in this
work, other techniques such as gas chromatography could also be
optionally used for quantification when employing appropriate
derivatization and calibration as necessary.
LAB Color Measurements
[0119] A Hunterlab COLORQUEST.TM. Spectrocolorimeter (Reston, Va.)
was used to measure the color. Color numbers are measured as APHA
values (Platinum-Cobalt System) according to ASTM D-1209. The "b*"
color of FDCA and/or FDME solids was calculated from the UV/VIS
spectra and computed by the instrument. Color is commonly expressed
in terms of Hunter numbers which correspond to the lightness or
darkness ("L") of a sample, the color value ("a*") on a red-green
scale, and the color value ("b*") on a yellow-blue scale. Each
sample was prepared by adding 6 wt. % solids in dimethylformamide
(Sigma Aldrich).
Size Exclusion Chromatography (SEC) Method for Humins Analysis
[0120] A screening assay to estimate weight concentration of
soluble humin byproduct was developed using Size Exclusion
Chromatography (SEC). An Alliance 2695 chromatograph (Waters
Corporation, Milford, Mass.) was coupled to a 2498 dual-channel
UV/Visible detector (Waters Corporation). UV absorbance was
collected at wavelengths of 280 and 450 nm. The stationary phase
consisting of a 4 column set (SHODEX.TM. KD-801, KD-802, and two
KD-806M) was kept at a constant temperature of 50.degree. C.
Dimethylacetamide (Thermo Fisher, Wilmington, Del.) with 0.5% (w/v)
lithium chloride (Sigma Aldrich) was used as mobile phase at a flow
rate of 1 mL/min. Samples were prepared by dissolving or diluting
in mobile phase, followed by agitation at room temperature for 4
hours, filtering using 0.45 .mu.m PTFE (Pall, Fort Washington,
N.Y.), and finally injecting 100 .mu.L. A calibration curve was
constructed using humin byproduct isolated from an acid-catalyzed
fructose dehydration reaction. Resulting humin concentration in
research samples was determined by integrating any eluting peak
(450 nm absorbance) in the humin region of the chromatogram and
comparing peak area to the calibration curve. A lower limit of
detection in the sample as prepared was found to be approximately
50 ng humins.
Example 1: Purification of FDCA
Step 1.1 Oxidation of a Feedstock Comprising HMF and Humins
[0121] Oxidation of HMF to FDCA was carried out in a 1 L titanium
reactor (Autoclave Engineers, Serial #85-00534-1). The reactor was
charged with 440 mL of acetic acid, 23 mL of water, 4.566 g of
cobalt(II) acetate tetrahydrate, 0.285 g of manganese(II) acetate
tetrahydrate, and 632 .mu.L of hydrobromic acid (48%). The reactor
was pressurized to 450 psig under an air atmosphere, and heated to
a temperature of 200.degree. C. Air was then sparged in through a
dip tube which had eight 229 .mu.m diameter holes at a rate of 2.0
slpm when reactor temperature reached 190.degree. C. Nitrogen was
fed to the inlet of the condenser at 4.5 slpm. When desired
temperature was achieved, the HMF feed was pumped into the reactor
at a rate of 0.9 mL/min through another dip tube which was
positioned close to the reactor impeller. The composition of the
HMF feed was 9.86 wt. % HMF, 19.0 wt. % AcMF, 0.22 wt. % HMF dimer
and 8.36 wt. % humins. This addition was performed over a 45 min
period. When the addition was complete, the reaction was further
heated for an additional 50 min of post oxidation when only air was
fed to the reactor. After post oxidation, the reactor was cooled
down to room temperature and depressurized. The FDCA solids were
then vacuum filtered and dried in a vacuum oven at 75.degree. C. at
a pressure of 200-300 torr. After drying, 8.8 g of crude FDCA (with
a molar FDCA yield of 59.18%) solids was obtained. A detailed
analysis of this sample is given in Table 2. This crude FDCA sample
is referred as sample 1.1.
Step 1.2: Esterification of FDCA Containing Humins to FDME
[0122] FDCA sample 1.1 was esterified in a 75 mL mini Parr reactor
model 5050 equipped with an IKA RCT Basic hotplate stirrer. A total
of 6 g of FDCA (sample 1.1), 24 g methanol and TFE stir bar were
added to the reactor. The reactor was placed in an aluminum block
and was kept insulated. The reactor was then purged a minimum of 5
times with nitrogen. At room temperature, 300 psi of N.sub.2 was
introduced in the reactor head. The reactor was then heated to a
temperature of 200.degree. C. and both the temperature and pressure
were monitored. After 4 hr, heat was turned off and the reactor was
allowed to cool to room temperature. The pressure was then released
and the reactor was opened. The reactor contents (containing mainly
FDME product) were removed and transferred to an aluminum pan.
Solids were dried overnight on aluminum pan (while methanol was
evaporated). The dried solids were then analyzed using HPLC and
SEC. This sample of the crude methyl ester of FDCA was referred as
Sample 1.2 in Table 2.
Step 1.3: Purification of the Crude Methyl Ester of FDAC Via
Distillation/Sublimation
[0123] The solid product obtained after the esterification reaction
was purified using sublimation. The sublimation device was a two
piece glass unit that was connected together by a metal clamp. The
bottom piece of the sublimator had a rounded bottom so that there
was a larger area for heat transfer from a heating mantle. The top
piece was placed on top of the bottom piece with an o-ring in
between so that a seal between the top and bottom was created. The
top piece of the device had a conical water jacket that was used to
cool the sublimated vapor phase, and allow the solids to collect on
the inside of the cone. The top of the conical piece had a glass
valve which allowed the device to be connected to a vacuum source.
Sublimation conditions were maintained at a pressure of from 15 to
30 torr and a temperature of about 100.degree. C. After completion
of the sublimation, the apparatus was disassembled and the
sublimation product was collected from the inside of the cone on
the top piece. The sublimation bottoms were collected off of the
rounded bottom of the bottom piece. The solids collected from top
of the sublimator were analyzed for their purity using HPLC, SEC
and colorimetry. This sample was referred as Sample 1.3-1 in Table
2. The sublimator was operated in such a way that about 10% of the
starting material was purified and collected on top. The rest 90%
remained in the bottom. The bottom sample was labeled as Sample
1.3-2.
Results
TABLE-US-00002 [0124] TABLE 2 Table 2: Results obtained after the
analysis of solids collected at the end of stability tests Wt. %
Wt. % Wt. % Humins Sample L* b* FDME FDMME FDCA (ppm) 1.1 (after
96.72 13.66 0.00 0.00 96.84 1403 oxidation) 1.2 (after 48.98 80.66
88.79 12.84 0.356 1045 esterification 1.3-1 (after 99.99 0.19
99.248 0.752 0 <10 sublimation, collected from top) 1.3-2 (after
42.46 72.65 85.273 14.389 0.338 1200 sublimation, collected from
bottom)
[0125] From the results shown in Table 2, it has been surprisingly
found that humins-containing FDCA can be converted into FDME which
can be further purified via sublimation. The FDME obtained at the
end of the sublimation did not contain any humins and also had
L*>99 and b*<1. This high purity monomer can be used in the
manufacture of different polymers. Thus, the above example shows
that crude humins-containing FDCA can be purified using
esterification followed by sublimation to obtain a high purity
polymer-grade monomer without a need for intermediate purification
steps such as crystallization, hydrogenation, etc.
Example 2: Purification of FDCA without a Post Oxidation Step
Step 2.1--Oxidation of HMF to FDCA
[0126] Oxidation of HMF to FDCA experiment was carried out in a 1 L
titanium reactor (Autoclave Engineers, Serial #85-00534-1). The
reactor was charged with 440 mL of acetic acid, 23 mL of water,
6.2511 g of cobalt(II) acetate tetrahydrate, 0.44 g of
manganese(II) acetate tetrahydrate, and 698 .mu.L of hydrobromic
acid (48%). The unit was pressurized to 450 psig using air, and
heated to a reaction temperature of 180.degree. C. Air was then
sparged in through a dip tube which had eight 229 .mu.m diameter
holes at a rate of 4.5 slpm when reactor temperature reached
170.degree. C. Nitrogen was fed to the inlet of the condenser at
4.5 slpm. When desired temperature was achieved, the HMF feed was
pumped into the reactor at a rate of 3.6 mL/min through another dip
tube which was positioned by the reactor impeller. The composition
of the HMF feed for this run was 4.48 wt % HMF, 5.18 wt % AcMF,
0.15 wt % HMF dimer and 5.4 wt. % humins. This addition was
performed over a 45 min period. After the addition was complete,
the reactor was cooled to room temperature and depressurized. The
FDCA solids were then vacuum filtered and dried in a vacuum oven at
75.degree. C. and 200 to 300 torr to give 13.1 g of crude FDCA
(with a molar FDCA yield of 80.2%). A detailed analysis of this
sample is given in Table 3. This sample is referred as sample
2.1.
Step 2.2 Esterification of FDCA to FDME
[0127] FDCA sample 2.1 was esterified in a 75 mL mini Parr reactor
model 5050 equipped with an IKA RCT Basic hotplate stirrer. 8 g
FDCA sample 2.1, 32 g methanol and TFE stir bar were added to the
reactor. The reactor was placed in an aluminum block and was kept
insulated. The reactor was then purged a minimum of 5 times with
nitrogen. At room temperature, 300 psi of N.sub.2 was introduced in
the reactor head. The reactor was then heated to a temperature of
200.degree. C. and both the temperature and pressure were
monitored. After 4 hr, heat was turned off and the reactor was
allowed to cool to room temperature. The pressure was then released
and the reactor was opened. The reactor contents (containing mainly
FDME product) were removed and transferred to an aluminum pan.
Solids were dried overnight on aluminum pan (while methanol was
evaporated). The dried solids were then analyzed using HPLC and
SEC. This sample of the crude methyl ester of FDCA was referred as
Sample 2.2 in Table 3. A portion of the crude methyl ester Sample
2.2 was sublimed using the procedure given above. The sublimed top
and bottom samples are labeled 2.3-1 and 2.3-2 in Table 3.
TABLE-US-00003 TABLE 3 Table 3: Results obtained after the analysis
of solids collected at the end of stability tests Wt. % Wt. % Wt. %
Wt. % Humins Sample L* b* FDME FDMME FDCA FFME (ppm) 2.1 (after
oxidation) 90.46 25.47 0.00 0.00 98.79 0 41 2.2 (after
esterification 91.12 25.69 82.85 15.73 0.64 0.51 455 2.3-1 (after
sublimation, 98.38 2.77 96.85 0.76 0 2.39 <10 collected from
top) 2.3-2 (after sublimation, 87.93 39.77 81.74 16.75 1.51 0.37 52
collected from bottom)
[0128] From the results shown in Table 3, it is unexpectedly found
that impure FDCA solids (containing humins & other impurities)
can be converted into FDME which can be further purified with
sublimation. The purified FDME obtained at the end of sublimation
does not contain any humins and also has L*>98 and b*<3. The
FDCA solids obtained at the end of oxidation reaction contained
some FFCA (1.21 wt. %) impurity. This impurity was converted to
FFME during the esterification step. In the example 2, the FFME
impurity was also removed during the sublimation of the FDME and
this resulted in imparting some color to the FDME solids.
* * * * *