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Advances in conversion of hemicellulosic biomass to furfural and upgrading


to biofuels

Article  in  Catalysis Science & Technology · October 2012


DOI: 10.1039/c2cy20235b

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www.rsc.org/catalysis MINIREVIEW
Advances in conversion of hemicellulosic biomass to furfural and
upgrading to biofuels
Saikat Dutta, Sudipta De, Basudeb Saha* and Md. Imteyaz Alam
Received 14th April 2012, Accepted 28th May 2012
Published on 01 June 2012 on http://pubs.rsc.org | doi:10.1039/C2CY20235B

DOI: 10.1039/c2cy20235b

Recent approaches to furfural synthesis from hemicellulosic biomass and pentose sugars with
both homogeneous and solid acidic catalysts have been summarized by addressing the associated
sustainability issues. The features of deconstruction of hemicellulosic biomass by acid hydrolysis
to produce pentose sugar feedstock for furfural have been discussed in brief. Several strategies
including solvent extraction in a biphasic process, application of surface functionalized materials
such as acidic resins, mesoporous solids and mechanistic insight in limited cases are discussed.
The present status of the promising furfural platform in producing second generation biofuels
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(furanics and hydrocarbon) is reviewed. The performances of each catalytic system are assessed
in terms of intrinsic reactivity and selectivity toward furfural production. Overall, this minireview
attempts to highlight the scope of further developments for a sustainable furfural process and
upgrading to fuels.

1. Introduction fossil resources. Hence, much research is being devoted to


exploring non-fossil carbon energy sources. Among these,
While the easily accessible oil fields are becoming depleted and biofuels derived from cellulosic and hemicellulosic fractions
CO2 emissions from fossil fuels are affecting the earth’s of the biomass are considered as a promising alternative for
climate, the most imminent result that awaits mankind is the transportation fuel under test. The driving factors for biofuels
tremendous crisis of energy if we remain dependent on the derived from biorenewable sources are not only confined to
exploring new energy platform and CO2 savings, but include
opportunities to secure the local supply of energy and support
Laboratory of Catalysis, Department of Chemistry, North Campus,
University of Delhi, Delhi, India. E-mail: bsaha@chemistry.du.ac.in; agricultural economics.1,2 The conversion of lignocellulosic
Fax: +91 2766 7794; Tel: +011-2766 6646 biomass into fuels and chemicals requires effective utilization

Dr Saikat Dutta obtained Sudipta De obtained his BSc


his PhD in organometallic in chemistry from University
chemistry from Indian Insti- of Calcutta in 2008. After
tute of Science, Bengaluru, in receiving his MSc from
2008. After a couple of post- University of Calcutta in
doctoral appointments in 2010, he enrolled in the PhD
Taiwan and in India, he was Program at the University of
awarded a Fulbright–Nehru Delhi under supervision of
Postdoctoral Fellowship in Professor Basudeb Saha.
2012. Dr Dutta is a co-author Currently he is working in
of more than 20 research the area of biomass conversion
publications in scientific jour- to valued chemicals and liquid
nals. His research experience fuels with a major focus in
includes transition metal design and development of
Saikat Dutta organometallics,polymerization Sudipta De materials for catalytic appli-
catalysis, materials develop- cations. His research interests
ment for photophysical/catalytic applications, biomass conversion also include the template directed synthesis of mesoporous
for platform chemicals and fuels. His current research interest is and nanocrystalline materials having various catalytic and
in the area of materials design for photochemical conversion of photophysical applications.
CO2, degradation of non-biodegradable polymers and chemistry
of main-group elements.

This journal is c The Royal Society of Chemistry 2012 Catal. Sci. Technol.
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of the C5 and C6 sugars present in hemicellulose and cellulose,


respectively, by either processing these fractions together or
separating and processing them separately. The fractionation
of hemicellulose and cellulose allows the processing of each
fraction to be tailored to take advantage of the different
chemical and physical properties of these fractions, and
provides increased flexibility of operation. For example,
chemical processing methods can be employed to convert C5
sugars in hemicelluloses into fuels/chemicals. The conversion
of cellulose to chemicals and liquid fuels has been demon-
strated through the formation of several platform molecules,
such as glucose, 5-hydroxymethylfurfural, and levulinic acid
(LA), utilizing chemical routes.3–6 However, limited studies
Published on 01 June 2012 on http://pubs.rsc.org | doi:10.1039/C2CY20235B

addressed the conversion of hemicellulose into chemicals and Scheme 1 Furfural platform for biofuels (modified from Fig. 1 in
fuels.7,8 Hemicellulosic fraction of biomass can be used as feed- ref. 13).
stock to produce many important chemicals, such as furfuryl
alcohol, furan, and THF.9 conversion of furfural to different components for example
This contribution is an account of most recent results in the 2-methylfuran, 2-methyltetrahydrofuran etc. Furfural hydrogena-
field of furfural synthesis from the biomass resources with a tion and acid–base-catalyzed reactions applied to upgrade furfural
variety of catalysts including metal salts and solid acidic to fuels have recently been initiated commercially.13
materials in aqueous, organic and biphasic media, highlighting Synthesis routes shown in Scheme 1 are ranked based on
their respective catalytic performances/efficiencies and overall their industrial potential by considering their manufacturing
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advantages. Possible outlooks and scope of this work are also footprint, investment cost and CO2 emission of furfural upgrade.
included. For example, 2-methylfuran (2-MF) has been considered as a
promising liquid fuel candidate and an extensive road trial of
over 90 000 km with promising outcomes has been reported.13
2. Furfural platform
Furfural is the most common industrial chemical derived from
3. Hemicellulose structure
lignocellulosic biomass, with an annual production volume of
more than 200 000 tonnes.10,11 The commercial utility of furfural Hemicelluloses, a heterogeneous polymer constructed with C5
was first discovered at the Quaker Oats Company in 1921.12 and C6 sugars (such as xylose, arabinose, glucose, galactose,
Quaker Oats tested a variety of processes to valorize the hulls mannose, etc.), is typically the second-most-abundant component
and found that treating them with dilute sulfuric acid yields of biomass, after cellulose.14 In most grasses and hardwoods,
useful amounts of furfural. Furfural also deserves attention as a xylan, a polymer of xylose, is often found as the primary
potential platform for biofuels. Furfural is produced by the hemicellulose. As a result, xylan conversion is critical for
hydrolysis and dehydration of xylan contained in lignocellulose. utilization of important biomass feedstocks such as corn stover,
The value chains of furanic biofuels are realized in terms of Miscanthus, switchgrass, and poplar. Major hemicelluloses are

Dr Basudeb Saha, born in Md. Imteyaz Alam obtained


Calcutta (India), graduated his BSc in chemistry from Jai
in chemistry at Calcutta Prakash University (India) in
University and received his 2006, and MSc from Univer-
PhD from Indian Association sity of Delhi (India) in 2009.
for the Cultivation of Science, After a brief research experi-
India. He did postdoctoral ence in S. C. Johnson Pro-
research with Professor James ducts Pvt. Ltd. and Indian
Espenson at Iowa State Uni- Agricultural Research Insti-
versity (USA), jointly with tute (India), he enrolled in
BP Chemical Company, on the PhD program at the
removal of toxic by-products University of Delhi in 2011
in the manufacture of under supervision of Professor
terephthalic acid (PTA). In Basudeb Saha. His research
Basudeb Saha 2007, he joined the poly- Md. Imteyaz Alam interests include mesoporous
urethane business R&D and nanocrystalline materials
division of Dow Chemical Company, USA, where he led several synthesis and their catalytic
breakthrough and implementation research projects. Since 2009, applications.
he has been an Associate Professor at Delhi University and has
been pursuing research on utilization of bio-renewable feed-
stocks for chemicals and fuels production via effective catalysis.

Catal. Sci. Technol. This journal is c The Royal Society of Chemistry 2012
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hydrolysis rate compared with that of pyranose is the higher


structural angle strains in the furanoside sugar units, whereas
pyranose rings are strain-free.
The acid hydrolysis rate of wood chips depends on the type
of tree; for example, softwoods, especially pine, are generally
more difficult to hydrolyze than hardwoods.23 Acid hydrolysis
of hemicelluloses fraction of the lignocellulosic biomass produces
sugars like xylose, mannose, galactose etc. Selective dilute acid
hydrolysis of wood chips and agricultural wastes has been
investigated and very high mannose yields were achieved from
balsam, whereas the yield was very low from switchgrass. The
mechanism of acid hydrolysis of hemicelluloses proceeds through
the cleavage of glycosidic bonds (Fig. 1) via protonation either of
Published on 01 June 2012 on http://pubs.rsc.org | doi:10.1039/C2CY20235B

the glycosidic bond or of pyranic oxygen.24 Although the


formation of a cyclic intermediate via the conformational
Fig. 1 The most important hemicelluloses of softwoods: (a) xylan, changes of the tetrahydropyran is proposed, this route needs
(b) glucomannan. more energy compared to the acyclic route.25
From the mechanistic point of view, acid hydrolysis rate
mannans, xylan, arabinans, and galactans among which of hemicelluloses varies depending on their structure. Both
most important in softwoods (coniferous trees) are galacto- random scission26 and selective scission of the side chain have
glucomannans (20%) and arabinoglucurunoxylans (10%)15,16 been reported.27 Furthermore, acid hydrolysis of xylan was
(Fig. 1). reported to be random,27 whereas hydrolysis of the vegetable
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In the hydrolysis of hemicelluloses, selective cleavage of the fibers, L-arabinose was selective when using dilute acids as
C–O bonds present between adjacent sugar units is very catalysts.28,29 From these results, it is revealed that furanosides
important to yield intact monomer sugar molecules. Mineral hydrolyze faster than pyranosides30 due to the fact that
acids and enzymes are generally used as catalyst to hydrolyze hydrolysis rate is faster for glycosidic linkages exhibiting
these polymeric carbohydrates.17 Selective acid hydrolysis of nonreducing ends.31 Sugars from hemicelluloses are easy to
hemicellulose substrates produces xylose in good yield which separate almost quantitatively32,33 due to their structures and
essentially depends on the hydrolysis kinetics. Furthermore, noncrystalline nature.
softwoods contain arabinogalactan, xyloglucans, and other Acid hydrolysis of biomass starting from plant biomass
glucans. Pine (Pinus sylvestris) and spruce (Picea abies) contain substrates for production of xylose has been intensively
about 20 wt% O-acetyl-galactoglucomannan and 510 wt% studied (Table 2), for example, from sugar cane bagasse, wheat
arabino-4-O-methyl glucuronoxylan.18 The amounts of different straw, rice straw, cotton-seed, cotton stalk, sunflower stalk,
hemicelluloses in wood are listed in Table 1.19 corn stover, and many more.20 Different strategies of decon-
The selective acid hydrolysis of hemicelluloses to produce struction of hemicelluloses such as acid hydrolysis, enzymatic
pentose sugars is an interesting process, especially for the hydrolysis, hot water extraction, and microwave treatment, to
production of rare sugars (mannose, galactose, lactose), which prepare xylo-oligosaccharides have been reported.20 Unlike
are value-added compounds in biorefinery. Acid hydrolysis of pure xylan, hemicelluloses in biomass serve as linkers of
hemicelluloses from biomass can be compared with cellulose cellulose fibers to microfibrils, and cross-linkers of cellulose
hydrolysis. Selective dilute acid catalyzed hydrolysis of hemi- with lignin to create complex networks that provide structural
celluloses from both wood chips and agricultural wastes has stability.34 Such network in lignocellulosic biomass turns the
been investigated by many researchers in the past.20 The rate
of acid hydrolysis of hemicellulose is partially determined by
the anhydrosugar structure, for example, whether it is an a- or Table 2 The yield of xylose in acid hydrolysis of lignocellulosic
a b-anomer or it is furanose or pyranose form. It is known that biomass and hemicelluloses (Table 2 in ref. 20)
the b-anomers react faster than a-anomers.21 Furthermore, the
Biomass Acid Temp/1C Time/min Yield (%)
rate of acid hydrolysis is faster for furanose compared with
pyranose, thus indicating that arabinose undergoes easier Wheat straw TFA 99 420 80
hydrolysis than xylose.22 The reason for the faster furanose Wheat straw TFA 99 1380 70
Wheat straw HCl 99 120 73
Wheat straw H2SO4 90 720 97
Table 1 The percentage of hemicellulose in wood20 Rice straw H2SO4 145 20
Rice straw H2SO4 121 27 77
Hemicellulose Hardwood Softwood Corncob/corn stover H2SO4 140 50 81
Corn stover H2SO4 180 0.67 80
Methylglucuronoxylans 80–90 5–15 Sugarcane bagasse H2SO4 160 15 88
Arabinomethylglucuronoxylans 0.1–1 15–30 Sugarcane bagasse H2SO4 140 20 83.3
Glucomannans 1–5 1–5 Sugarcane bagasse H2SO4 120 60 80
Galactoglucomannans 0.1–1 60–70 Eucalyptus chips H2SO4 140 10 21.18
Arabinogalactans 0.1–1 1–15 Poplar H2SO4 180 1 80
Other galactans 0.1–1 0.1–1 Arpen wood H2SO4 140 16 76.4
Pectins 1–5 1–5 Oak hardwood H2SO4 150 83

This journal is c The Royal Society of Chemistry 2012 Catal. Sci. Technol.
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hydrolysis of hemicellulose more difficult than that of pure It was found that a chromium-based process offers an
xylan. Although, cellulose hydrolysis with solid acid catalysts advantageous route from pentoses and pentosans to furfural.
has been reported,35,36 methods for one-pot conversion of solid Based on initial studies by Binder et al. xylose conversion into
hemicelluloses (without any pre-treatment) into xylose, arabinose furfural by using combination of chromium(II) or chromium(III)
and furfural using solid acid catalysts (HZSM-5 and HUSY zeolites salts and HCl cocatalyst results in moderate yields via isomeriza-
with 0.5 to 0.74 nm pore diameters, layered clays, aluminum tion and dehydration. This dual catalyst has been used for the
incorporated mesoporous silica Al-MCM-41, Al-SBA-15) in xylose and xylan conversion in N,N-dimethylacetamide containing
aqueous medium are also known.37 As per the results and claim, lithium chloride (DMALiCl) and related solvents.48 Halide
the method is also capable of selectively converting just the additives (LiCl, LiBr etc.) were found to be effective for the
hemicelluloses in lignocellulosic biomass using solid acid catalysts. xylose conversion, affording a maximum yield of furfural
A reaction using 1 wt% sulphuric acid catalyst at 170 1C produced (56%) with CrCl2 (6 mol%) in DMA containing 10 wt% LiBr
50% xylose + arabinose and 10% furfural in 1 h, however, a in 4 h at 100 1C. Analysis revealed a first-order dependence of
maximum of 41% xylose + arabinose was achieved at 170 1C in furfural formation on xylose concentration and half-order
Published on 01 June 2012 on http://pubs.rsc.org | doi:10.1039/C2CY20235B

3 h with HUSY (Si/Al = 15) catalyst. In this solid catalyzed dependence on CrII concentration, indicating direct involvement
process, maximum 12% furfural can be obtained when using of Cr in the process. Kinetic analyses and deuterium-labeling
HUSY (Si/Al = 15) and K10 montmorillonite clay catalyst. The experiments supported hydride-shift mechanism involving
higher yield of xylose + arabinose with sulfuric acid compared to chromium for xylose isomerization through a 1,2-hydride
HUSY (Si/Al = 15) can be explained by the fact that while sulfuric shift by forming xylulose, a reactive ketose intermediate that
acid releases 12 mmol H+ in the reaction mixture, HUSY releases dehydrates readily into furfural. More challenging xylan
0.165 mmol H+ under the reaction conditions. conversion into furfural, however, afforded 25% furfural,
and 22% from corn stover even at the higher temperature of
140 1C and with HCl as a cocatalyst.
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4. Homogeneous catalytic strategy Zhao et al. obtained furfural from xylan in 63% yield with
Conversion of pentoses into furfural has been a well-explored CrCl3 catalyst in ionic liquids under microwave-assisted heating
process.38–40 The process invented by Quaker Oats employs a at B200 1C and later extended this method for real biomass corn
dilute sulfuric acid catalyst and stream pressure, achieving stalk, rice straw, and pinewood.49 Furfural yields from these
50% molar yields of furfural from xylan.41 Most industrial biomass variants were only 23–31%, including significant humin
processes reported similar yields, likely limited by side reactions formation. Solid residues (humins) have been a challenge for
such as homopolymerization and condensation with unreacted Jones et al. reported acid-catalyzed production of furfural from
xylose. Furfural can be produced from the dehydration of xylose in 1-butyl-3-methylimidazolium chloride ([BMIM]Cl) in
xylose by using Brønsted acids, such as HCl and H2SO4.42–44 the presence of Brønsted acid H2SO4.42
However, these mineral acids are limited by the fact that they In search of a new catalyst that would potentially replace
cause corrosion, safety problems, and require critical reaction the industrially used mineral acid catalysts, recent studies
conditions. Very recently, homogeneously catalyzed process of in aqueous–organic biphasic media showed new directions.
furfural synthesis from the pentose sugars and hemicellulosic Earlier, for sugar dehydration, metal chlorides (CrCl2, ZnCl2,
biomass has been investigated and will be the subject of the FeCl3) have been assessed in non-aqueous deep-eutectic
discussion herein. solvents such as chlorine chloride fructose mixtures50 as well
Dehydration reactions play vital roles in liquid-phase catalytic as in monophasic aqueous media.51,52 A biphasic medium
processing and aqueous phase reforming to produce jet and composed of aqueous solution of FeCl36H2O and NaCl
diesel fuel range alkanes from biomass-derived oxygenated combined with biomass derivable 2-methyltetrahydrofuran
hydrocarbons.45,46 Furfural is a feedstock to make gasoline, (2-MTHF) phase has been demonstrated as an effective
diesel, or jet fuel47 and a kinetic model for the dehydration of biorefinery strategy for xylose dehydration (Fig. 2) by Leitner
xylose in biphasic reaction using a homogeneous catalyst and Maria et al.53 This method exhibited a maximum of 71%
(Scheme 2) depicts the overall scheme. Furfural and xylose can furfural yield in the presence of 20 wt% of NaCl additive.
react together to form undesired solid humins, highly polymerized When 2-methyltetrahydrofuran (2-MTHF) was used as an
insoluble carbonaceous species. Self-reaction of furfural also can extractant, the authors reported an extraction of 98% furfural
result in solid humins. by enhancing the furfural production in aqueous phase.
Gratifyingly, in this case the direct use of seawater comprising
different salts with FeCl36H2O also resulted in an improved
furfural production rate. Conversion of nonpurified xylose
effluents e.g. beech wood (particle size 0.5 to 0.1 mm) in
biphasic water/2-MTHF using oxalic acid as catalyst to
furfural that has been performed also emphasizes the potential
of FeCl36H2O as catalyst.54
Similar to the iron system, AlCl36H2O was employed as catalyst
in biphasic water–THF medium at 140 1C giving 499% xylose
conversion with the formation of xylulose as intermediate with
maximum 30% furfural yield in 5 min.55 AlCl36H2O was
Scheme 2 Xylose dehydration in aqueous phase. also effective for the conversion of lignocellulosic biomass

Catal. Sci. Technol. This journal is c The Royal Society of Chemistry 2012
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order Cl 4 Br 4 I; on the other hand, selectivity, and


thus furfural yield, are also improved by following the opposite
order I 4 Br 4 Cl in aqueous acidic solution.59 Highest
yield (87.5%) and selectivity (95.3%) of furfural was achieved
using a combination of KCl and KI due to the synergistic effect.

5. Solid catalysts
Unlike in the homogeneous regime, several factors such as
Fig. 2 Conversion of xylose to furfural in aqueous-2-MTHF biphasic preparation conditions of the catalyst, structural properties,
medium using iron catalyst starting from beech wood fractionation. and accessibility of acid sites are associated with the efficiency
(modified from Fig. 3 in ref. 53). of solid acid catalyzed conversion of xylose to furfural (Fig. 4).
Published on 01 June 2012 on http://pubs.rsc.org | doi:10.1039/C2CY20235B

For example, sulfonic acid functionalized ordered mesoporous


(corn stover, pinewood, switchgrass, and poplar), affording silica SBA-15 (Santa Barbara amorphous) with hexagonal array
different furfural yields due to species-dependent hemicellulo- or pores were prepared by both co-condensation and grafting
sic recalcitrance. methods, respectively. However, the grafting SBA-15-SO3H(G)
For commercial purpose, it is realized that the production of exhibits slightly weaker catalytic activity than the co-condensation
furfural (FuAl) from C5 sugars (i.e. xylose) suffers from the SBA-15-SO3H(C), possibly due to the less uniformly distributed
low concentrations of FuAl in the product stream due to sulfonic acid sites on the surface and within pore walls.60
the low xylose concentrations (12 wt%) obtained from Valente and co-workers have extensively studied the catalytic
hemicelluloses deconstruction.7,8,53 A new biorefining strategy activity of various solid acid catalysts for the dehydration of xylose.
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for converting the hemicellulose fraction of lignocellulosic These include modified mesoporous silicas,61,62 exfoliated aggre-
biomass to FuAl by utilizing biphasic systems that consist of gated nanosheets of metal oxides,63 sulfonated metal oxides,64 and
an extractive organic layer (2-sec-butylphenol) and an aqueous microporous silicoaluminophosphates (SAPO).65 Their studies
layer that contains a mineral acid has been demonstrated by revealed that a delaminated zeolite (Si/Al = 29) prepared from
Dumesic and co-workers.56 This biphasic system achieved lamellar precursor (Nu-6(1)) can be an efficient catalyst in
high concentrations of FuAl with maximum 75% yield and water–toluene biphasic media at 170 1C affording 47% furfural
82% selectivity. The use of alkylphenol solvents (Fig. 3) was yield.66 It is revealed that del-Nu-6(1) material could be a
advantageous because of (i) high partition coefficients for promising alternative to conventional zeolites or mesoporous
extraction of FuAl; (ii) not extracting significant amounts of materials for the production of furfural probably due to
mineral acids from aqueous phase; (iii) higher boiling points the easier accessibility of its active sites. Possibly, catalyst
than the final product; and (iv) the fact that they can be performance can be further improved by optimizing the Si/Al
derived from biomass (i.e., lignin). We envisaged the potential ratio and the delamination procedure.
of similar solvents (e.g. eugenol) which can also be extracted Advantage was taken of the extraction solvent for the
from certain essential oil (mainly clove oil) and found them to conversion of xylose to furfural catalyzed by mesoporous
be an efficient extracting agent when used in a biphasic molecular sieve MCM-41 in biphasic water/1-butanol media
aqueous–organic system in the presence of cellulose-derived and the strategy was further enhanced by addition of NaCl as
solid acid for xylose conversion. an auxiliary catalyst.67 The ability to efficiently execute the
A recent study demonstrated an efficient xylose and xylan dehydration step with solid catalysts in a biphasic regime could
conversion process with 72% furfural yield using maleic acid be beneficial from both economical and ecological points of view.
as catalyst in an aqueous medium at 200 1C.54,57 A kinetic That being said, there are still many unanswered questions
study also revealed that xylose degradation rates are lower in pertaining to the behavior of solid catalysts in aqueous medium.
aqueous medium which may be due to the reason that furfural An area of particular focus is the interfacial interactions between
plays the role of a Brønsted base, which reacts with H3O+,
thus decreasing the total acid concentration of the aqueous
system and slowing the degradation of xylose as proposed by
Antel et al.58 It was demonstrated that xylose reaction
rate increases by the addition of potassium halides in the

Fig. 4 Solid acid catalysts employed for the conversion of hemicellulose


Fig. 3 Effective extracting agents derived from lignin biomass. biomass to furfural.

This journal is c The Royal Society of Chemistry 2012 Catal. Sci. Technol.
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aqueous solutions and metal oxides. The metal oxide–water


interface is reactive due to a range of chemistries, including
acid–base, ligand exchange, and/or redox.68 In general, the
exposure of solid oxides to water gives rise to electrical charges
on the solid surface due to hydration effects that can involve
H+ and OH: ions from the bulk aqueous phase. Incomplete
coordination of the exposed metal or oxide ions at the solid
surface is the cause of this phenomenon. As a result, positive
and negative sites are present on the solid surface, and the
excess of one type of site determines the net charge. Contrary
to biomass conversion, solid catalysts in the oil and petro-
chemical industries are typically used in gas phase or in liquid
phase, where the reaction medium is usually non-polar.69 On
Published on 01 June 2012 on http://pubs.rsc.org | doi:10.1039/C2CY20235B

the catalyst surface, Brønsted acid sites (proton donors) can be


generated from highly polarized hydroxyl groups. Alternatively,
Lewis acid sites form coordinately unsaturated cationic sites,
which leave Mn+ exposed to interact with guest molecules as an
acceptor of an electron pair. Exposure of the catalyst to a polar Fig. 5 Naflon 117 with Brønsted and Lewis acidic sites and AFM
solvent such as water can potentially alter the intrinsic nature of image showing the smooth surface of the material before the reaction
the surface due to solvation effects. For instance, the hydroxyl (a) and after reaction (b). (AFM image is reproduced from ref. 73 with
permission, Copyright (2010) Wiley-VCH).
ion from the water molecule (Lewis base) can react with a Lewis
acid site (Mn+) on the surface to generate Brønsted sites.70
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Poisoning of the acid sites by water may also occur depending thermal stability under the xylose dehydration conditions.73
on the surface hydrophilicity/hydrophobicity of the catalyst.71 After 15 consecutive runs under the optimized reaction conditions,
With the objective of investigating the role of Lewis and the robust Nafion membrane remained intact with furfural yields
Brønsted sites in solid acid catalysts for the dehydration of ranging from 58 to 62% in 2 h at 150 1C in DMSO. Deprotona-
carbohydrates in aqueous media, it is desirable to maintain a tion of the sulfonic acid groups of Nafion 117 would deactivate the
high ratio of Brønsted to Lewis acid sites. This conclusion was catalyst by reducing the number of available acid sites for xylose
based on results of comparative catalytic activity for a series of dehydration. Nanoparticulate-sized organic residue deposits are
catalysts Zr–P, SiO2–Al2O3, WOx/ZrO2, g–Al2O3 and HY also responsible for covering up the smooth surface of the Naflon
zeolite for aqueous phase dehydration of xylose.72a Lewis acid as revealed from AFM study (Fig. 5(b)).73 Use of sulfonic acid
sites decrease furfural selectivity by catalyzing side reaction functionalized resin Amberlyst 70 as catalyst afforded 65% xylose
between xylose and furfural to form insoluble humins, e.g. HY conversion with B100% furfural selectivity, however, this process
zeolite due to strong irreversible adsorption of the furfural in challenges economics due to requirement of high xylose loadings.74
the pores, causing an increase in the rate of humin formation. In another approach, hydrothermally stable porous siliceous
Analysis also suggests that the catalyst with the highest materials containing solid silica core and porous silica shell were
number of Lewis acid sites was the most active. The catalyst investigated for the dehydration of xylose in aqueous media
pore confinement was found to have an adverse effect on furfural (Scheme 3). The modified mesoporous core–shell structured
selectivity. Adsorption–desorption studies in the aqueous phase silica (MSHS) spheres (260 nm diameter, solid core and shell)
and decomposition experiments with furfural in aqueous functionalized with sulfonic acid acted as an efficient catalyst
solutions have confirmed that HY zeolite causes furfural to for the dehydration of xylose to furfural with higher selectivity
irreversibly adsorb in the zeolite pores and polymerize to form than the aluminosilicate.75
humic substances. Therefore, it can be concluded that a Sulfated tin oxide (SO42/SnO2), with the SO42 group on
micropore containing catalyst may not be suitable for xylose SnO2 exhibited superior catalytic activity in producing furfural
dehydration due to strong adsorption of the product in from xylose.76 An aqueous phase cyclodehydration of xylose
the catalyst pore. Dehydration of xylose using ion-exchange was carried out using a composite material consisting of
polymer resins (Naflon SAC-13 and Amberlyst 70) with strong zeolite Beta (BEA) nanocrystals (Si/Al = 12) embedded in a
Brønsted acidic sites showed similar furfural selectivity to pure siliceous TUD-1 mesoporous matrix (BEATUD) at 170 1C.
Zr–P and HCl. This confirms that furfural selectivity is a direct A significantly higher xylose conversion to furfural was noted
function of the Brønsted acid sites concentration. Ebitani et al. with the BEATUD catalyst than that with the BEA catalyst as
have reported high yield of furfural and 5-hydroxymethylfurfural the former contained a lower amount of carbonaceous matter
(HMF) from xylose and polysaccharides, respectively, in their and hence favourable for an efficient adsorption caused by the
one-pot synthetic approach using Amberlyst-15 and hydrotalcite surrounding silica matrix.77 Fine tuning of the Si/Al ratio
catalysts.72b–c These furfurals are also efficiently synthesized might change the total amount of acid sites and surface
using tin–tungsten mixed oxide catalyst.72d polarity which may affect the dispersion and the total number
Ion-exchange membrane Nafion 117 (Fig. 5), a sulfonated of accessible acid sites of the zeolite.
tetrafluroethylene based fluropolymer-copolymer, as robust Carbonaceous materials are promising catalysts due to their
and reusable catalyst is promising in terms of economical high surface area and hence provide adequate catalytic active
furfural production as this possesses excellent chemical and sites. Sulfonated graphene oxide (SGO) has been demonstrated

Catal. Sci. Technol. This journal is c The Royal Society of Chemistry 2012
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Fig. 6 (a) Sn-beta-zeolite structure derived from EXAFS in which


the pair of Sn (red) atoms occupies opposite vertexes of the six-
member rings. (Reproduced from ref. 82 with permission, Copyright
(2005) American Chemical Society.) (b) Proposed active site of Sn-
beta-zeolite. (c) Proposed intermediate 1,2-hydride shift at the active
site.
Published on 01 June 2012 on http://pubs.rsc.org | doi:10.1039/C2CY20235B

xylose isomerizes to xylulose with a Lewis acid catalyst


advocating for dual acidic sites of a catalyst. Formation of
xylulose is a key step to furfural and requires either functional
group rearrangement or a configurational change around the
Scheme 3 Mesoporous silica bead with solid core and mesoporous
C1 and C2 carbon atoms. Structural studies using an X-ray
shell for catalytic cyclodehydration of xylose to furfural (reproduced
absorption fine structure (EXAFS) technique reveals that Sn is
from ref. 75, Copyright (2011) Elsevier).
substituted in pairs on opposite sides of six-membered rings,
i.e. uniform crystallographic location of Sn in the b crystal
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to be a rapid and water-tolerant carbocatalyst at a low catalyst


structure that leads to sites with uniform catalytic activity and
loading at 200 1C with an average yield of 61% furfural from
high chemical selectivity (Fig. 6).82 The results of the Sn-beta
xylose.78 Surface area analysis and reaction results suggested
zeolite catalyzed process indicate that the active site of the
that the aryl sulfonic acid groups were the key active sites for
catalyst interacts with the carbonyl group of C1 and the adjacent
high temperature production of furfural in water. In all four
hydroxyl group on C2. Kinetic studies of isomerization reactions
cases (grapheme, grapheme oxide, sulfonated grapheme, and
indicate that certain acids and metals are able to transfer the
sulfonate grapheme oxide), the materials exhibited sheet-like
hydrogen directly through a hydride shift between C-2 and C-1.83
appearances (TEM study), despite the presence of oxygen-
Lewis acidity in the catalyst is essential to polarize the carbonyl
bearing and SO3H functional groups that might disrupt the sp2
group in the ketone while also coordinating both the alcohol and
carbon network in GO, SGO and SG among which SGO contains
the ketone to facilitate a hydride shift between them.84 It is
large surface area (680 m2 g1). High stability of the C–C bond
therefore plausible that Sn in zeolite Beta performs the isomer-
anchoring arylSO3H groups is responsible for the catalytic
ization reaction followed by an intramolecular hydride shift
activity, and remains active after repeated reactions at 200 1C.
between the carbonyl-containing C-1 and the hydroxyl-bearing
Direct evidence of isomerization of xylose to xylulose followed
C-2 of glucose by way of a 5-member complex.
by dehydration to furfural parallels the conversion of hexoses,
Important factors in the Sn-beta isomerization of glucose in
for example, the isomerization of glucose to fructose followed by
aqueous media include the role of the solvent, the confinement
dehydration to HMF.79a Moliner et al. have investigated the
and polarity effects within the micropores of the zeolite,
isomerization of glucose to fructose using the Sn-beta zeolite with
and the impact of the coordination state of the Sn atom on
yields comparable to biological catalysis (Scheme 4).79b,80 By
the framework as either partially hydrolyzed framework
combining the Sn-beta zeolite (Lewis acid) with a Brønsted acid
Sn centers (–Si–O–)3Sn–OH or fully framework coordinated
(Amberlyst-15), furfural can be prepared from xylose via the
Sn atoms Sn(–Si–O–)4.
xylulose intermediate at 120 1C in aqueous medium.81
It was shown that in the presence of organic solvent, para-
A 60% conversion of xylose with a 27% xylulose yield at
xylene, the aqueous phase hydrolysis of hemicelluloses with
100 1C prompted us to investigate the role of Sn-beta zeolite. It
H-Beta (Si/Al = 19) and HUSY (Si/Al = 15) catalysts
was found that xylose does not react with Amberlyst-15
increased the furfural yield from 18% to 56%.85 A comparative
or HCl at low temperatures; however, when xylulose is
analysis of the catalytic performance indicates that high surface
the reactant, conversion is B66%, and furfural yield is 24%.
and easy accessibility of the acidic sites are the key factors for
This result supports a reaction network in which xylulose
efficient xylose to furfural conversions. Despite new develop-
dehydrates rapidly to furfural via Brønsted acid catalysis and
ments described above, the cost and energy expense of furfural
production and recovery requires significant improvement by the
use of efficient solid catalyst and superior extracting media.

6. Furfural upgrade to fuels


Furfural is considered as a platform chemical for the produc-
Scheme 4 Sn-beta zeolite catalyzed furfural synthesis via xylose tion of liquid hydrocarbons86 and gasoline additives such as
intermediate. 2-methyltetrahydrofuran (2-MTHF).87 Hydrogenation remains

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the most versatile reaction to upgrade furanic components to


biofuels. For instance, it can lead to promising gasoline blends
including 2-methylfuran (2-MF), 2,5-dimethylfuran (DMF)
and 2-methyltetrahydrofuran (2-MTHF).88,89 Synthesis of
biofuel components, including DMF from biomass and
Scheme 5 Conversion of furfural into EL by catalytic hydrogenation
biomass derived carbohydrates via HMF platform chemical and ethanolysis in acid conditions.
has received significant attention in the recent years.87,90a,b The
literature report suggested that selective conversion of furfural
(95%) to 2-MF can be achieved by using Cu catalysts at high solid catalyst methylimidazolebutylsulfate phosphotungstate
temperature (200–300 1C) under the condition of H2/furfural ([MIMBS]2PW12O40) affording a high yield of n-butyl levulinate
molar ratio of 5–8.90c The reaction proceeds through (93%).102 As revealed, the mechanistic route of the alcoholysis of
the formation of furfuryl alcohol (FAlc) as intermediate. the furfuryl alcohol involves the formation of a-angelica lactone
Raney-Cu, Cu/Al2O3 and Cu-chromite showed similar and oxonium ion which then turns into alkyl levulinates.103
Published on 01 June 2012 on http://pubs.rsc.org | doi:10.1039/C2CY20235B

behavior, although the latter was more active and stable. Sen and Yang have demonstrated that pentose sugars and
However, the catalysts deactivated rapidly and regeneration lignocellulosic biomass (e.g. corn stover) can be converted into
process at 400 1C was energy expensive. Carbon-supported 2-methyltetrahydrofuran (2-MTHF) by employing a soluble
Cu-chromite was found to be selective for 2-MF, however, robust rhodium catalyst and HI/HCl + NaI additive in the
deactivated within a few days.91 In a recent study, furfural was presence of H2.87,104 Using corn stover (glucan 40.1% and xylan
hydrogenated over a Cu/Fe catalyst in gas phase with 99% 24.1%) as feed, maximum 63% 2-MTHF yield was achieved. Even
conversion and 98% selectivity in 2-MTHF.92 2-MTHF was though the process is uneconomical due to the use of expensive
also obtained via hydrogenation of furfural over the Cu-based rhodium salt, corrosive acids, and dihydrogen, lignocellulosic
catalyst in the vapor phase.93 In the case of 2-MF synthesis, a pretreatment, enzymatic hydrolysis of cellulose/hemicelluloses,
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rapid deactivation of the catalyst was observed in gas-phase to obtain sugars is simplified to obtain 2-MTHF as the final
hydrogenation which triggered the necessity of a process at product. Previously, 2-MTHF was synthesized by the coupling
milder temperature and in liquid phase. Nudelman et al.94 of the dehydrogenation of cyclohexanol and the hydrogenation
described the hydrogenolysis of furfural to 2-MF and of of furfural over the Cu–Zn–Al catalyst with optimal hydrogen
5-methylfurfural to DMF, using Pd supported on carbon utilization.105 In vapor phase hydrogenation of furfural to
(Pd/C) at room temperature and 0.2 MPa H2. Sun et al.95 2-methylfuran (2-MF), unselective formation of several furan
reported a polymer-supported PdII complex that catalyzed the products including 2-MTHF was recorded.106 Similarly, 2-MF
hydrogenolysis of furfural to MF. and 2-MTHF were obtained as a mixture of products from
Ethyl levulinate (EL), being known as a potential fuel super critical carbon dioxide (scCO2) mediated continuous-flow
additive with a boiling point of 206 1C, is a novel diesel hydrogenation using a commercial catalyst containing copper
miscible biofuel usually produced by esterification of levulinic chromite and Pd/activated C.107 Liquid phase hydrogenation of
acid (LA) in ethanol.96,97 Traditionally, the formation of EL furfural was also attempted with the NiMoB/g–Al2O3 catalyst
depends on the yield of levulinic acid obtained from biomass affording furfuryl alcohol as a major product.108
by the treatment with aqueous mineral acid (H2SO4 and HCl) In a recent study, the vapor phase conversion of furfural
at 100 1C which provided maximum 40% yield of LA.98 The with SiO2-supported Ni and Ni–Fe bimetallic catalysts in the
same was improved to 60–70% by continuous flow conditions presence of H2 (1 bar) demonstrated a significant deviation in
at higher temperatures and pressure using H2SO4 as catalyst activity. When monometallic Ni catalyst favors formation of
associated with complicated work-up during the separation.99 furfuryl alcohol and furan as primary products via hydrogena-
However, furfural to ethyl levulinate conversion via hydro- tion and decarbonylation, the Ni–Fe bimetallic catalyst
genation to furfuryl alcohol over copper-based catalysts and formed 2-MF as a major product via C–O hydrogenolysis of
subsequent ethanolysis in the presence of strong acids has been furfuryl alcohol.109 In this case, addition of Fe suppresses the
reported (Scheme 5).100 decarbonylation activity of Ni while promoting the CQO
Furfuryl alcohol derived from furfural was then converted hydrogenation (at low temperatures) and the C–O hydro-
to EL by the use of several strong acidic resins on a sulphonated genolysis (at high temperatures). DFT analysis of the possible
polystyrene framework (Amberlyst) and zeolites as solid acid surface species on the mono- and bimetallic surfaces suggests
catalysts since these are known to sustain cock burnt-off during that the differences in selectivity displayed by these catalysts
regeneration.101 The optimum result was achieved by balancing can be attributed to the stability of the Z2-(C,O) surface
the number of acid sites with their accessibility in the resin. The species, which is higher on the NiFe than on pure Ni. As
data presented by authors showed that the efficiency of the acid a result, Z2-(C,O) species can be readily hydrogenated to
catalysts decreases in the following order: H2SO4 4 macro- furfuryl alcohol and subsequently hydrogenolyzed to 2-MF
reticular resins 4 gel resins 4 zeolites. This ranking, however, on the bimetallic alloy due to a strong interaction between the
appears to result from two critical catalysts parameters, carbonyl O and the oxyphilic Fe atoms. On the pure Ni
namely, the acidity of the catalyst and the accessibility of its surface, Z2-(C,O) species can be converted into a surface acyl
acid sites. Good accessibility of the acid sites, for example, species, which can be decomposed to produce furan and CO.
through surface sulfonation as in the case of Amberlyst 46, DFT calculations for geometries and relative stabilities of the
seems therefore favorable. Furfural platform has been further possible furfural species on the catalyst surface showed the
upgraded to alkyl levulinate by the use of a novel hybrid difference in heats of adsorption and bond lengths of furfuryl

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Scheme 6 Sylvan diesel process. First, one molecule of 2-MF is


hydroxyalkylated by an aldehyde and the corresponding product
Published on 01 June 2012 on http://pubs.rsc.org | doi:10.1039/C2CY20235B

alkylated a second sylvan molecule resulting a precursor which on


subsequent hydrodeoxygenation produces alkanes.

2-MF because one of the two reactive carbons (2-positions) is


blocked by a methyl group preventing the polymerization of
Fig. 7 Optimized structures of furfuryl alcohol dissociatively adsorbed
2-MF with aldehydes. Hydrodeoxygenation of a C15 diesel
on the Ni(111) surface (a) and the NiFe(111) surface (b). Side view of
precursor with a mixture of Pt/C and Pt/TiO2 catalysts gave
surface and gas-phase hydroxyalkyl intermediate structures are shown
in (c) and (d), respectively. (Reproduced from ref. 109 with permission,
6-butylundecane as the main product (Scheme 6), which can be
Copyright (2011) Elsevier.) blended directly with fossil-derived commercial diesel.
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alcohol adsorbate by considering both upright and planar


7. Summary and outlook
configuration of furfural on Ni(111) and bimetallic NiFe(111)
alloy surface. Consistent lengthening of the C1O1 bond of the So far in this contribution, we have been engaged in a
furfural species on the Ni–Fe(111) bimetallic surfaces compared short discussion on hemicellulose structure and results of the
to that on pure Ni (1.433 vs. 1.377 Å) afforded higher CO hydrolysis of lignocellulosic biomass to obtain pentose sugars,
hydrogenolysis rate. DFT analysis on Ni(111) and bimetallic e.g. xylose, a feedstock for furfural on industrial scale. Strategies
NiFe(111) by considering a hydroxyalkyl intermediate for the homogeneously catalyzed process have been explored for
(C5H4O(OH)) that is expected to result from the dissociative xylose conversion using an acid catalyst and a powerful extrac-
adsorption of furfuryl alcohol (C5H5O(OH)) (Fig. 7) indicates tion solvent. However, significant development has been made
that the CO hydrogenolysis is much faster with furfuryl with the materials design, synthesis and their application for the
alcohol than with furfural; so, it is possible that the formation xylose dehydration to furfural in aqueous and organic media.
of 2-MF goes through an alcohol intermediate. Typical time scales for many solid catalysts are in the order of
Inspired by this method, we have investigated the synthesis hours, leading to limited space time yields. In most cases, large
of 2-MF via liquid phase hydrogenation of furfural and scale utilization of lignocellulosic biomass containing significant
furfuryl alcohol using the Ru/C–formic acid catalytic system hemicellulosic components will need to be addressed in
under mild conditions in tetrahydrofuran (THF). The process the following years since there is limited development in
is also clubbed with a dehydration step of pentose sugar (xylose) in this direction with both homogeneous and solid catalysts.
the presence of Brønsted acidic ionic liquid [DMA]+[CH3SO3].110 Xylose dehydration into furfural has an activation barrier of
Similar strategy has also been extended for a bimetallic catalyst B30 kcal mol1,114 and hence it is carried out at high
(Pd–Ru/C) with promising outcomes and would be the subject temperatures (4150 1C) in aqueous medium. Under these
of upcoming contribution. This attempt is the extension of our conditions, the furfural yield is B30% when carried out in a
recent efforts for a sustainable one-pot synthetic protocol for single-phase system, and the same has been further improved
hydrogenation–hydrogenolysis of HMF to gasoline blendstock, (71–78%) by developing continuous extraction processes,115,116
DMF, using the Ru/C–formic acid catalytic system.111 using extracting solvents such as alkylphenol and 2-methyl-
A remarkable synthesis strategy to derive branched hydro- tetrahydrofuran which can be derived from biomass feedstocks.
carbons with ten to eighteen carbon atoms within the diesel Recently homogeneously catalyzed processes have been
fraction was recently developed by Corma et al. by using the developed with chloride salts including (FeCl66H2O and
furfural platform derived 2-MF as a building block.112 2-MF AlCl36H2O) in aqueous–organic biphasic medium in line with
is derivable from hemicelluloses and available as raw material the fact that Cl promotes the formation of 1,2-enediol from
on an industrial scale. An oxygenated C13 fuel precursor was acyclic form of xylose and subsequent dehydration from an
derived by condensation of 2-MF with acetone, which was aqueous acidic solution.117 However, processes that are more in
then hydrodeoxygenated into a C12/C13 mixture (Scheme 6).113 line with green chemistry principles and are of higher furfural
However, in the presence of Brønsted acid catalysts the selectivity are still needed. Towards the application of furfural
reaction medium became sufficiently acidic that it produced platform for the synthesis of hydrocarbon and furanic fuels,
ring-opening of 2-MF, allowing a trimerization to produce a combined efforts for efficient production of furfural via both
C15 diesel precursor. Trimerization is possible in the case of homogeneous and solid catalytic method must be improved.

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1. The mineral acid catalyzed industrial process of furfural is carried out over homogeneous and solid catalysts and coupled
must be replaced with an environmentally sustainable process to other reactions for a better utilization of the feedstock.
towards which limited developments have been made. Ionic Hemicellulosic fraction of lignocellulosic biomass is the best
liquid catalyzed xylose dehydration to furfural and subsequent source for pentose sugars and it does not compete with food
molecular level monitoring of the process using 1H NMR supply. However, these materials are resistant to chemicals
spectroscopy is something yet to be investigated. In spite of transformation. Current practice has demonstrated that there is
tremendous interest in this topic, mechanistic studies on ionic indeed promise. Transformation of sugars into transportation
liquids are rather complicated due to the lack of a powerful fuels and chemical commodities has received much more
analytic tool. Though many investigations have claimed to attention. In the long term, however, the success of the
reveal the mechanistic nature of hexose to 5-hydroxymethyl- biorefinery concept also depends on the development of
fural conversion via cyclic and acyclic routes in aqueous and energetically efficient processes to convert lignocellulosic
organic solvents,118,119 such studies are missing for the pentose biomass directly into biofuels.
sugars to xylose conversion except in limited cases where
Published on 01 June 2012 on http://pubs.rsc.org | doi:10.1039/C2CY20235B

xylulose intermediate has been proposed and estimated.51,80


A knowledge of mechanistic pathways of xylose conversion in Acknowledgements
aqueous or organic media is of principle importance to create The authors gratefully acknowledge financial support from the
efficient procedures, control of selectivity, and to restrict side University Grant Commission (UGC), India. SD thanks UGC,
reactions leading to insoluble and soluble humins.120,121 The India, for a DS Kothari Postdoctoral Research Fellowship.
goal of our future research is to understand the mechanistic
nature of xylose to furfural at the molecular level. We believe
in an NMR scale reaction, running the process in the NMR Notes and references
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