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Abstract
The oxidation of benzoic acid (BA) to phenol (the Dow Phenol Process) has been studied in high temperature water (HTW) using a continuous
flow system over various metal oxide heterogeneous catalysts: NiO, CuO, Carulite® , MnO2 and Al2 O3 . Excellent selectivities (>99%) and good
yields for phenol (up to 70%) were obtained. The reaction conditions were optimised by varying the temperature, the pressure and the effect
of O2 . Experiments were carried out for sustained periods in order to study the catalyst deactivation. The results are presented in most of the
cases in dynamic conditions; results observed versus time-on-stream for each catalyst tested. Carulite® 300 catalyst was the most effective with a
good activity/robustness over time-on-stream. Activity and regeneration of the catalyst with oxygen is reported. Overall HTW shows considerable
potential as a medium for this process. Possibilities for extending this chemistry are discussed.
© 2006 Elsevier B.V. All rights reserved.
Keywords: Benzoic acid; Phenol; High temperature water; Oxidative decarboxylation; Heterogeneous catalysis; Carulite®
0896-8446/$ – see front matter © 2006 Elsevier B.V. All rights reserved.
doi:10.1016/j.supflu.2005.12.012
J. Fraga-Dubreuil et al. / J. of Supercritical Fluids 39 (2006) 220–227 221
this reaction is copper with various metal promoters, supported The gas phase oxidation of BA to phenol has been performed
on carriers, e.g. alumina or kieselguhr [6–8]. Selectivities are with O2 over heterogeneous catalysts in the presence of H2 O as
70–90% with yields of phenol of up to 50% per pass. Some steam [6–12]. However, the main challenge for any HTW pro-
researchers have obtained even better results using NiO-based cess is to find heterogeneous catalysts which are stable under
catalysts with high selectivities and conversion of BA [9,10]. the harsh conditions of HTW [23,24]. The most promising sys-
There have also been reports that the use of promoters such as tems are transition metal oxides, especially for oxidations [25]
Na2 O [11] or V2 O5 [12] can improve the activity and the sta- because metal oxides can be very stable and, indeed, can be
bility of the catalyst. However, acceptable selectivities can be synthesized in HTW [14,15].
only obtained if the catalysts have been properly prepared by There are relatively few papers reporting heterogeneously
calcination. catalysed selective oxidations in HTW compared the huge num-
The properties of sub- and supercritical water (Tc = 374 ◦ C, ber on total oxidations (gasification) [26]. The thermal decar-
pc = 22.1 MPa) are unique [13] and have attracted the attention of boxylation of the isomeric dicarboxylic acids has been studied in
many scientists for developing more sustainable and alternative HTW [27] and, very much in the tradition of Professor Franck’s
processes in organic synthesis as well as in the field of nanoma- pioneering work, the decarboxylation has been monitored by
terials [14,15]. For instance, in the area of selective oxidation of Raman spectroscopy [16,28]. In this paper, we investigate the
methyl aromatics to their corresponding carboxylic acids, our oxidation (oxidative decarboxylation) of BA to phenol over a
research team [16–18] and other groups [19] have demonstrated selection of different metal oxide heterogeneous catalysts in
many advantages in using high temperature water, HTW, as a HTW.
reaction medium. The oxidation of toluene to BA in supercriti-
cal water has been described using MnBr2 as catalyst via a batch 2. Experimental
experiment to give a BA yield of 63% [19a].
The study of the oxidation of toluene to phenol in HTW would 2.1. Apparatus and procedure
be attractive because, traditionally, toluene is oxidised to BA in
the liquid phase at a temperature between 90 and 200 ◦ C using Reactions were carried out using a tubular continuous flow
homogeneous Co/Br catalyst, sometimes in combination with reactor at Nottingham. Because the maximum solubility of BA
Mn/Br [20,21]. An organic solvent such as acetic acid is often in H2 O at ambient conditions is ca. 3400 ppm, a concentration
needed and the reaction requires relatively long residence times of 2500 ppm was chosen to avoid precipitation during pumping
(0.5–3 h). Oxidation in the vapor-phase has also been reported the organic feed. The reactor configuration in Fig. 1 was set up
using heterogeneous catalysts [22]. However, for both liquid and to accommodate a fixed-bed catalyst in 15 cm of 1/2 in. tubing
vapor-phase, the selectivity to BA is sometimes unsatisfactory. with a maximum allowable pressure and temperature of 30 MPa
Fig. 1. Flow scheme for HTW oxidation of BA to phenol using a heterogeneous catalyst. Temperatures in the reactor were measured by in situ Inconel® thermocouples,
one measuring HTW at the exit of the pre-heater (T2), one in the cross-piece (T3) and another one at the outlet of the reactor (T5). They were monitored and recorded
along with pressures using PicoLogTM software. Apart from the main reactor, the rest of the equipment was similar to the one that has been previously described [16]
(pressure relief valve, PRV, heaters, cooler, filters and Tescom® back pressure regulator, BPR). A cold stream of BA in water was mixed with HTW (water which has
been pre-heated as in the oxidation of xylenes) via a cross-piece M before passing through the heterogeneous fixed-bed catalyst. The H2 O2 solution was pumped
into the system and decomposed in a pre-heater under the required experimental conditions to generate a homogeneous mixture of O2 and HTW [29].
222 J. Fraga-Dubreuil et al. / J. of Supercritical Fluids 39 (2006) 220–227
Table 1
Effect of temperature, pressure and amount of CuO catalyst on the selectivity and yield of phenol
1 200 25 92 0 0 –
2 350 25 75 0 12 >99
3 360 25 69 0 13 >99
4 370 25 63 0 12 >99
5 380 25 66 6 10 64
6 390 25 70 4 11 72
7c 340 14 30 0 24 >99
8d 340 20 52 0 28 >99
9e 340 20 96 0 2 >99
10f 340 20 82 0 3 >99
a All reactions were carried out using the following flow rates: F
water = 4.5 mL/min, Forg = 1 mL/min except for entries 7–10, Fwater = 5 mL/min. Entries 1–7: 4.4 g
CuO, entry 8: 6 g CuO.
b Yields and selectivities of product(s) calculated via HPLC as mean of samples collected in sequential periods of 4 min every 10 min.
c Optimum yield obtained after 140 min, presence of 4 equiv. O .
2
d Optimum yield obtained after 160 min.
e No catalyst.
f 3.6 equiv. O , no catalyst.
2
on the catalyst surface before producing phenol. Following the by hydrolysis to phenol. A second paper [10] proposed a nucle-
induction period, the catalyst did not show appreciable deacti- ophilic aromatic substitution of hydrogen by an oxygen ion,
vation over 2 h. The highest phenol yields were obtained when or more probably the formation of a peroxoacid, which would
more catalyst was employed (6 g rather than 4.4 g) (entry 8 result in the formation of phenol after oxygen transfer to the
and Fig. 3). The optimum balance of selectivity to phenol and ortho position and subsequent decarboxylation.
carbon loss is observed at ca. 340 ◦ C and 20 MPa. X-ray diffrac-
tion (XRD) analysis of the CuO collected after the experiments 3.3. Carulite® —CuO and MnO2 supported on Al2 O3
showed that Cu(II) has been reduced to Cu(I) (as Cu2 O), support-
ing a mechanism in which oxygen from the catalyst participates Commercial Carulite® catalysts have been used for catalytic
in the reaction. partial [30] or total [25,31] oxidation of organic materials. These
Two mechanisms have previously been suggested for the catalysts are composed of 40–60% MnO2 and 1–3% CuO, sup-
catalysed oxidation of BA by CuO and by NiO catalysed oxi- ported on X-ray amorphous Al2 O3 . An initial experiment was
dation of BA. In one mechanism [5c], the reaction involves the carried out over 6 g of ground pellets (1–2 mm diameter) of
formation of a copper dibenzoate intermediate, which is con- Carulite 300® at 14 MPa and 340 ◦ C in presence of 18% molar
verted to a phenylbenzoate or benzoylsalicylic acid, followed NaOH (Fig. 4) because Miki et al. [11] have reported that the
reaction can be promoted by addition of Na2 O via the formation
of sodium benzoate. As the reaction proceeded, phenol yields
increased, reaching a maximum of 65% at 134 min with selectiv-
ities between 90 and 95%. However, after 160 min, the activity of
the catalyst began to decrease gradually; the reaction produced
about 5–7% benzene and BA recovery increased.
After 280 min, the BA feed was stopped and only oxy-
gen (H2 O2 solution) was pumped (100 equiv. O2 based on the
organic flow which had previously been fed) under the same
conditions of T and p. When the BA feed was restarted, the phe-
nol yield reached 70% and selectivities were again very high
(∼95%). This regeneration can be understood if we assume that
CuO is the active component of the catalyst. Then, our results are
consistent with Cu(II) being gradually reduced and BA adsorp-
tion on the catalyst becomes less as the oxygen of the catalyst is
consumed in the reaction (CuO to Cu(II)benzoate and then for-
mation of Cu(I)benzoate). It seems clear that Cu(II)O has been
regenerated in presence of O2 from Cu(I)benzoate or Cu2 (I)O Fig. 6. Continuous oxidation of BA to phenol over Carulite 300® (6 g) at 350 ◦ C
and 20 MPa. Number of O2 equivalents injected in the system: (a) 11.2; (b) 112;
formed during the process, and furthermore, it seems that the (c) 0.9; (d) 0.45; (e) no O2 . Phenol yield and ♦ BA recovery.
reactivation was complete.
The experiment was repeated in the absence of NaOH, but the
reaction appeared to be less efficient. The highest yield achieved Fig. 6 shows a longer run to study the catalyst lifetime and
was 46% and the selectivity to phenol decreased from 90 to 60% the effect of O2 concentration on its regeneration at 350 ◦ C and
as the catalyst deactivated. This supports the results reported 20 MPa. Phenol selectivity was higher than 99% throughout the
previously concerning the benefit in forming sodium benzoate run since almost no benzene was produced. An induction period
in situ [11]. Unless justified by improved phenol yields, there are was again observed during which the BA was probably adsorb-
some disadvantages in performing the reaction at low pressure ing onto the catalyst leading to the increase of phenol yields to
(14 MPa): the phenol selectivity decreases and some benzene is almost 30%. After this induction, which was generally between
formed when the catalyst is deactivating. Therefore, we focused 1 and 2 h, the BA recovery increased up to about 80% while
on reaction pressures >20 MPa and in absence of NaOH in order the yield of phenol decreased very slowly to a steady value of
to prevent thermal decomposition at these conditions. 10–12% after a 10–11 h operation time. As soon as O2 was intro-
The experiment was repeated at 25 MPa and the effect of duced, even with the BA solution feed continuing, the recovery
varying the temperature (300–400 ◦ C) was studied in pres- of organic material dropped dramatically, suggesting that BA,
ence of 1 equiv. of O2 in order to maintain the catalyst activ- along with phenol is almost totally oxidised to gaseous carbon
ity. The results presented in Fig. 5 show that, if the tem- oxides. However, the catalyst was almost completely regener-
perature is >350 ◦ C, the phenol yields and BA conversion ated with the excess of O2 used (11.2 equiv.); when the oxygen
increase (up to 30% at 400 ◦ C). However, the phenol selec- feed was stopped and only water was pumped with the BA feed
tivity decreases with more benzene being formed. When the on, phenol was produced very quickly again and yields reached
temperature was lowered back to 300 ◦ C (337 min), our initial their previous levels. Similar results were obtained each time O2
results were reproduced with a phenol selectivity approaching was supplied. The only drawback was that organic material was
100%. totally oxidised by the excess of O2 during catalyst regeneration.
In an attempt to limit this over-oxidation, the reaction was
conducted with lower oxygen concentrations (from 0.9 to no
equivalent), so that an ideal compromise between catalyst reac-
tivation and organic breakdown could be found. The results show
that although O2 was supplied at only a low concentration, the
phenol yield decreased while the BA recovery increased. No
by-products such as benzene were observed. It seems that BA
which accumulated on the surface of the catalyst (as copper I or II
benzoate)—possibly along with the intermediates of the reaction
(for instance phenyl benzoate) and phenol—was decomposed to
carbon oxides when O2 was fed.
These results suggest that in presence of O2 the catalyst is
more active for total oxidation rather than the selective oxida-
tion of BA to phenol. This confirms previous observation on
the activity of CuO based catalysts for gasification of phenol in
Fig. 5. Effect of temperature on the continuous oxidation of BA to phenol over
HTW [25,31]. Thus, feeding BA and O2 simultaneously does
Carulite 300® (6 g) at 25 MPa in presence of 1 equiv. O2 . Note that the best
performance in terms of selectivity is observed at temperatures <350 ◦ C and not seem to be a fruitful strategy.
that the effects of temperature appear to be reversible. Phenol yield, phenol The experiment was repeated (350 ◦ C and 20 MPa) with a
selectivity, benzene yield and ♦ BA recovery. large amount of catalyst (8.3 g) and a longer run (15 h) was
J. Fraga-Dubreuil et al. / J. of Supercritical Fluids 39 (2006) 220–227 225
Table 2
Oxidation of BA to phenol over different metal oxides
Entrya T (◦ C) p (MPa) Catalyst O2 equiv. BA recovery (%) Phenol yieldb (%) Phenol selectivityb (%)
performed to establish the lifetime of a fresh Carulite® sample Bulk MnO2 and Al2 O3 , which are the main components of
in the absence of O2 (Fig. 7). We obtained a set of results similar Carulite® catalysts, did not individually display any catalytic
to before but, interestingly, phenol was produced in a higher activity in the reaction as no phenol was produced (entries 3 and
yield, 50%. This could be due to a larger amount of catalyst 4) but they may increase the surface area of the active catalyst
being used with a corresponding increase in the total number compared to the use of bulk CuO.
of the active sites on the surface of the catalyst. Although the
surface area of Carulite 300® in pellet form is quite high (ca. 4. Conclusion
260 m2 /g), an increase of the surface area may be responsible
for more phenol being produced. Whilst the relative activity The oxidative decarboxylation of BA to phenol has been stud-
decreased, the catalyst continued to produce phenol for quite ied in HTW using commercial heterogeneous catalysts such as
some time. Even after this prolonged period (∼15 h), we again NiO, CuO, Carulite® , MnO2 and Al2 O3 . The best catalyst for
obtained reactivation of the catalyst and phenol production at this reaction was Carulite 300® , which displayed a relatively
almost the same yields as before, after O2 was injected in the high robustness and good activity under the experimental con-
system for 1 h. This demonstrates the relative robustness of the ditions used in this work. The HTW environment provides a
Carulite 300® under these experimental conditions [32]. suitable medium for the selective catalytic oxidation of BA to
Commercial Carulite 110 TR® (6 g of spherical pellets, Carus phenol. No reaction intermediates were detected and the main
Chemical) was also investigated as a catalyst. As in the case of by-product, benzene, was obtained in very small amounts. The
Carulite 300® , very good phenol selectivity was observed even reaction is efficient because fast hydrolysis and decarboxylation
at lower pressures (14 MPa, Table 2). Although the composi- of reaction intermediates are achieved. Although the regenera-
tion of the catalyst is very similar to Carulite 300® , the BET
surface area is slightly lower, ca. 170 m2 /g (versus 260 m2 /g),
which might explain the lower phenol yields obtained under
same experimental conditions. The lower yields could also be
due to the fact that Carulite 110 TR® was used in pellet form
(not ground), so the number of available active sites may have
been less. Again, the presence of an excess of O2 (4 equiv.) did
not improve the yields because the organic material was totally
oxidised (entry 2).
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