Production of adipic acid and derivatives from carbohydrate-containing materials
The present invention generally relates to processes for the chemocatalytic conversion of a glucose source to an adipic acid product. The present invention includes processes for the conversion of glucose to an adipic acid product via glucaric acid or derivatives thereof. The present invention also includes processes comprising catalytic oxidation of glucose to glucaric acid or derivative thereof and processes comprising the catalytic hydrodeoxygenation of glucaric acid or derivatives thereof to an adipic acid product. The present invention also includes products produced from adipic acid product and processes for the production thereof from such adipic acid product.
1. A process for preparing glucaric acid or derivative thereof, the process comprising:
reacting glucose with oxygen in the presence of a heterogeneous oxidation catalyst comprising a metal selected from the group consisting of Pd, Pt, and a combination thereof to convert at least a portion of the glucose to glucaric acid or derivative thereof, wherein the pH of the reaction mixture is less than 7 and the weight ratio of glucose to Pd and/or Pt is no greater than about 200:1 and wherein the reaction is conducted in the substantial absence of added base.
2. The process of claim 1 wherein the weight ratio of glucose to Pd and/or Pt is no greater than about 90:1.
3. The process of claim 1 wherein the weight ratio of glucose to Pd and/or Pt is from about 40:1 to about 200:1.
4. The process of claim 1 wherein the at least a portion of the glucose is converted to glucaric acid.
5. The process as set forth in claim 1 wherein at least about 50% of the glucose is converted to glucaric acid.
6. The process as set forth in claim 1 wherein at least about 60% of the glucose is converted to glucaric acid.
7. The process of claim 1 wherein the at least a portion of the glucose is converted to a glucarolactone.
8. The process as set forth in claim 1 wherein the reaction mixture is maintained at a temperature of at least about 60° C.
9. The process as set forth in claim 1 wherein the temperature of the reaction mixture is from about 60° C. to about 150° C.
10. The process as set forth in claim 1 wherein the reaction is conducted under a partial pressure of oxygen in the range of from about 15 psia (104 kPa) to about 2000 psia (13790 kPa).
11. The process as set forth in claim 1 wherein the heterogeneous oxidation catalyst comprises Pt.
12. The process as set forth in claim 1 wherein the heterogeneous oxidation catalyst further comprises a second metal besides Pd and/or Pt.
13. The process as set forth in claim 1 wherein the heterogeneous oxidation catalyst is a supported catalyst and the catalyst support comprises a material selected from the group consisting of carbon, alumina, silica, titania, zirconia, and zeolite.
14. The process as set forth in claim 13 wherein the catalyst support comprises carbon.
15. The process as set forth in claim 13 wherein the heterogeneous oxidation catalyst comprises Pt and the support comprises carbon black.
16. The process as set forth in claim 1 wherein the heterogeneous oxidation catalyst comprises Pt and Au.
17. The process as set forth in claim 1 wherein at least a portion of the glucose is solubilized with a weak carboxylic acid.
18. The process as set forth in claim 1 wherein the temperature of the reaction mixture is from about 70° C. to about 150° C.
19. The process as set forth in claim 1 wherein at least a portion of the glucose is obtained from a carbohydrate source.
20. The process of claim 1 wherein the temperature of the reaction mixture is from about 80° C. to about 120° C.
21. A process for preparing glucaric acid or derivative thereof, the process comprising:
reacting glucose with oxygen in the presence of a heterogeneous oxidation catalyst comprising a metal selected from the group consisting of Pd, Pt, and a combination thereof to convert at least a portion of the glucose to glucaric acid or derivative thereof, wherein the reaction is conducted under a partial pressure of oxygen of at least about 25 psia (172 kPa), the pH of the reaction mixture is less than 7 and is maintained at a temperature of at least 60° C., the glucaric acid yield is at least about 15%, and the weight ratio of glucose to Pd and/or Pt is no greater than about 200:1.
22. The process of claim 21 wherein the glucaric acid yield is at least about 30%.
23. The process of claim 21 wherein the weight ratio of glucose to Pd and/or Pt is no greater than about 90:1.
24. The process of claim 21 wherein the weight ratio of glucose to Pd and/or Pt is from about 40:1 to about 200:1.
25. A process for preparing an adipic acid product, the process comprising:
a) reacting glucose with oxygen in the presence of a heterogeneous oxidation catalyst comprising a metal selected from the group consisting of Pd, Pt, and a combination thereof to convert at least a portion of the glucose to glucaric acid or derivative thereof, wherein the pH of the reaction mixture is less than 7, wherein the weight ratio of glucose to Pd and/or Pt is no greater than about 200:1; and
b) reacting, in the presence of a hydrodeoxygenation catalyst, a halogen source and hydrogen, at least a portion of the glucaric acid or derivative thereof, to convert at least a portion of the glucaric acid or derivative thereof to an adipic acid product.
26. The process of claim 25 wherein the at least a portion of the glucose is converted to glucaric acid.
27. The process as set forth in claim 25 wherein at least a portion of the glucose and glucaric acid or derivative thereof is solubilized in a weak carboxylic acid.
28. The process of claim 25 wherein the weight ratio of glucose to Pd and/or Pt is no greater than about 90:1.
29. The process of claim 25 wherein the weight ratio of glucose to Pd and/or Pt is from about 40:1 to about 200:1.
30. The process as set forth in claim 25 wherein at least about 50% of the glucose is converted to glucaric acid.
31. The process as set forth in claim 25 wherein at least about 60% of the glucose is converted to glucaric acid.
32. The process as set forth in claim 25 wherein the at least a portion of the glucose is converted to a glucarolactone.
33. The process as set forth in claim 25 wherein the reaction is conducted in the substantial absence of added base.
34. The process as set forth in claim 25 wherein the reaction mixture is maintained at a temperature of at least about 60° C.
35. The process as set forth in claim 25 wherein the temperature of the reaction mixture is from about 60° C. to about 150° C.
36. The process as set forth in claim 25 wherein the temperature of the reaction mixture is from about 70° C. to about 150° C.
37. The process as set forth in claim 25 wherein the temperature of the reaction mixture is from about 80° C. to about 120° C.
38. The process as set forth in claim 25 wherein the partial pressure of oxygen is in the range of from about 15 psia (104 kPa) to about 2000 psia (13790 kPa).
39. The process as set forth in claim 25 wherein the heterogeneous oxidation catalyst comprises Pt.
40. The process as set forth in claim 25 wherein the heterogeneous oxidation catalyst further comprises a second metal besides Pd and/or Pt.
41. The process as set forth in claim 25 wherein the heterogeneous oxidation catalyst is a supported catalyst and the catalyst support comprises a material selected from the group consisting of carbon, alumina, silica, titania, zirconia, and zeolite.
42. The process as set forth in claim 41 wherein the catalyst support comprises carbon.
43. The process as set forth in claim 41 wherein the heterogeneous oxidation catalyst comprises Pt and the support comprises carbon black.
44. The process as set forth in claim 25 wherein the heterogeneous oxidation catalyst comprises Pt and Au.
45. The process as set forth in claim 25 wherein at least a portion of the glucose is obtained from a carbohydrate source.
46. The process as set forth in claim 21 wherein the glucaric acid yield is in excess of 50%.
47. The process as set forth in claim 21 wherein the glucaric acid yield is in excess of 60%.
48. The process as set forth in claim 21 wherein the at least a portion of the glucose is converted to a glucarolactone.
49. The process as set forth in claim 21 wherein the reaction is conducted in the substantial absence of added base.
50. The process as set forth in claim 46 wherein the reaction is conducted in the substantial absence of added base.
51. The process as set forth in claim 50 wherein the temperature of the reaction mixture is from about 70° C. to about 150° C.
52. The process as set forth in claim 21 wherein the temperature of the reaction mixture is from about 80° C. to about 120° C.
53. The process as set forth in claim 21 wherein the partial pressure of oxygen is in the range of from about 15 psia (104 kPa) to about 2000 psia (13790 kPa).
54. The process as set forth in claim 51 wherein the heterogeneous oxidation catalyst comprises Pt.
55. The process as set forth in claim 21 wherein the heterogeneous oxidation catalyst further comprises a second metal besides Pd and/or Pt.
56. The process as set forth in claim 51 wherein the heterogeneous oxidation catalyst is a supported catalyst and the catalyst support comprises a material selected from the group consisting of carbon, alumina, silica, titania, zirconia, and zeolite.
57. The process as set forth in claim 21 wherein the catalyst support comprises carbon.
58. The process as set forth in claim 56 wherein the heterogeneous oxidation catalyst comprises Pt and the support comprises carbon black.
59. The process as set forth in claim 21 wherein the heterogeneous oxidation catalyst comprises Pt and Au.
60. The process as set forth in claim 21 wherein at least a portion of the glucose is solubilized with a weak carboxylic acid.
61. The process as set forth in claim 21 wherein at least a portion of the glucose is obtained from a carbohydrate source.