E.i. Dupont De Nemours and Company

Basf Se Corporation

Dsm N.v.

Archer Daniels Midland Company

Dupont Industrial Biosciences Usa, LLC

Ronnie Ozer

Paul Joseph Fagan

Kostantinos Kourtakis

Sourav Kumar Sengupta

Emilio Enrique Bunel

Bhuma Rajagopalan

Theodore Augur Koch

Pranit S Metkar

Thomas G Calvarese

Eric J Till

Ke Li

David Richard Corbin

Michael Brian D'Amore

Ronald James Davis

Keith Ward Hutchenson

Carmo Joseph Pereira

Stuart Fergusson

Bruce Edwin Murphree

Kevin Rodney Gerzevske

Shawn Homer Phillips

Marisa Bonilla

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.

Processes for preparing 2,5-furandicarboxylic acid and esters thereof

Catalytic processes to produce a reaction product comprising 1-butanol by contacting a reactant comprising ethanol with a catalyst composition under suitable reaction conditions are provided. The catalyst composition may comprise a hydroxyapatite of the Formula (MM'M&#x2033;M&#x2032;&#x2033;)(PO)(OH), wherein M is Mg; M&#x2032; is Ca; M&#x2033; is Sr; M&#x2032;&#x2033; is Ba; w is any number between 0 and 1 inclusive; x is any number from 0 to less than 0.5; y is any number between 0 and 1 inclusive; z is any number between 0 and 1 inclusive; and w+x+y+z=1. Base-treated catalyst compositions may be used. Also provided are processes for contacting an initial catalyst composition comprising the hydroxyapatite with a base to produce a base-treated catalyst composition, and the base-treated catalyst compositions so obtained.

Conversion of ethanol to a reaction product comprising 1-butanol using hydroxyapatite catalysts

Furfural is produced by mixing an aqueous feedstock solution containing Csugar and/or Csugar with a heated, high boiling, water-miscible solvent, such as sulfolane, and a soluble acid catalyst. Furfural product and water are distilled off through a multistage distillation column, leaving non-volatile solvent behind. Typical furfural yields with sulfolane as the reaction solvent are about 80% at as high as 99% conversion. Also, certain by-products (e.g., humins) solubilized in the reaction solvent can be precipitated by addition of water or aqueous feedstock solution and then removed by filtration, thereby providing a convenient and effective way of removing these undesirable byproducts from the reaction mixture.

Process for the production of furfural

Furfural is produced by mixing an aqueous feedstock solution containing Csugar and/or Csugar with a heated high boiling, water-miscible solvent, such as sulfolane, and a solid acid catalyst. Furfural product and water can be distilled off, leaving non-volatile solvent behind. Furfural yields of over 70% at as high as 99% conversion have been obtained with this process with sulfolane as the reaction solvent and zeolite beta as the solid acid catalyst. Also, certain by-products (e.g., humins) solubilized in the reaction solvent can be precipitated by addition of water or aqueous feedstock solution and then removed by filtration, thereby providing a convenient and effective way of removing these undesirable byproducts from the reaction mixture.

A process is provided for the synthesis of furan and related compounds by vapor phase decarbonylation of furfural and derivatives. The reaction rate, conversion, and selectivity are enhanced by adding water to the feed. The process can be run at lower temperatures than in similar processes run with essentially dry furan and related compounds.

Vapor-phase decarbonylation process

Furfural is produced by contacting a feedstock solution containing Csugar and/or Csugar with a solid acid catalyst using reactive distillation. Both high yield and high conversion are obtained, without production of insoluble char in the reaction vessel. Degradation of furfural is minimized by its low residence time in contact with the solid acid catalyst. Higher catalyst lifetime can be achieved because the catalyst is continually washed with the refluxing aqueous solution and not sitting in high-boiling byproducts like humins, which are known to be deleterious to catalyst lifetime.

A process is provided for the synthesis of furan and related compounds by vapor-phase decarbonylation of furfural and derivatives, using a palladium/metal aluminate catalyst that has been promoted with an alkali carbonate, such as cesium carbonate. The use of such catalysts, which are inherently less acidic than alumina, results in improved lifetime and high productivity.

A process is provided for the synthesis of furan and related compounds by vapor-phase decarbonylation of furfural and derivatives, using a palladium/metal aluminate catalyst. The use of such catalysts, which are inherently less acidic than alumina, results in improved lifetime and high productivity. The compounds so produced can be used as starting materials for industrial chemicals for use as pharmaceuticals, herbicides, stabilizers, and polymers such as polyether ester elastomers and polyurethane elastomers.

Vapor phase decarbonylation process

A process is provided for the synthesis of furan and related compounds by liquid-phase decarbonylation of furfural and derivatives, using a palladium/metal aluminate catalyst. The compounds so produced can be used as starting materials for industrial chemicals for use as pharmaceuticals, herbicides, stabilizers, and polymers such as polyether ester elastomers and polyurethane elastomers.

Decarbonylation process

Catalytic processes to produce a reaction product comprising 2-ethylhexanol by contacting a reactant comprising 1-butanol with a catalyst composition under suitable reaction conditions are provided. The catalyst composition may comprise a hydroxyapatite of the Formula (MM'M&#x2033;M&#x2032;&#x2033;)(PO)(OH), wherein M is Mg; M&#x2032; is Ca; M&#x2033; is Sr; M&#x2032;&#x2033; is Ba; w is any number between 0 and 1 inclusive; x is any number from 0 to less than 0.5; y is any number between 0 and 1 inclusive; z is any number between 0 and 1 inclusive; and w+x+y+z=1. Base-treated catalyst compositions may be used.

Conversion of butanol to a reaction product comprising 2-ethylhexanol using hydroxyapatite catalysts

A process is provided for the synthesis of furan and related compounds by vapor phase decarbonylation of furfural and derivatives, using a palladium/alumina catalyst that has been promoted with an alkali carbonate. Catalyst lifetime is improved. The catalyst can be regenerated in situ by feeding a mixture of air and steam, with a composition of between about 2% and about 40% air, to the catalyst bed at a temperature between about 300&#xb0; C. and about 500&#xb0; C.

The present invention further contemplates a process for making a dialkyl ether composition comprising two or more ethers of the formula R&#x2014;O&#x2014;R. The present invention further contemplates a process for making a dialkyl ether composition starting from a first reaction product comprising 1-butanol. The invention further contemplates a dialkyl ether composition comprising two or more ethers of the formula R&#x2014;O&#x2014;R, where each Rand Rcan independently be any carbon chain length, saturated or unsaturated; branched or straight-chain, of between Cand C; specifically between Cand C; more specifically between Cand C; more specifically C; more specifically 0. The present invention further contemplates a process where a first reaction product comprising 1-butanol is used to produce a dialkyl ether composition where each Rand Rcan independently be any carbon chain length, saturated or unsaturated; branched or straight-chain, of between Cand C; specifically between Cand C; more specifically between Cand C; more specifically C; more specifically C.

Process for making a composition comprising at least two different dialkyl ethers

A process is provided for making a reaction product comprising 1-butanol by contacting a reactant comprising ethanol containing a significant amount of water with a decomposed hydrotalcite catalyst. The catalyst may be 1) hydrotalcites which have been thermally decomposed, either partially or fully, to form catalytically active species; 2) combinations of hydrotalcites (optionally containing transition metals) and metal carbonates; and 3) hydrotalcites (optionally containing transition metals) surface-impregnated with a transition metal nitrate, where catalysts 2) and 3) have also been thermally decomposed, either partially or fully, to form catalytically active species. The catalyst, at a selected reaction time, has greater activity when the ethanol contains water as compared to when the ethanol is anhydrous.

Growing community of inventors

Arden, DE, United States of America

Ronnie Ozer