method for converting fermentation mixture into fuels

专利摘要:
METHOD FOR CONVERTING FERMENTATION MIXTURE IN FUELS. The present disclosure provides methods for producing ketones suitable for use as fuels and lubricants by catalytic conversion of an acetone-butanol-ethanol (ABE) fermentation product that can be derived from biomass.
公开号:BR112013030207B1
申请号:R112013030207-0
申请日:2012-04-26
公开日:2020-10-20
发明作者:F. Dean Toste；Pazhamalai Anbarasan；Joseph B. Binder；Paul A. Willems；Douglas S. Clark；Zach Baer；Sanil Sreekumar；Harvey W. Blanch
申请人:The Regents Of The University Of California；Bp Corporation North America Inc；
IPC主号:

专利说明:

CROSS REFERENCES TO RELATED REQUESTS
This application claims priority for US Provisional Patent Application No. 61 / 491,141, filed on May 27, 2011, which is hereby incorporated by reference in its entirety. TECHNICAL FIELD
This disclosure relates in general to the production of fuels from biomass. More specifically, the present disclosure relates to the catalytic conversion of products resulting from the fermentation of saccharides derived from biomass, such as an acetone-butanol-ethanol (ABE) fermentation product mixture into ketones suitable for use as fuels. BACKGROUND OF THE INVENTION
The production of fuels from renewable sources has become increasingly important as a means of reducing the production of greenhouse gases and reducing oil imports. See L. D. Gomez, C. G. Steele-King, S. J. McQueen-Mason, New Phytologist, 178, 473-485, (2008). Lignocellulosic biomass is generally composed of cellulose, hemicellulose and lignin. These biomass components are non-edible polymers rich in carbohydrates that can serve as a renewable energy source. They normally make up to about 75% of the dry weight of the biomass. As such, the conversion of these non-edible biomass components into biofuels is of continuous interest that can benefit the environment and reduce oil imports. See A. Demirbas, Energy Sources, Part B: Economics, Planning and Policy, 3 (2) 177-185 (2008).
Currently, several approaches are available for converting biomass to fuels. For example, chemical processing pathways may involve high temperature pyrolysis or liquefaction of biomass; pyrolysis products (synthesis gas) can be converted using Fischer-Tropsch chemistry into fuels with a higher number of carbons. Biological pathways usually first hydrolyze the polysaccharide content of biomass to monosaccharides using cellulase enzymes. These monosaccharides are then converted to fuels by microbial action.
Early efforts to produce biologically based fuels from biomass include fermenting carbohydrates derived from starch and derivatives of lignocellulose into bioalcohols, such as bioethanol and biobutanol. See Blanch, H.W. and C.R. Wilke, Sugars and Chemicals from Cellulose, Reviews in Chemical Engineering, eds., N.E. Amundson and D. Luss, vol 1, 1 (1982). These natural biological routes for producing alcohols (eg, ethanol and butanol) from carbohydrates normally produce low molecular weight compounds that are generally more suitable as gasoline additives than as aviation and diesel fuel compounds. Although advances in metabolic engineering have allowed the biological production of several compounds of aviation fuel and higher molecular weight diesel, these processes usually suffer from low titers and yields.
The most recent efforts have focused on the source of carbohydrates obtained from lignocellulosic biomass. Cellulose and hemicellulose obtained from lignocellulosic biomass after pre-treatment and hydrolysis produce hexoses and pentoses, respectively. Subsequent dehydration of these sugars in furfural and 5-hydroxymethylfurfural (HMF) can be achieved by chemical processes. Biological routes can ferment hexoses and pentoses in short-chain alcohols (eg, ethanol and butanols) or in alkanes and alkenes with a higher number of carbons, terpenes and fatty acids that can be esterified for use as diesel fuels.
Although there are efficiencies for converting hexose and pentose to short-chain alcohols, current microbial routes for products with a higher carbon content generally produce low yields and product titles. These products are currently not economically attractive as fungible fuels that can be used as gasoline, additives or substitutes for aviation fuels and diesel.
Thus, a commercially viable process is required in the art to produce fungible fuels, such as transport fuels and other biomass chemicals, which allows the product to be selectively controlled. In addition, a commercially viable process is required in the art to produce higher molecular weight fuel compounds and other biomass-derived saccharide chemicals, such as an acetone-butanol-ethanol (ABE) mixture. BRIEF SUMMARY
The present disclosure addresses this need through a process that converts a mixture of the fermentation product, such as an ABE fermentation mixture, obtained from biomass-derived carbohydrates into ketones suitable for use as fuels (for example, transport) and lubricants.
In certain embodiments, when an ABE fermentation mixture is provided, acetone has a nucleophilic α carbon that is favorable to the formation of a C-C bond with electrophilic alcohols, such as ethanol and butanol. Using the reaction conditions described in this document, higher molecular weight hydrocarbons suitable for use as aviation fuels and diesel can be produced from the ABE fermentation mixture. Thus, the methods provided in this document can integrate biological and chemocatalytic routes to convert the ABE fermentation products into ketones of different lengths, by palladium-catalyzed alkylation. In addition, the methods provided in the present invention make it possible to selectively produce gasoline, jet fuel compounds and diesel from biomass, such as lignocellulosics and sugarcane, in high yields.
One aspect of the present disclosure provides method A of producing one or more compounds of Formula I,
wherein each R1 and R2 is, independently, an alkyl, alkenyl, alkynyl, cycloalkyl, heterocycloalkyl, aryl, heteroaryl or substituted arylalkyl; wherein the method includes: a) providing a fermentation product mixture that includes acetone and one or more optionally substituted alcohols; b) combining the fermentation product mixture with a metal based catalyst in the presence of a base; and c) producing one or more compounds of Formula I, wherein at least one of one or more compounds of Formula I is a double alkylated compound.
In an embodiment of method A, each Ri and R2 can independently be an optionally substituted alkyl, cycloalkyl, heterocycloalkyl, aryl, heteroaryl or arylalkyl. In another embodiment, each R2 and R2 can independently be an optionally substituted alkyl, alkenyl or alkynyl. In another embodiment, each R1 and R2 can independently be substituted alkyl. In another modality, each R2 and R2 can be replaced. In another embodiment, each R1 and R2 is, independently, optionally substituted C1-C20 alkyl. In another embodiment, each R2 and R2 is, independently, optionally substituted C1-C15 alkyl. In yet another embodiment, each R1 and R2 is, independently, optionally substituted C1-C9 alkyl. In yet another embodiment, each R1 and R2 is, independently, optionally substituted C1-C8 alkyl. In yet another embodiment, each R1 and R2 is, independently, optionally substituted C1-C5 alkyl.
In certain embodiments of method A, each R2 and R2 is independently unsubstituted C1-C9 alkyl. In certain modalities, each R2 and R2 is independently methyl, ethyl, propyl, isopropyl, butyl, pentyl, hexyl, heptyl, octyl or nonyl. In other embodiments, C1-C9 alkyl may be straight or branched. In yet another embodiment, each R2 and R2 is independently unsubstituted C1-C5 alkyl. In some embodiments, each R2 and R2 is independently methyl, ethyl, propyl, isopropyl, butyl or pentyl. In some embodiments, each RT and R2 is independently methyl, propyl, isopropyl or pentyl. In other embodiments, unsubstituted C1-C5 alkyl may be straight or branched. In some embodiments, Ri and R2 may be the same or different.
In some embodiments of method A, delivery of the fermentation product mixture includes: providing a saccharide; and placing the saccharide in contact with a fermentation host to produce the fermentation product mixture. In some embodiments, the saccharide may include C5 saccharides, Ce saccharides or a mixture thereof. In certain embodiments, the saccharide may include glucose, sucrose, cellobiose and xylose, or a combination thereof. In certain embodiments, saccharides can be derived from biomass. Biomass can include cellulose, hemicellulose and lignin. In certain embodiments, delivery of the fermentation product mixture also includes contacting the saccharide and fermentation agent with an extractor. In some embodiments, the extractor has one or more of the following properties: i) it is non-toxic to the fermentation agent (for example, Clostirdium); ii) has partition coefficients for acetone and butanol equal to or greater than 1; and iii) it has a partition coefficient for ethanol less than 0.5. In other modalities, the extractor is selected from glyceryl tributyrate, glyceryl tripropionate, oleyl alcohol and polypropylene glycol, or a combination thereof. In still other embodiments, the fermentation product mixture has less than about 5% by weight, about 4% by weight, about 3% by weight, about 2% by weight or about 1% by weight of water .
In some embodiments of method A, each of one or more optionally substituted alcohols is independently a primary alcohol or a secondary alcohol. In yet another embodiment, each of one or more optionally substituted alcohols is independently a C1-C20 primary alcohol or a C1-C20 secondary alcohol. In yet another embodiment, each of one or more optionally substituted alcohols is, independently, a C1-C15 primary alcohol or a C1-C15 secondary alcohol. In yet another embodiment, each of one or more optionally substituted alcohols is, independently, a primary C1-C8 alcohol or a secondary C1-C8 alcohol. In yet another embodiment, each of one or more optionally substituted alcohols is independently a C1-C5 primary alcohol or a C1-C5 secondary alcohol. In some embodiments, the one or more optionally substituted alcohols are two unsubstituted primary alcohols, unsubstituted primary and a substituted secondary alcohol.
In some modalities of method A, the fermentation product mixture is composed of acetone and an optionally substituted alcohol. In other modalities of method A, the fermentation product mixture is composed of acetone and two optionally substituted alcohols. In still other embodiments of method A, the fermentation product mixture is composed of acetone and two or more optionally substituted alcohols. In certain embodiments, the optionally substituted alcohols are C1-C20 primary alcohols. In other embodiments, the fermentation product mixture is composed of acetone and two or more optionally substituted primary C1-C15 alcohols. In other embodiments, the fermentation product mixture is composed of acetone and two or more optionally substituted primary C1-C8 alcohols. In still other embodiments, the fermentation product mixture is composed of acetone and two or more optionally substituted primary C1-C4 alcohols. In still other embodiments, the fermentation product mixture is composed of acetone, a first C1-C4 primary alcohol and a second C1-C4 primary alcohol. In other embodiments, the fermentation product mixture is composed of acetone, butanol and ethanol.
In certain embodiments of method A, acetone, the first C1-C4 primary alcohol and the second C1-C4 primary alcohol are present in the fermentation product mixture in a weight ratio of about 2 to 4 ketones to about 5 to 7 of the first primary alcohol to about 0.01 to 2 of the second primary alcohol. In some embodiments, acetone, butanol and ethanol are present in the fermentation product mixture in a weight ratio of about 2 to 4 acetone to about 5 to 7 butanol to about 0.01 to 2 ethanol. In other embodiments, acetone, butanol and ethanol are present in the fermentation product mixture in a weight ratio of about 3 to about 6 to about 0.01 to 1. In still other embodiments, acetone, butanol and ethanol are present in the fermentation product mixture in a weight ratio of about 3 to about 6 to about 1.
In still other modalities of method A, the fermentation product mixture is composed of acetone, a primary alcohol C1-C4 and a secondary alcohol C1-C6. In other embodiments, the fermentation product mixture is composed of acetone, butanol and hexanol. In one embodiment, the fermentation product mixture is composed of acetone, linear butanol and branched hexanol (for example, 2-methylhexan-1-ol, 2-ethylhexan-1-ol).
In certain modalities of method A, where the fermentation product mixture is composed of acetone, butanol and ethanol, the amount of base for butanol and ethanol is between 0.3 to 1.5 mol equivalents. In other embodiments, the amount of base for butanol and ethanol is between 0.32 to 1.3 mol equivalents. In yet other embodiments, the amount of base for butanol and ethanol is between 0.95 to 1.3 mol equivalents.
In some embodiments that can be combined with any of the previous embodiments of method A, the metal based catalyst can include nickel, ruthenium, rhodium, palladium, rhenium, iridium, platinum or copper, or a combination of these metals. In certain embodiments, the metal-based catalyst can be [Ir (COD) Cl] 2, RUC12 (COD), PtCl2 (COD), [Rh (COD) Cl] 2, Ni / Si-Alumina, Ru / C, Rh / C, Pt / C or Pd / C, or a combination of these metal based catalysts. In still other embodiments, the metal-based catalyst may include a palladium-based catalyst, such as Pd (OAc) 2, Pd2 (dba) 3, Pd (OH) 2 / C, Pd / C, Pd / CaCO3, Pd / Alumina or PD- polyethylenimines on silica, or a combination of these palladium-based catalysts.
In some modalities that can be combined with any of the previous modalities of method A, the base can be K3PO4, KOH, Ba (OH) 2.8H2O, K2CO3, KOAc, KH2PO4, Na2HPO4, pyridine, or Et3N, or a combination of these bases .
In other embodiments that can be combined with any of the previous embodiments of method A, the method further includes combining the fermentation product mixture in step (b) with a solvent. In some embodiments, the solvent is an organic solvent. In certain embodiments, the solvent may be toluene, ethyl acetate, diethylene glycol dimethyl ether, monoglyph, butanol, diethylene glycol butyl ether, oleyl alcohol, dibutyl phthalate or mixtures of these solvents. In still other modalities, method A is carried out pure.
In some embodiments that can be combined with any of the previous embodiments of method A, the method further includes heating the reaction mixture from step (b) to a temperature sufficient to form the one or more compounds of Formula I. In certain embodiments, the temperature is between 100 ° C and 200 ° C. In other modalities, the temperature is between 110 ° C and 180 ° C. In still other embodiments, the temperature is between 110 ° C and 145 ° C. In still other modalities, the temperature is between 140 ° C and 220 ° C.
In some embodiments that can be combined with any of the previous embodiments of Method A, the one or more compounds of Formula I may include pentanone, heptanone, nonanone and undecanone. In certain embodiments, the one or more compounds of Formula I may include linear or branched pentanone, linear or branched heptanone, linear or branched nonanone, linear or branched undecanone, linear or branched tridecanone and / or linear or branched pentadecanone.
In some embodiments, the one or more compounds of Formula I may include 2-pentanone, 4-heptanone, 2-heptanone, 4-nonanone, 2-methyl-4-nonanone, 6-undecanone, 5-ethylundecan-6-one, 5,7-diethylundecan-6-one, 5,7-dibutylundecan-6-one, 9-ethyltridecan-6-one, 5,11-diethylpentadecan-8-one, 5-butylundecan-6-one and / or 5- butyl-7-ethylundecan-6-one. In certain embodiments, the one or more compounds of Formula I may include 2-pentanone, 4-heptanone, 2-heptanone, 4-nonanone, 2-methyl-4-nonanone and 6-undecanone. In still other embodiments, the one or more compounds of Formula I may include 5-ethylundecan-6-one, 5,7-diethylundecan-6-one, 5,7-dibutylundecan-6-one, 9-ethyltridecan-6-one , 5,11- diethylpentadecan-8-one, 5-butylundecan-6-one and 5-butyl-7-ethylundecan-6-one.
In certain embodiments, the one or more compounds of Formula I is a mixture of compounds selected from 4-heptanone, 2-heptanone, 4-nonanone, 2-methyl-4-nonanone, 6-undecanone, 5-ethylundecan-6-one , 5,7-diethylundecan-6-one, 5,7-dibutylundecan-6-one, 9-ethyltridecan-6-one, 5,11- diethylpentadecan-8-one, 5-butylundecan-6-one and / or 5 -butyl-7-ethylundecan-6-one.
In some embodiments that can be combined with any of the previous embodiments of method A, the yield of one or more compounds of Formula I in relation to the amount of acetone present in the fermentation product mixture is at least 35%, at least 40 %, at least 50%, at least 60%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95% or at least 99%. In other embodiments, the yield of one or more Formula I compounds in relation to the amount of acetone present in the fermentation product mixture is between about 35 to 95%, between about 50 to 95%, between about 60 to 90 % or between about 70 to 85%.
In some embodiments of method A, the method produces two or more compounds of Formula I, wherein at least two of the two or more compounds of Formula I are double-alkylated compounds. In some embodiments, the yield of the two or more Formula I compounds in relation to the amount of acetone present in the fermentation mixture is at least 10%, at least 15%, at least 20%, at least 30%, at least 40 %, at least 50%, at least 60%, at least 70%, at least 75%, at least 80%, at least 85% or at least 90%. In some embodiments, the yield of the double-alkylated compounds of Formula I in relation to the amount of acetone present in the fermentation mixture is at least 10%, at least 15%, at least 20%, at least 30%, at least 40 %, at least 50%, at least 60%, at least 70%, at least 75%, at least 80%, at least 85% or at least 90%. In other embodiments, the yield of the double-alkylated compounds of Formula I in relation to the amount of acetone present in the fermentation product mixture is between about 10 to 90%, between about 10 to 85%, between about 15 to 70 % or between about 15 to 65%.
In other embodiments that can be combined with any of the previous modalities of Method A, the one or more Formula I products can serve as one or more precursors to fuel additives. In yet other embodiments that can be combined with any of the preceding embodiments, the one or more Formula I products can serve as one or more precursors to the fuel. In yet other embodiments that can be combined with any of the foregoing embodiments, the one or more Formula I products can serve as one or more precursors for lubricants.
In still other modalities that can be combined with any of the previous modalities of Method A, the method further includes the addition of one or more compounds to the fermentation product mixture, wherein the one or more compounds can be a ketone or an alcohol . In certain embodiments, the one or more compounds added to the fermentation product mixture may include RaC (= O) Rb, (Rc) H2COH, (Rd)> HCOH, or (RθHCOH, where Ra, Rb, Rc, Rd and Re 'in each occurrence, can be, independently, an alkyl, alkenyl, alkynyl, cycloalkyl, heterocycloalkyl, aryl, heteroaryl or arylalkyl optionally substituted. In some modalities, Ra, Rb, Rc, Rd and Re, in each occurrence, can be independently, an optionally substituted C1-C20 alkyl, C1-C20 alkenyl or C1-C20 alkynyl Ra, Rb, R Rd and Re, in each occurrence, can be independently an optionally substituted C1-C15 alkyl. At least one of Ra, Rb, Rc, Rd and Re is methyl. In some embodiments, the one or more compounds added to the fermentation product mixture are obtained from a biological process or from a renewable source. o one or more compounds are added to the fermentation product mixture before combining with the metal-based catalyst and base.
In another embodiment that can be combined with any of the previous embodiments of method A, the method further includes hydrogenation, deformylation, isomerization, hydrodeoxygenation or catalytic reform of one or more Formula I compounds produced by the methods described herein. In one embodiment, hydrogenation, deformylation, isomerization, hydrodeoxygenation or catalytic reform of one or more compounds of Formula I involves a multi-step process in a reaction vessel. In other embodiments of Method A, the method further includes combining one or more compounds of Formula I with a second metal-based catalyst. In some modalities, the group selected consisting of platinum, nickel, molybdenum, tungsten, cobalt and combinations of these metals. In certain embodiments, the second metal-based catalyst includes platinum, nickel-molybdenum (Ni-Mo), nickel-tungsten (Ni-W), cobalt-molybdenum (Co-Mo) and combinations of these metals. In specific embodiments, the second metal-based catalyst can be Pd / C, Ni0-Mo03 / Al203, Pt / SiO2-Al2O3 or combinations of these catalysts. In other embodiments, the combination of one or more Formula I compounds with the second metal-based catalyst converts the one or more Formula I compounds to one or more alcohols. In still other embodiments, the combination of one or more Formula I compounds with the second metal-based catalyst converts the one or more Formula I compounds to one or more alkanes.
In some modalities of Method A, a fuel is produced after hydrogenation, deformylation, isomerization, hydrodeoxygenation or catalytic reform steps. In some modalities of Method A, a lubricant is produced after hydrogenation, deformylation, isomerization, hydrodeoxygenation or catalytic reform steps.
Another aspect of the present disclosure provides for the use of one or more Formula I compounds produced by method A for the manufacture of a fuel or a lubricant.
Another aspect of the present disclosure provides a composition A that includes: a mixture of fermentation product that includes acetone and one or more optionally substituted alcohols; a metal-based catalyst; and a base.
In certain embodiments of composition A, each of the one or more alcohols optionally substituted in the fermentation product mixture is independently a primary alcohol C1-C20 or a secondary alcohol C1-C20. In yet another embodiment, each of one or more optionally substituted alcohols is independently a C1-C15 primary alcohol or a C1-C15 secondary alcohol. In yet another embodiment, each of one or more optionally substituted alcohols is independently a C1-C8 primary alcohol or a C1-C8 secondary alcohol. In yet another embodiment, each of one or more optionally substituted alcohols is independently a C1-C5 primary alcohol or a C1-C5 secondary alcohol. In some embodiments, the one or more optionally substituted alcohols are two unsubstituted primary alcohols, two unsubstituted secondary alcohols or an unsubstituted primary alcohol and an unsubstituted secondary alcohol.
In some embodiments of composition A, the fermentation product mixture is composed of acetone and an optionally substituted alcohol. In other embodiments of composition A, the fermentation product mixture is composed of acetone and two optionally substituted alcohols. In still other embodiments of composition A, the fermentation product mixture is composed of acetone and two or more optionally substituted alcohols. In certain embodiments, the optionally substituted alcohols are primary C1-20 alcohols. In other embodiments, the fermentation product mixture is composed of acetone and two or more optionally substituted primary C1-C15 alcohols. In other embodiments, the fermentation product mixture is composed of acetone and two or more optionally substituted primary C1-C8 alcohols. In still other embodiments, the fermentation product mixture is composed of acetone and two or more optionally substituted primary C1-C5 alcohols. In still other embodiments, the fermentation product mixture is composed of acetone, a first C1-C5 primary alcohol and a second C1-C5 primary alcohol. In some embodiments, the fermentation product mixture is composed of acetone, an optionally substituted first primary alcohol and an optionally substituted second primary alcohol. In some embodiments, the fermentation product mixture is composed of acetone, an optionally substituted first primary C1-C4 alcohol and an optionally substituted second primary C1-C4 alcohol. In other embodiments, the fermentation product mixture is composed of acetone, butanol and ethanol.
In certain embodiments of composition A, acetone, the first optionally substituted primary alcohol and the second optionally substituted primary alcohol are present in the fermentation product mixture in a weight ratio of about 2 to 4 of acetone to about 5 to 7 of the first optionally substituted primary alcohol to about 0.01 to 2 of the optionally substituted second primary alcohol. In some embodiments, acetone, butanol and ethanol are present in the fermentation product mixture in a weight ratio of about 2 to 4 acetone to about 5 to 7 butanol to about 0.01 to 2 ethanol. In other embodiments, acetone, butanol and ethanol are present in the fermentation product mixture in a weight ratio of about 3 to about 6 to about 0.01 to 1. In still other embodiments, acetone, butanol and ethanol are present in the fermentation product mixture in a weight ratio of about 3 to about 6 to about 1,
In certain embodiments of the composition in which the fermentation product mixture is composed of acetone, butanol and ethanol, the amount of base for butanol and ethanol is between 0.3 to 1.5 mol equivalents. In other embodiments, the amount of base for butanol and ethanol is between 0.32 to 1.3 mol equivalents. In yet other embodiments, the amount of base for butanol and ethanol is between 0.95 to 1.3 mol equivalents.
In some embodiments that can be combined with any of the foregoing embodiments, the metal based catalyst can include nickel, ruthenium, rhodium, palladium, rhenium, iridium, platinum, copper or combinations of these metals. In certain embodiments, the metal-based catalyst can be [Ir (COD) Cl] 2, RUC12 (COD), PtCl2 (COD), [Rh (COD) Cl] 2, Ni / Si-Alumina, Ru / C, Rh / C, Pt / C or Pd / C, or a combination of these metal based catalysts. In still other embodiments, the metal-based catalyst may include a palladium-based catalyst, such as Pd (OAc) 2, Pd2 (dba) 2, Pd (OH) 2 / c, Pd / C, Pd / CaCO3, Pd / Alumina or Pd-polyethylenimines on silica, or a combination of these palladium-based catalysts.
In some embodiments that can be combined with any of the preceding embodiments, the base can be K3PO4, KOH, Ba (OH) 2.8H2O, K2CO3, KOAC, KH2PO4, Na2HPO4, pyridine or Et3N, or a combination of these bases.
In other embodiments that can be combined with any of the foregoing embodiments, the composition further includes a solvent. In some embodiments, the solvent is an organic solvent. In certain embodiments, the solvent may be toluene, ethyl acetate, diethylene glycol dimethyl ether, monoglyph, butanol, diethylene glycol butyl ether, oleyl alcohol, dibutyl phthalate or a mixture of these solvents.
In still other embodiments that can be combined with any of the foregoing embodiments, the composition further includes one or more compounds which can be a ketone or an alcohol. In certain embodiments, the one or more compounds added to the fermentation product mixture may include RaC (= O) Rb, (RC) H2COH, (Rd) 2HCOH, OR (Re) 3COH, where Ra, Rb, Rc, Rd and Re 'at each occurrence, an optionally substituted heterocycloalkyl, aryl, heteroaryl or arylalkyl may be independent. In some embodiments, Ra, Rb, Rc, Rd and Rθ, at each occurrence, can be independently an optionally substituted C1-C20 alkyl, C1-C20 alkenyl or C1-C20 alkynyl. In some embodiments, Ra, Rb, Rc, Rd and Re, at each occurrence, can be independently optionally substituted C1-C15 alkyl. In one embodiment, at least one of Ra, Rb, Rc, Rd and Re is methyl. In some embodiments, the one or more compounds is obtained from a biological process or from a renewable source. In some embodiments, one or more compounds are added to the fermentation product mixture prior to combining with the metal-based catalyst and the base.
Another aspect of the present disclosure provides a Method B of production of one or more compounds of Formula I,
wherein each R1 and R2 is independently an optionally substituted alkyl, alkenyl, alkynyl, cycloalkyl, heterocycloalkyl, aryl, heteroaryl or arylalkyl; and wherein the method includes: a) providing composition A described above; and b) heating the composition to a temperature sufficient to form the one or more compounds of Formula I, wherein at least one of one or more compounds of Formula I is a double-alkylated compound.
In an embodiment of method B, each Ri and R2 is, independently, an optionally substituted alkyl, cycloalkyl, heterocycloalkyl, aryl, heteroaryl or arylalkyl. In another embodiment, each R2 and R2 can independently be an optionally substituted alkyl, alkenyl or alkynyl. In another embodiment, each Ri and R2 is independently substituted alkyl. In another embodiment, each R2 and R2 is, independently, optionally substituted C1-C30 alkyl. In another embodiment, each R2 and R2 is, independently, an optionally substituted C1-20 alkyl. In another embodiment, each R2 and R2 is, independently, optionally substituted C1-C15 alkyl. In yet another embodiment, each R2 and R2 is, independently, optionally substituted C1-C9 alkyl. In yet another embodiment, each R2 and R2 is, independently, optionally substituted C1-C8 alkyl. In yet another embodiment, each R2 and R2 is independently replaced. In still other embodiments, each R1 and R2 is independently unsubstituted C1-C5 alkyl. In still other embodiments, each R-j and R2 is, independently, methyl, ethyl, propyl, isopropyl, butyl or pentyl. In yet other embodiments, each R2 and R2 is, independently, methyl, propyl, isopropyl or pentyl. In some embodiments, R2 and R2 may be the same or different.
In some modalities that can be combined with any of the previous modalities of method B, the temperature is between 110 ° C to 145 ° C. In certain embodiments, the temperature is between 100 ° C and 200 ° C. In other modalities, the temperature is between 110 ° C and 180 ° C. In still other embodiments, the temperature is between 110 ° C and 145 ° C. In still other modalities, the temperature is between 140 ° C and 220 ° C.
In some embodiments that can be combined with any of the previous embodiments of method B, the one or more compounds of Formula I may include pentanone, heptanone, nonanone and undecanone. In certain embodiments, the one or more compounds of Formula I may include linear or branched pentanone, linear or branched heptanone, linear or branched nonanone, linear or branched undecanone, linear or branched tridecanone and / or linear or branched pentadecanone.
In some embodiments, the one or more compounds of Formula I may include 2-pentanone, 4-heptanone, 2-heptanone, 4-nonanone, 2-methyl-4-nonanone, 6-undecanone, 5-ethylundecan-6-one, 5,7-diethylundecan-6-one, 5,7-dibutylundecan-6-one, 9-ethyltridecan-6-one, 5,11-diethylpentadecan-8-one, 5-butylundecan-6-one and / or 5- butyl-7-ethylundecan-6-one. In certain embodiments, the one or more compounds of Formula I may include 2-pentanone, 4-heptanone, 2-heptanone, 4-nonanone, 2-methyl-4-nonanone and 6-undecanone. In still other embodiments, the one or more compounds of Formula I may include 5-ethylundecan-6-one, 5,7-diethylundecan-6-one, 5,7-dibutylundecan-6-one, 9-ethyltridecan-6-one , 5,11- diethylpentadecan-8-one, 5-butylundecan-6-one and 5-butyl-7-ethylundecan-6-one.
In certain embodiments, the one or more compounds of Formula I is a mixture of compounds selected from 4-heptanone, 2-heptanone, 4-nonanone, 2-methyl-4-nonanone, 6-undecanone, 5-ethylundecan-6-one , 5,7-diethylundecan-6-one, 5,7-dibutylundecan-6-one, 9-ethyltridecan-6-one, 5,11- diethylpentadecan-8-one, 5-butylundecan-6-one and / or 5 -butyl-7-ethylundecan-6-one.
In some embodiments that can be combined with any of the previous embodiments of method B, the yield of one or more compounds of Formula I in relation to the amount of acetone present in the fermentation product mixture is at least 35%, at least 40 %, at least 50%, at least 60%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95% or at least 99%. In other embodiments, the yield of one or more Formula I compounds in relation to the amount of acetone present in the fermentation product mixture is between about 35 to 95%, between about 50 to 95%, between about 60 to 90 % or between about 70 to 85%.
In some embodiments of method B, the method produces two or more compounds of Formula I, wherein at least two of the two or more compounds of Formula I are double-alkylated compounds. In some embodiments, the yield of the two or more Formula I compounds in relation to the amount of acetone present in the fermentation mixture is at least 10%, at least 15%, at least 20%, at least 30%, at least 40 %, at least 50%, at least 60%, at least 70%, at least 75%, at least 80%, at least 85% or at least 90%. In some embodiments, the yield of the double-alkylated compounds of Formula I in relation to the amount of acetone present in the fermentation product mixture is at least 10%, at least 15%, at least 20%, at least 30%, at least at least 40%, at least 50%, at least 60%, at least 70%, at least 75%, at least 80%, at least 85% or at least 90%. In other embodiments, the yield of the double-alkylated compounds of Formula I in relation to the amount of acetone present in the fermentation product mixture is between about 10 to 90%, between about 10 to 85%, between about 15 to 70 % or between about 15 to 65%.
In other embodiments that can be combined with any of the previous modalities of Method B, the one or more Formula I products can serve as one or more precursors to fuel additives. In yet other embodiments that can be combined with any of the preceding embodiments, the one or more Formula I products can serve as one or more precursors to the fuel. In yet other embodiments that can be combined with any of the foregoing embodiments, the one or more Formula I products can serve as one or more precursors for lubricants.
In still other modalities that can be combined with any of the previous modalities of Method B, the method further includes the addition of one or more compounds to the fermentation product mixture, wherein the one or more compounds can be a ketone or an alcohol . In certain embodiments, the one or more compounds added to the fermentation product mixture may include RaC (= O) Rb, (Rc) H2COH, (Rd) 2HCOH, or (Re) 2COH, where Ra, Rb, R ", Rd and Re 'in each occurrence, can be independently an alkyl, alkenyl, alkynyl, cycloalkyl, heterocycloalkyl, aryl, heteroaryl or arylalkyl optionally substituted. In some embodiments, Ra, Rb, R ", Rd and Re, in each occurrence , can be independently an optionally substituted C1-C20 alkyl, C1-C20 alkenyl or C1-C20 alkynyl. In some embodiments, Ra, Rb, Rc, Rd and Re, at each occurrence, can be independently, optionally substituted C1-C15 alkyl. In one embodiment, at least one of Ra, Rb, Rc, Rd and Re is methyl. In some embodiments, the one or more compounds added to the fermentation product mixture are obtained from a biological process or from a renewable source. In some embodiments, one or more compounds are added to the fermentation product mixture prior to combining with the metal-based catalyst and the base.
In another embodiment that can be combined with any of the previous embodiments of method B, the method further includes hydrogenation, deformylation, isomerization, hydrodeoxygenation or catalytic reform of one or more compounds of Formula I produced by the methods described herein. In one embodiment, hydrogenation, deformylation, isomerization, hydrodeoxygenation or catalytic reform of one or more compounds of Formula I involves a multi-step process in a reaction vessel. In other embodiments of Method B, the method further includes combining one or more compounds of Formula I with a second metal-based catalyst. In some embodiments, the second metal-based catalyst includes a metal selected from the group consisting of platinum, nickel, molybdenum, tungsten, cobalt and combinations of these metals. In certain embodiments, the second metal-based catalyst includes platinum, nickel-molybdenum (Ni-Mo), nickel-tungsten (Ni-W), cobalt-molybdenum (Co-Mo) and combinations of these metals. In specific embodiments, the second metal-based catalyst can be Pd / C, NIO-M0O3 / AI2O3, Pt / SiO; -Al2O3 or combinations of these catalysts. In other embodiments, the combination of one or more Formula I compounds with the second metal-based catalyst converts the one or more Formula I compounds to one or more alcohols. In still other embodiments, the combination of one or more Formula I compounds with the second metal-based catalyst converts the one or more Formula I compounds to one or more alkanes.
In some modalities of method B, fuel is produced after hydrogenation, deformylation, isomerization, hydrodeoxygenation or catalytic reform steps. In some modalities of method B, fuel is produced after hydrogenation, deformylation, isomerization, hydrodeoxygenation or catalytic reform steps.
Another aspect of the present disclosure provides for the use of one or more compounds of Formula I produced by method B for the manufacture of a fuel or a lubricant.
Another aspect of the present disclosure provides a method C of production of one or more compounds of Formula II or III,
wherein the method includes: a) providing a fermentation product mixture that includes acetone and one or more optionally substituted alcohols; b) combining the fermentation product mixture with a metal based catalyst in the presence of a base; c) produce one or more compounds of Formula I,
wherein at least one of one or more compounds of Formula I is a double-alkylated compound; and d) converting the one or more compounds of Formula I into one or more compounds of Formula II or III, wherein each Ri, R2, R5 and Re is independently an alkyl, alkenyl, alkynyl, cycloalkyl, heterocycloalkyl, aryl, heteroaryl or optionally substituted arylalkyl. In some modalities of method C, the conversion in step (d) employs hydrogenation, deformylation, isomerization, hydrodeoxygenation or catalytic reform to one or more Formula I compounds to produce one or more Formula II or III compounds.
In some embodiments that can be combined with any of the previous embodiments of method C, each R1 and R2 can independently be an optionally substituted alkyl, alkenyl or alkynyl. In another embodiment, each R1 and R2 is, independently, an optionally substituted C1-C20 alkyl or C1-C20 alkenyl. In one embodiment, each Ri and R2 is independently substituted alkyl. In another embodiment, each R2 and R2 is, independently, an optionally substituted C1-30 alkyl. In another embodiment, each R1 and R2 is, independently, optionally substituted C1-C20 alkyl. In another embodiment, each R2 and R2 is, independently, optionally substituted C1-C15 alkyl. In yet another embodiment, each R2 and R2 is, independently, optionally substituted C1-C9 alkyl. In yet another embodiment, each R2 and R2 is, independently, optionally substituted C1-C8 alkyl. In yet another embodiment, each R2 and R2 is, independently, optionally substituted C1-C5 alkyl. In still other embodiments, each R2 and R2 is independently unsubstituted C1-C5 alkyl. In yet other embodiments, each R2 and R2 is, independently, methyl, ethyl, propyl, isopropyl, butyl or pentyl. In yet other modalities, each R2 and R2 is independently methyl, propyl, isopropyl or pentyl. In some embodiments, R2 and R2 may be the same or different.
In an embodiment that can be combined with any of the previous embodiments of method C, each Rs and Re is, independently, an optionally substituted alkyl, cycloalkyl, heterocycloalkyl, aryl, heteroaryl or arylalkyl. In one embodiment, each R5 and R6 is, independently, optionally substituted alkyl. In another embodiment, each Rs and R6 is, independently, optionally substituted C1-C20 alkyl. In another embodiment, each Rx and R2 is, independently, an optionally substituted C1-15 alkyl. In yet another embodiment, each Rs and R6 is, independently, optionally substituted C1-C9 alkyl. In yet another embodiment, each R5 and Re is, independently, optionally substituted C1-C8 alkyl. In yet another embodiment, each Rs and Re is, independently, optionally substituted C1-C5 alkyl. In still other embodiments, each Rs and R6 is independently unsubstituted C1-C5 alkyl. In yet other embodiments, each Rs and R6 is, independently, methyl, ethyl, propyl, isopropyl, butyl or pentyl. In still other modalities, each Rs θ Re is, independently, methyl, propyl, isopropyl or pentyl. In some modalities, R5 and Re can be the same or different.
In some embodiments that can be combined with any of the previous embodiments of method C, providing the fermentation product mixture includes: providing a saccharide; placing the saccharide in contact with a fermentation agent to produce the fermentation product mixture. In some embodiments, the saccharide may include C5 saccharides, C6 saccharides or a mixture thereof. In certain embodiments, the saccharide may include glucose, sucrose, cellobiose and xylose, or a combination thereof. In certain embodiments, saccharides can be derived from biomass, which can include cellulose, hemicellulose and / or lignin. In certain embodiments, the delivery of the fermentation product mixture also includes contacting the saccharide and the fermenting agent with an extractor. In some embodiments, the extractor has one or more of the following properties: i) it is non-toxic to the fermentation agent (for example, Clostirdium); ii) has partition coefficients for acetone and butanol equal to or greater than 1; and iii) it has a partition coefficient for ethanol less than 0.5. In other modalities, the extractor is selected from glyceryl tributyrate, glyceryl tripropionate, oleyl alcohol and polypropylene glycol, or a combination thereof. In still other embodiments, the fermentation product mixture is less than about 5% by weight, about 4% by weight, about 2% by weight or about 1% by weight of water.
In some embodiments of method C, each of one or more optionally substituted alcohols is, independently, a primary alcohol or a secondary alcohol. In yet another embodiment, each of one or more optionally substituted alcohols is, independently, a C1-C20 primary alcohol or a C1-C20 secondary alcohol. In yet another embodiment, each of one or more optionally substituted alcohols is independently a C1-C15 primary alcohol or a C1-C15 secondary alcohol. In yet another embodiment, each of one or more optionally substituted alcohols is independently a C1-C8 primary alcohol or a C1-C8 secondary alcohol. In yet another embodiment, each of one or more optionally substituted alcohols is independently a C1-C5 primary alcohol or a C1-C5 secondary alcohol. In some embodiments, the one or more optionally substituted alcohols are two unsubstituted primary alcohols, two unsubstituted secondary alcohols, an unsubstituted primary alcohol and an unsubstituted secondary alcohol.
In some embodiments that can be combined with any of the previous embodiments of method C, the fermentation product mixture is composed of acetone and an optionally substituted alcohol. In other embodiments, the fermentation product mixture is composed of acetone and two optionally substituted alcohols. In still other embodiments, the fermentation product mixture is composed of acetone and two or more optionally substituted alcohols. In certain embodiments, the optionally substituted alcohols are C1-C14 primary alcohols. In other embodiments, the fermentation product mixture is composed of acetone and two or more optionally substituted primary C1-C8 alcohols. In still other embodiments, the fermentation product mixture is composed of acetone and two or more optionally substituted primary C1-C4 alcohols. In still other embodiments, the fermentation product mixture is composed of acetone, a first C1-C4 primary alcohol and a second C1-C4 primary alcohol. In other embodiments, the fermentation product mixture is composed of acetone, butanol and ethanol.
In certain embodiments that can be combined with any of the preceding modalities of method C, acetone, the first primary alcohol C1-C4 and the second primary alcohol C1-C4 are present in the fermentation product mixture in a weight ratio of about from 2 to 4 for acetone to about 5 to 7 of the first primary alcohol to about 0.01 to 2 of the second primary alcohol. In some embodiments, acetone, butanol and ethanol are present in the fermentation product mixture in a weight ratio of about 2 to 4 acetone to about 5 to 7 butanol to about 0.01 to 2 ethanol. In other embodiments, acetone, butanol and ethanol are present in the fermentation product mixture in a weight ratio of about 3 to about 6 to about 0.01 to 1. In still other embodiments, acetone, butanol and ethanol are present in the fermentation product mixture in a weight ratio of about 3 to about 6 to about 1.
In certain modalities of method C, where the fermentation product mixture is composed of acetone, butanol and ethanol, the amount of base for butanol and ethanol is between 0.3 to 1.5 mol equivalents. In other embodiments, the amount of base for butanol and ethanol is between 0.32 to 1.3 mol equivalents. In yet other embodiments, the amount of base for butanol and ethanol is between 0.95 to 1.3 mol equivalents.
In some embodiments that can be combined with any of the previous embodiments of method C, the metal-based catalyst can include nickel, ruthenium, rhodium, palladium, rhenium, iridium, platinum, copper or combinations of these metals. In certain embodiments, the metal-based catalyst can be [Ir (COD) Cl] 2, RUC12 (COD), PtCl2 (COD), [Rh (COD) Cl] 2, Ni / Si-Alumina, Ru / C, Rh / C, Pt / C or Pd / C, or a combination of these metal based catalysts. In still other embodiments, the metal-based catalyst may include a palladium-based catalyst, such as Pd (OAc) 2, Pd2 (dba) 3, Pd (OH) 2 / C, Pd / C, Pd / CaCO3, Pd / Alumina or Pd-polyethylenimines on silica, or a combination of these palladium-based catalysts.
In some embodiments that can be combined with any of the previous embodiments of method C, the base may be K3PO4, KOH, Ba (OH) 2.8H2O, K2CO3, KOAc, KH2PO4, Na2HPO4, pyridine or Et3N, or a combination of these bases.
In other embodiments that can be combined with any of the previous embodiments of method C, the method further includes combining the fermentation product mixture in step (c) with a solvent. In some embodiments, the solvent is an organic solvent. In certain embodiments, the solvent may be toluene, ethyl acetate, diethylene glycol dimethyl ether, monoglyph, butanol, diethylene glycol butyl ether, oleyl alcohol, dibutyl phthalate or a mixture of these solvents. In still other modalities, the method is carried out pure.
In some embodiments that can be combined with any of the previous embodiments of method C, the method further includes heating the reaction mixture from step (c) to a temperature sufficient to form the one or more compounds of Formula I. In certain embodiments, the temperature is between 100 ° C and 200 ° C. In other modalities, the temperature is between 110 ° C and 180 ° C. In still other embodiments, the temperature is between 110 ° C and 145 ° C. In still other modalities, the temperature is between 140 ° C and 220 ° C.
In some embodiments that can be combined with any of the previous embodiments of Method C, the yield of one or more compounds of Formula I in relation to the amount of acetone present in the fermentation product mixture is at least 35%, at least 40 %, at least 50%, at least 60%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95% or at least 99%. In other embodiments, the yield of one or more Formula I compounds in relation to the amount of acetone present in the fermentation product mixture is between about 35 to 95%, at least 50 to 95%, at least 60 to 90 % or at least 70 to 85%.
In some embodiments of method C, the method produces two or more compounds of Formula I, wherein at least two of the two or more compounds of Formula I are double-alkylated compounds. In some embodiments, the yield of the two or more Formula I compounds in relation to the amount of acetone present in the fermentation mixture is at least 10%, at least 15%, at least 20%, at least 30%, at least 40 %, at least 50%, at least 60%, at least 70%, at least 75%, at least 80%, at least 85% or at least 90%. In some embodiments, the yield of the double-alkylated compounds of Formula I in relation to the amount of acetone present in the fermentation mixture is at least 10%, at least 15%, at least 20%, at least 30%, at least 40 %, at least 50%, at least 60%, at least 70%, at least 75%, at least 80%, at least 85% or at least 90%. In other embodiments, the yield of the double-alkylated compounds of Formula I in relation to the amount of acetone present in the fermentation product mixture is between about 10 to 90%, between about 10 to 85%, between about 15 to 70 % or between about 15 to 65%.
In some embodiments that can be combined with any of the previous embodiments of method C, the one or more compounds of Formula I produced in step (c) may include pentanone, heptanone, nonanone and undecanone. In certain embodiments, the one or more compounds of Formula I may include linear or branched pentanone, linear or branched heptanone, linear or branched nonanone, linear or branched undecanone, linear or branched tridecanone and / or linear or branched pentadecanone.
In some embodiments, the one or more compounds of Formula I may include 2-pentanone, 4-heptanone, 2-heptanone, 4-nonanone, 2-methyl-4-nonanone, 6-undecanone, 5-ethylundecan-6-one, 5,7-diethylundecan-6-one, 5,7-dibutylundecan-6-one, 9-ethyltridecan-6-one, 5,11-diethylpentadecan-8-one, 5-butylundecan-6-one and / or 5- butyl-7-ethylundecan-6-one. In certain embodiments, the one or more compounds of Formula I may include 2-pentanone, 4-heptanone, 2-heptanone, 4-nonanone, 2-methyl-4-nonanone and 6-undecanone. In still other embodiments, the one or more compounds of Formula I may include 5-ethylundecan-6-one, 5,7-diethylundecan-6-one, 5,7-dibutylundecan-6-one, 9-ethyltridecan-6-one , 5,11- diethylpentadecan-8-one, 5-butylundecan-6-one and 5-butyl-7-ethylundecan-6-one.
In certain embodiments, the one or more compounds of Formula I is a mixture of compounds selected from 4-heptanone, 2-heptanone, 4-nonanone, 2-methyl-4-nonanone, 6-undecanone, 5-ethylundecan-6-one , 5,7-diethylundecan-6-one, 5,7-dibutylundecan-6-one, 9-ethyltridecan-6-one, 5,11- diethylpentadecan-8-one, 5-butylundecan-6-one and / or 5 -butyl-7-ethylundecan-6-one.
The one or more compounds of Formula I can then be converted to one or more compounds of Formula II or III in step (d) of method C. In some embodiments of method C, the method produces one or more compounds of Formula II. In certain embodiments, the one or more compounds of Formula II may include pentanol, heptanol, nonanol and undecanol. In certain embodiments, the one or more compounds of Formula II may include linear or branched pentanol, linear or branched heptanol, linear or branched nonanol, linear or branched undecanol, linear or branched tridecanol and / or linear or branched pentadecanol.
In some embodiments, the one or more compounds of Formula II may include 2-pentanol, 4-heptanol, 2-heptanol, 4-nonanol, 2-methyl-4-nonanol, 6-undecanol, 5-ethylundecan-6-ol, 5,7-diethylundecan-6-ol, 5,7-dibutylundecan-6-ol, 9-ethyltridecan-6-ol, 5,11-diethylpentadecan-8-ol, 5-butylundecan-6-ol or 5-butyl- 7-ethylundecan-6-ol. In certain embodiments, the one or more compounds of Formula II may include 2-pentanol, 4-heptanol, 2-heptanol, 4-nonanol, 2-methyl-4-nonanol and 6-undecanol. In still other embodiments, the one or more compounds of Formula II may include 5-ethylundecan-6-ol, 5,7-diethylundecan-6-ol, 5,7-dibutylundecan-6-ol, 9-ethyltridecan-6-ol , 5,11-diethylpentadecan-8-ol, 5-butylundecan-6-ol and 5-butyl-7-ethylundecan-6-ol.
In some embodiments of Method C, the one or more compounds of Formula II is a mixture of compounds selected from 2-pentanol, 4-heptanol, 2-heptanol, 4-nonanol, 2-methyl-4-nonanol, 6-undecanol, 5-ethylundecan-6-ol, 5,7-diethylundecan-6-ol, 5,7-dibutylundecan-6-ol, 9-ethyltridecan-6-ol, 5,11-diethylpentadecan-8-ol, 5-butylundecan- 6-ol and / or 5-butyl-7-ethylundecan-6-ol.
In some embodiments of method C, the method produces one or more compounds of Formula III. In certain embodiments, the one or more compounds of Formula III comprise pentane, heptane, nonane and undecane. In certain embodiments, the one or more compounds of Formula III may include linear or branched pentane, linear or branched heptane, linear or branched nonane, linear or branched undecane, linear or branched tridecane and / or linear or branched pentadecane.
In some embodiments, the one or more compounds of Formula III may comprise pentane, heptane, nonane, 2-methyl-nonane, undecane, 5-ethylundecane, 5,7-diethylundecane, 5,7-dibutylundecane, 9-ethyltridecane, 5, 11-diethylpentadecane, 5-butylundecane and / or 5-butyl-7-ethylundecane. In certain embodiments, the one or more compounds of Formula III may include pentane, heptane, nonane, 2-methyl-nonane and undecane. In still other embodiments, the one or more compounds of Formula I may include 5-ethylundecane, 5,7-diethylundecane, 5,7-dibutylundecane, 9-ethyltridecane, 5,11-diethylpentadecane, 5-butylundecane and / or 5-butyl -7-ethylundecane.
In some embodiments, the one or more compounds of Formula III is a mixture of compounds selected from pentane, heptane, nonane, 2-methyl-nonane, undecane, 5-ethylundecane, 5,7-diethylundecane, 5,7-dibutylundecane, 9 - ethyltridecane, 5,11-diethylpentadecane, 5-butylundecane and / or 5-butyl-7-ethylundecane.
In another embodiment that can be combined with any of the previous embodiments of method C, steps (a) - (d) are performed as a multi-step process in a container. In other modalities of method C, a second metal-based catalyst is added in step (d) for hydrogenation, deformylation, isomerization, hydrodeoxygenation or catalytic reform of one or more compounds of the Formula. In some embodiments, the second metal-based catalyst includes a metal selected from the group consisting of platinum, nickel, molybdenum, tungsten, cobalt and combinations of these metals. In certain embodiments, the second metal-based catalyst includes platinum, nickel-molybdenum (Ni-Mo), nickel-tungsten (Ni-W), cobalt-molybdenum (Co-Mo) and combinations of these metals. In specific embodiments, the second metal-based catalyst can be Pd / C, NIO-M0O3 / AI2O3, Pt / SiO2-AI2O3 or combinations of these catalysts.
In some embodiments, a fuel or lubricant is produced by the C method.
Another aspect of the present disclosure provides for the use of one or more compounds of Formula II or III produced by method C as a fuel or a lubricant.
Another aspect of the present disclosure provides a D method of producing one or more compounds of Formula I,
wherein each R1 and R2 is independently an optionally substituted alkyl, alkenyl, alkynyl, cycloalkyl, heterocycloalkyl, aryl, heteroaryl or arylalkyl; and wherein the method includes: a) providing a fermentation product mixture that includes acetone and one or more optionally substituted alcohols; b) combining the fermentation product mixture with a metal based catalyst in the presence of a base; and c) produce one or more compounds of Formula I.
In some embodiments that can be combined with any of the previous embodiments of method D, delivery of the fermentation product mixture includes: providing a saccharide; placing the saccharide in contact with a fermentation agent to produce the fermentation product mixture. In some embodiments, the saccharide may include C5 saccharides, C6 saccharides or a mixture thereof. In certain embodiments, the saccharide may include glucose, sucrose, cellobiose and xylose, or a combination thereof. In certain embodiments, saccharides can be derived from lignin. In certain embodiments, the delivery of the fermentation product mixture also includes contacting the saccharide and the fermenting agent with an extractor. In some embodiments, the extractor has one or more of the following properties: i) it is non-toxic to the fermentation agent (for example, Clostirdium); ii) has partition coefficients for acetone and butanol equal to or greater than 1; and iii) it has a partition coefficient for ethanol less than 0.5. In other modalities, the extractor is selected from glyceryl tributyrate, glyceryl tripropionate, oleyl alcohol and polypropylene glycol, or a combination thereof. In still other embodiments, the fermentation product mixture has less than about 5% by weight, about 4% by weight, about 3% by weight, about 2% by weight or about 1% by weight of water .
In some embodiments of method D, at least one of one or more compounds of Formula I produced is a double-alkylated compound.
In an embodiment of method D, each Rx and R2 can independently be an optionally substituted alkyl, cycloalkyl, heterocycloalkyl, aryl, heteroaryl or arylalkyl. In another modality, each Rx and R; it may independently be an optionally substituted alkyl, alkenyl or alkynyl.
In another embodiment, each R1 and R2 can independently be substituted alkyl. In another embodiment, each R1 and R2 can independently be optionally substituted C1-C30 alkyl. In another embodiment, each R2 and R2 is, independently, optionally substituted C1-C20 alkyl. In yet another embodiment, each R2 and R2 is, independently, optionally substituted C1-C9 alkyl. In yet another embodiment, each R2 and R2 is, independently, optionally substituted C1-C8 alkyl. In yet another embodiment, each R2 and R2 is, independently, optionally substituted C1-C5 alkyl. In still other embodiments, each R2 and R2 is independently unsubstituted C1-C5 alkyl. In yet other embodiments, each Ri and R2 is independently methyl, ethyl, propyl, isopropyl, butyl or pentyl. In yet other embodiments, each Ri and R2 is independently methyl, propyl, isopropyl or pentyl. In some embodiments, R2 and R2 may be the same or different.
In an embodiment of method D, the ketone is R2C (= O) R4, where each R2 and R2 is independently an alkyl, alkenyl, alkynyl, cycloalkyl, heterocycloalkyl, aryl, heteroaryl or optionally substituted arylalkyl. In another embodiment, each R3 and R4 is independently an optionally substituted C1-C20 alkyl, C1-C20 alkenyl or C1-C20 alkynyl. In another embodiment, each R3 and R4 is independently an optionally substituted C1-C20 alkyl or C1-C20 alkenyl. In another embodiment, each R3 and R4 is independently an optionally substituted C1-C20 alkyl. In yet another embodiment, each R3 and R4 is independently optionally substituted C1-C15 alkyl. In another embodiment, each R3 and R4 is independently an optionally substituted C1-C9 alkyl. In another embodiment, each R3 and R4 is independently an optionally substituted C1-C8 alkyl. In another embodiment, each R3 and R4 is independently optionally substituted C1-C5 alkyl. In one embodiment, one of R3 and R4 is methyl. In another embodiment, the ketone is acetone. In some embodiments, R3 and R4 can be the same or different.
In some embodiments of method D, each of the one or more optionally substituted alcohols is independently a primary alcohol or a secondary alcohol. In other embodiments, each of one or more optionally substituted alcohols is independently a C1-C20 primary alcohol or a C1-C20 secondary alcohol. In yet another embodiment, each of one or more optionally substituted alcohols is independently a C1-C15 primary alcohol or a C1-C15 secondary alcohol. In yet another embodiment, each of one or more optionally substituted alcohols is independently a C1-C8 primary alcohol or a C1-C8 secondary alcohol. In yet another embodiment, each of one or more optionally substituted alcohols is independently a C1-C5 primary alcohol or a C1-C5 secondary alcohol. In some embodiments, the one or more optionally substituted alcohols are one or more unsubstituted primary alcohols or unsubstituted secondary alcohols.
In still other embodiments, the one or more optionally substituted alcohols is an optionally substituted alcohol. In still other embodiments, an optionally substituted alcohol is an unsubstituted primary alcohol or an unsubstituted secondary alcohol. In still other embodiments, the one or more optionally substituted alcohols are two optionally substituted alcohols. In certain embodiments, the two optionally substituted alcohols are two primary unsubstituted alcohols. In certain embodiments, the two optionally substituted alcohols are an unsubstituted primary alcohol and an unsubstituted secondary alcohol.
In some modalities of method D, the fermentation product mixture is composed of a ketone and one or more C1-C14 alcohols optionally substituted. In other embodiments, the fermentation product mixture is composed of acetone and one or more C1-C8 alcohols optionally substituted. In still other embodiments, the fermentation product mixture is composed of a ketone and one or more optionally substituted C1-C4 alcohols. In some embodiments, a ketone and an optionally substituted alcohol. In some embodiments, the fermentation product mixture includes acetone and two optionally substituted alcohols. In still other embodiments, the fermentation product mixture is composed of a ketone, a first C1-C4 alcohol and a second C1-C4 alcohol. In other embodiments, the fermentation product mixture is composed of acetone, butanol and ethanol.
In certain modalities of method D, where the fermentation product mixture is composed of acetone, butanol and ethanol, the amount of base for butanol and ethanol is between 0.3 to 1.5 mol equivalents. In other embodiments, the amount of base for butanol and ethanol is between 0.32 to 1.3 mol equivalents. In yet other embodiments, the amount of base for butanol and ethanol is between 0.95 to 1.3 mol equivalents.
In some embodiments that can be combined with any of the previous embodiments of method D, the metal-based catalyst can include nickel, ruthenium, rhodium, palladium, rhenium, iridium, platinum, copper or combinations of these metals. In certain embodiments, the metal-based catalyst can be [Ir (COD) Cl] 2, RUC12 (COD), PtCl2 (COD), [Rh (COD) Cl] 2, Ni / Si-Alumina, Ru / C, Rh / C, Pt / C, Pd / C, or combinations of these metal based catalysts. In still other embodiments, the metal-based catalyst may include a palladium-based catalyst, such as Pd (OAc) 2, Pd2 (dba) 3, Pd (OH) 2 / C, Pd / C, Pd / CaCO3, Pd / Alumina, Pd-polyethylenimines on silica or combinations of these palladium-based catalysts.
In some modalities that can be combined with any of the previous modalities of method D, the base can be K3PO4, KOH, Ba (OH) 2.8H2O, K2CO3, KOAc, KH2PO4, Na2HPO4, pyridine, Et3N or combinations of these bases.
In other embodiments that can be combined with any of the previous embodiments of method D, the method further includes combining the fermentation product mixture in step (b) with a solvent. In some embodiments, the solvent is an organic solvent. In certain embodiments, the solvent may be toluene, ethyl acetate, diethylene glycol dimethyl ether, monoglyph, butanol, diethylene glycol butyl ether, oleyl alcohol, dibutyl phthalate or mixtures of these solvents. In still other modalities, the method is carried out pure.
In some embodiments that can be combined with any of the previous embodiments of method D, the method further includes heating the reaction mixture from step (b) to a temperature sufficient to form the one or more compounds of Formula I. In certain embodiments, the temperature is between 100 ° C and 200 ° C. In other modalities, the temperature is between 110 ° C and 180 ° C. In still other embodiments, the temperature is between 110 ° C and 145 ° C. In still other modalities, the temperature is between 140 ° C and 220 ° C.
In some embodiments that can be combined with any of the previous embodiments of method D, the one or more compounds of Formula I may include pentanone, heptanone, nonanone and undecanone. In certain embodiments, the one or more compounds of Formula I may include linear or branched pentanone, linear or branched heptanone, linear or branched nonanone, linear or branched undecanone, linear or branched tridecanone and / or linear or branched pentadecanone.
In some embodiments, the one or more compounds of Formula I may include 2-pentanone, 4-heptanone, 2-heptanone, 4-nonanone, 2-methyl-4-nonanone, 6-undecanone, 5-ethylundecan-6-one, 5,7-diethylundecan-6-one, 5,7-dibutylundecan-6-one, 9-ethyltridecan-6-one, 5,11- diethylpentadecan-8-one, 5-butylundecan-6-one and / or 5- butyl-7-ethylundecan-6-one. In certain embodiments, the one or more compounds of Formula I may include 2-pentanone, 4-heptanone, 2-heptanone, 4-nonanone, 2-methyl-4-nonanone and 6-undecanone. In still other embodiments, the one or more compounds of Formula I may include 5-ethylundecan-6-one, 5,7-diethylundecan-6-one, 5,7-dibutylundecan-6-one, 9-ethyltridecan-6-one , 5,11-diethylpentadecan-8-one, 5-butylundecan-6-one and 5-butyl-7-ethylundecan-6-one.
In some embodiments, the one or more compounds of Formula I is a mixture of compounds selected from 2-pentanone, 4-heptanone, 2-heptanone, 4-nonanone, 2-methyl-4-nonanone, 6-undecanone, 5-ethylundecan -6-one, 5,7- diethylundecan-6-one, 5,7-dibutylundecan-6-one, 9-ethyltridecan-6-one, 5, 11-diethylpentadecan-8-one, 5-butylundecan-6-one and / or 5-butyl-7-ethylundecan-6-one.
In some modalities that can be combined with any of the previous modalities of Method D, the yield of one or more compounds of Formula I in relation to the amount of ketone present in the fermentation product mixture is at least 35%, at least 40 %, at least 50%, at least 60%, at least 75%, at least 80%, at least 85%, at least 90%, 95% or at least 99%. In other embodiments, the yield of one or more Formula I compounds in relation to the amount of ketone present in the fermentation product mixture is between about 35 to 95%, at least 50 to 95%, at least 60 to 90% or at least 70 to 85%.
In some embodiments of method D, the method produces two or more compounds of Formula I, wherein at least two of the two or more compounds of Formula I are double-alkylated compounds. In some embodiments, the yield of the two or more Formula I compounds in relation to the amount of ketone present in the fermentation mixture is at least 10%, at least 15%, at least 20%, at least 30%, at least 40 %, at least 50%, at least 60%, at least 70%, at least 75%, at least 80%, at least 85% or at least 90%. In some embodiments, the yield of the double-alkylated compounds of Formula I in relation to the amount of ketone present in the fermentation mixture is at least 10%, at least 15%, at least 20%, at least 30%, at least 40 %, at least 50%, at least 60%, at least 70%, at least 75%, at least 80%, at least 85% or at least 90%. In other embodiments, the yield of the double-alkylated compounds of Formula I in relation to the amount of ketone present in the fermentation product mixture is between about 10 to 90%, between about 10 to 85%, between about 15 to 70 % or between about 15 to 65%.
In other embodiments that can be combined with any of the previous embodiments of Method D, the one or more Formula I products can serve as one or more precursors to fuel additives. In other embodiments that can be combined with any of the above, the one or more Formula I products can serve as one or more precursors for fuel. In other embodiments that can be combined with any of the preceding embodiments, the one or more Formula I products can serve as one or more precursors for lubricants.
In still other modalities that can be combined with any of the previous modalities of Method D, the method further includes the addition of one or more compounds to the fermentation product mixture, wherein the one or more compounds can be a ketone or an alcohol . In some embodiments, the method further includes the addition of acetone to the fermentation product mixture. In certain embodiments, the one or more compounds added to the fermentation product mixture may include RaC (= O) Rb, (RC) H2COH, (Rd) 2HCOH or (Re) 3COH, where Ra, Rb, Rc, Rd and Re may independently be an optionally substituted alkyl, alkenyl, alkynyl, cycloalkyl, heterocycloalkyl, aryl, heteroaryl or arylalkyl. In some embodiments, Ra, Rb, Rc, Rd and Re, at each occurrence, can be independently an optionally substituted C2-C14 alkyl or alkenyl. In other embodiments, Ra, Rb, Rc, Rd and Re at each occurrence may independently be an optionally substituted C2-C14 alkyl. In one embodiment, at least one of Ra, Rb, Rc, Rd and Re is methyl. In some embodiments, the one or more compounds added to the fermentation product mixture are obtained from a biological process or from a renewable source. In some embodiments, one or more compounds are added to the fermentation product mixture prior to combining with the metal-based catalyst and the base.
In another embodiment that can be combined with any of the previous embodiments of method D, the method further includes hydrogenation, deformylation, isomerization, hydrodeoxygenation or catalytic reform of one or more compounds of Formula I produced by the methods described herein. In one embodiment, hydrogenation, deformylation, isomerization, hydrodeoxygenation or catalytic reform of one or more compounds of Formula I involves a multi-step process in a reaction vessel. In other modalities of Method D, the method further includes combining one or more compounds of Formula I with a second metal-based catalyst. In some embodiments, the second metal-based catalyst includes a metal selected from the group consisting of platinum, nickel, molybdenum, tungsten, cobalt and combinations of these metals. In certain embodiments, the second metal-based catalyst includes platinum, nickel-molybdenum (Ni-Mo), nickel-tungsten (Ni-W), cobalt-molybdenum (Co-Mo) and combinations of these metals. In specific embodiments, the second metal-based catalyst can be Pd / C, Ni0-Mo03 / Al203, Pt / SiO2-Al2O3 or combinations of these catalysts. In other embodiments, the combination of one or more Formula I compounds with the second metal-based catalyst converts the one or more Formula I compounds to one or more alcohols. In still other embodiments, the combination of one or more Formula I compounds with the second metal-based catalyst converts the one or more Formula I compounds to one or more alkanes.
In some modalities of method D, a fuel or lubricant is produced following the steps of hydrogenation, deformylation, isomerization, hydrodeoxygenation or catalytic reform.
Another aspect of the present disclosure provides the use of one or more Formula I compounds produced by method D for the manufacture of a fuel or a lubricant.
Another aspect of the present disclosure provides a composition B that includes: a fermentation product mixture that includes a ketone and one or more optionally substituted alcohols; a metal-based catalyst; and a base.
In some embodiments of composition B, the fermentation product mixture is produced by contacting the saccharide with a fermentation host to produce the fermentation product mixture. In some embodiments, the saccharide may include C5 saccharides, Ce saccharides or a mixture thereof. In certain embodiments, the saccharide may include glucose, sucrose, cellobiose and xylose, or a combination thereof. In certain embodiments, saccharides can be derived from biomass, which can include cellulose, hemicellulose and / or lignin. In certain embodiments, the delivery of the fermentation product mixture also includes contacting the saccharide and the fermenting agent with an extractor. In some embodiments, the extractor has one or more of the following properties: i) it is non-toxic to the fermentation agent (eg, Clostirdium) ii) it has partition coefficients for acetone and butanol equal to or greater than 1; and iii) it has a partition coefficient for ethanol less than 0.5. In other modalities, the extractor is selected from glyceryl tributyrate, glyceryl tripropionate, oleyl alcohol and polypropylene glycol, or a combination thereof. In still other embodiments, the fermentation product mixture has less than about 5% by weight, about 4% by weight, about 3% by weight, about 2% by weight or about 1% by weight of water .
In some embodiments of composition B, the ketone is R3C (= O) R4; where each R3 and R4 is independently an optionally substituted alkyl, alkenyl, alkynyl, cycloalkyl, heterocycloalkyl, aryl, heteroaryl or arylalkyl. In another embodiment, each R3 and R4 is independently a C1-C20 alkyl, C1-C20 alkenyl or C1-C20 alkynyl. In another embodiment, each R3 and R4 is independently an optionally substituted C1-C20 alkyl. In yet another embodiment, each R3 and R4 is independently optionally substituted C1-C15 alkyl. In another embodiment, each R3 and R4 is independently an optionally substituted C1-C9 alkyl. In another embodiment, each R3 and R4 is independently an optionally substituted C1-C8 alkyl. In another embodiment, each R3 and R4 is independently an optionally substituted C1-C5 alkyl. In one embodiment, one of R3 and R4 is methyl. In another embodiment, the ketone is acetone. In some embodiments, R3 and R4 can be the same or different.
In another embodiment of composition B, each of one or more optionally substituted alcohols is independently a primary alcohol or a secondary alcohol. In yet another embodiment, each of one or more optionally substituted alcohols is independently a primary alcohol C1-C20. In yet another embodiment, each of one or more optionally substituted alcohols is independently a primary C1-C15 alcohol. In yet another embodiment, each of one or more optionally substituted alcohols is independently a primary C1-C8 alcohol. In yet another embodiment, each of one or more optionally substituted alcohols is independently a primary C1-C5 alcohol.
In some embodiments of composition B, the fermentation product mixture is composed of a ketone and one or more optionally substituted C1-C14 alcohols. In other embodiments, the fermentation product mixture is composed of acetone and one or more C1-C8 alcohols optionally substituted. In still other embodiments, the fermentation product mixture is composed of acetone and one or more C1-C4 alcohols optionally substituted. In some embodiments, the fermentation product mixture is composed of a ketone and an optionally substituted alcohol.
In still other embodiments of composition B, the fermentation product mixture is composed of a ketone and two optionally substituted alcohols. In certain embodiments, the fermentation product mixture is composed of a ketone, a first C1-C4 alcohol and a second C1-C4 alcohol. In some embodiments, the fermentation product mixture is composed of a ketone, an optionally substituted first alcohol and an optionally substituted second alcohol. In some embodiments, the fermentation product mixture is composed of a ketone, an optionally substituted first C1-C4 alcohol and an optionally substituted second C1-C4 alcohol. In other embodiments, the fermentation product mixture is composed of acetone, butanol and ethanol.
In certain embodiments that can be combined with any of the previous embodiments, the ketone, the optionally substituted first alcohol and the optionally substituted second alcohol are present in the fermentation product mixture in a weight ratio of about 2 to 4 acetone to about from 5 to 7 of the first optionally substituted alcohol to about 0.01 to 2 of the optionally substituted second alcohol.
In some embodiments that can be combined with any of the foregoing embodiments, the metal based catalyst can include nickel, ruthenium, rhodium, palladium, rhenium, iridium, platinum, copper or combinations of these metals. In certain embodiments, the metal-based catalyst can be [Ir (COD) Cl] 2, RUC12 (COD), PtCl2 (COD), [Rh (COD) Cl] 2, Ni / Si-Alumina, Ru / C, Rh / C, Pt / C, Pd / C, or combinations of these metal based catalysts. In still other embodiments, the metal-based catalyst may include a palladium-based catalyst, such as Pd (OAc) 2, Pd2 (dba) 2, Pd (OH) 2 / C, Pd / C, Pd / CaCO3, Pd / Alumina, Pd-polyethyl nimines on silica or combinations of these palladium-based catalysts.
In some embodiments that can be combined with any of the previous embodiments, the base can be K3PO4, KOH, Ba (OH) 2.8H2O, K2CO3, KOAC, KH2PO4, Na2HPO4, pyridine, Et3N or combinations of these bases.
In other embodiments that can be combined with any of the foregoing embodiments, the composition further includes a solvent. In some embodiments, the solvent is an organic solvent. In certain embodiments, the solvent may be toluene, ethyl acetate, diethylene glycol dimethyl ether, monoglyph, butanol, diethylene glycol butyl ether, oleyl alcohol, dibutyl phthalate or mixtures of these solvents.
In yet other embodiments that can be combined with any of the foregoing embodiments, the composition further includes one or more compounds which can be a ketone, a secondary alcohol or a tertiary alcohol. In certain embodiments, the one or more compounds can be RaC (= O) Rb, (RC) H2COH, (Rd) sHCOH, or (Re) 3COH, where Ra, Rb, Rc, Rd and Re can be independently alkyl optionally substituted alkenyl, alkynyl, cycloalkyl, heterocycloalkyl, aryl, heteroaryl or arylalkyl. In some embodiments, Ra, Rb, Rc, Rd and Re, at each occurrence, can be independently optionally substituted C2-C14 alkyl. In one embodiment, at least one of Ra, Rb, Rc, Rd and Re is methyl. In some embodiments, the one or more compounds is obtained from a biological process or from a renewable source. In some embodiments, one or more compounds are added to the fermentation product mixture prior to combining with the metal-based catalyst and the base.
Another aspect of the present disclosure provides an E method of producing one or more compounds of Formula II or III,
wherein the method includes: a) providing a fermentation product mixture that includes a ketone and one or more optionally substituted alcohols; b) combining the fermentation product mixture with a metal based catalyst in the presence of a base; c) produce one or more compounds of Formula I,
d) converting the one or more compounds of Formula I into one or more compounds of Formula II or III, wherein each Rx, R2, Rs and Re is independently an alkyl, alkenyl, alkynyl, cycloalkyl, heterocycloalkyl, aryl, heteroaryl or arylalkyl optionally replaced. In some modalities of method E, the conversion in step (d) employs hydrogenation, deformylation, isomerization, hydrodeoxygenation or catalytic reform to one or more Formula I compounds to produce one or more Formula II or III compounds.
In some embodiments that can be combined with any of the previous embodiments of method E, each R1 and R2 is independently an optionally substituted alkyl, alkenyl or alkynyl. In one embodiment, each R2 and R2 is, modality, each Ri and R2 can independently be optionally substituted C1-C30 alkyl. In another embodiment, each R1 and R2 is, independently, an optionally substituted C1-20 alkyl. In yet another embodiment, each R1 and R2 is, independently, optionally substituted C1-C9 alkyl. In yet another embodiment, each R1 and R2 is, independently, optionally substituted C1-C8 alkyl. In yet another embodiment, each R2 and R2 is, independently, optionally substituted C1-C5 alkyl. In still other embodiments, each R2 and R2 is independently unsubstituted C1-C5 alkyl. In yet other modalities, each R2 and R2 is independently methyl, ethyl, propyl, isopropyl, butyl or pentyl. In yet other modalities, each R2 and R2 is independently methyl, propyl, isopropyl or pentyl. In some embodiments, Ri and R2 may be the same or different.
In a modality that can be combined with any of the previous modalities of method E, each R5 and R & is independently an optionally substituted alkyl, cycloalkyl, heterocycloalkyl, aryl, heteroaryl or arylalkyl. In one embodiment, each Rs and R6 is independently an optionally substituted alkyl. In another embodiment, each Rs and Rs is, independently, optionally substituted C1-C20 alkyl. In yet another embodiment, each Rs e is, independently, optionally substituted C1-C9 alkyl. In yet another embodiment, each Rs θ Re is, independently, optionally substituted C1-C8 alkyl. In yet another embodiment, each Rs and Re is, independently, optionally substituted C1-C5 alkyl. In still other embodiments, each Rs and Re is independently unsubstituted C1-C5 alkyl. In still other modalities, each R5 and R6 is independently methyl, ethyl, propyl, isopropyl, butyl or pentyl. In yet other modalities, each Rs and Re is independent of methyl, propyl, isopropyl or pentyl. In some embodiments, R5 and R6 can be the same or different.
In some embodiments that can be combined with any of the previous embodiments of method E, delivery of the fermentation product mixture includes: providing a saccharide; placing the saccharide in contact with a fermentation agent to produce the fermentation product mixture. In some embodiments, the saccharide may include C5 saccharides, C6 saccharides or a mixture of the
In certain embodiments, the saccharide may include glucose, sucrose, cellobiose and xylose, or a combination thereof. In certain embodiments, saccharides can be derived from biomass, which can include cellulose, hemicellulose and / or lignin. In certain embodiments, delivery of the fermentation product mixture also includes contacting the saccharide and fermentation agent with an extractor. In some embodiments, the extractor has one or more of the following properties: i) it is non-toxic to the fermentation agent (for example, Clostirdium); ii) has partition coefficients for acetone and butanol equal to or greater than 1; and iii) it has a partition coefficient for ethanol less than 0.5. In other modalities, the extractor is selected from glyceryl tributyrate, glyceryl tripropionate, oleyl alcohol and polypropylene glycol, or a combination thereof. In still other embodiments, the fermentation product mixture has less than about 5% by weight, about 4% by weight, about 3% by weight, about 2% by weight or about 1% by weight of water .
In some embodiments of method E, the fermentation product mixture is composed of a ketone and one or more C1-C14 alcohols optionally substituted. In other embodiments, the fermentation product mixture is composed of acetone and one or more C1-C8 alcohols optionally substituted. In still other embodiments, the fermentation product mixture is composed of acetone and one or more C1-C4 alcohols optionally substituted. In some embodiments, the fermentation product mixture is composed of a ketone and an optionally substituted alcohol.
In other embodiments, the fermentation product mixture is composed of a ketone and an optionally substituted alcohol. In still other embodiments, the fermentation product mixture is composed of a ketone, a first C1-C4 alcohol and a second C1-C4 alcohol. In other embodiments, the fermentation product mixture is composed of acetone, butanol and ethanol.
In some embodiments that can be combined with any of the previous embodiments of method E, the metal-based catalyst can include nickel, ruthenium, rhodium, palladium, rhenium, iridium, platinum, copper or combinations of these metals. In certain embodiments, the metal-based catalyst can be [Ir (COD) Cl] 2, RUC12 (COD), PtCl2 (COD), [Rh (COD) Cl] 2, Ni / Si-Alumina, Ru / C, Rh / C, Pt / C, Pd / C, or combinations of these metal based catalysts. In still other embodiments, the metal-based catalyst may include a palladium-based catalyst, such as Pd (OAc) 2, Pd2 (dba) 3, Pd (OH) 2 / C, Pd / C, Pd / CaCO3, Pd / Alumina, Pd-polyethylenimines on silica or combinations of these palladium-based catalysts.
In some embodiments that can be combined with any of the previous embodiments of method E, the base can be K3PO4, KOH, Ba (OH) 2,8H2O, K2CO3, KOAc, KH2PO4, Na2HPO4, pyridine, Et3N or combinations of these bases.
In other embodiments that can be combined with any of the previous embodiments of method E, the method further includes combining the fermentation product mixture in step (c) with a solvent. In some embodiments, the solvent is an organic solvent. In certain embodiments, the solvent may be toluene, ethyl acetate, diethylene glycol dimethyl ether, monoglyph, butanol, diethylene glycol butyl ether, oleyl alcohol, dibutyl phthalate or mixtures of these solvents. In still other modalities, the method is carried out pure.
In some embodiments that can be combined with any of the previous embodiments of method E, the method further includes heating the reaction mixture from step (c) to a temperature sufficient to form the one or more compounds of Formula I. In certain embodiments, the temperature is between 100 ° C and 200 ° C, in other embodiments, the temperature is between 110 ° C and 180 ° C. In still other modalities, the temperature is between 110 ° C and 145 ° C. In still other modalities, the temperature is between 140 ° C and 220 ° C.
In some modalities that can be combined with any of the previous modalities of method E, the yield of one or more compounds of Formula I in relation to the amount of ketone present in the fermentation product mixture is at least 35%, at least 40 %, at least 50%, at least 60%, at least 75%, at least 80%, at least 85%, at least 90%, 95% or at least 99%. In other embodiments, the yield of one or more Formula I compounds in relation to the amount of ketone present in the fermentation product mixture is between about 35 to 95%, 50 to 95%, 60 to 90% or 70 to 85% .
In some embodiments of method E, the method produces two or more compounds of Formula I, wherein at least two of the two or more compounds of Formula I are double-alkylated compounds. In some embodiments, the yield of the double-alkylated compounds of Formula I in relation to the amount of ketone present in the fermentation mixture is at least 10%, at least 15%, at least 20%, at least 30%, at least 40 %, at least 50%, at least 60%, at least 70%, at least 75%, at least 80%, at least 85% or at least 90%. In other embodiments, the yield of the double-alkylated compounds of Formula I in relation to the amount of ketone present in the fermentation product mixture is between 10 to 90%, 10 to 85%, 15 to 70% or 15 to 65%.
In some embodiments that can be combined with any of the previous embodiments of method E, the one or more compounds of Formula I produced in step (c) may include pentanone, heptanone, nonanone and undecanone. In certain embodiments, the one or more compounds of Formula I may include linear or branched pentanone, linear or branched heptanone, linear or branched nonanone, linear or branched undecanone, linear or branched tridecanone and / or linear or branched pentadecanone.
In some embodiments, the one or more compounds of Formula I may include 2-pentanone, 4-heptanone, 2-heptanone, 4-nonanone, 2-methyl-4-nonanone, 6-undecanone, 5-ethylundecan-6-one, 5,7-diethylundecan-6-one, 5,7-dibutylundecan-6-one, 9-ethyltridecan-6-one, 5, 11-diethylpentadecan-8-one, 5- certain modalities, the one or more compounds of Formula I can include 2-pentanone, 4-heptanone, 2-heptanone, 4-nonanone, 2-methyl-4-nonanone and 6-undecanone. In still other embodiments, the one or more compounds of Formula I may include 5-ethylundecan-6-one, 5,7-diethylundecan-6-one, 5,7-dibutylundecan-6-one, 9-ethyltridecan-6-one , 5,11- diethylpentadecan-8-one, 5-butylundecan-6-one and 5-butyl-7-ethylundecan-6-one.
In some embodiments, the one or more compounds of Formula I is a mixture of compounds selected from 2-pentanone, 4-heptanone, 2-heptanone, 4-nonanone, 2-methyl-4-nonanone, 6-undecanone, 5-ethylundecan -6-one, 5,7- diethylundecan-6-one, 5,7-dibutylundecan-6-one, 9-ethyltridecan-6-one, 5, 11-diethylpentadecan-8-one, 5-butylundecan-6-one and / or 5-butyl-7-ethylundecan-6-one.
The one or more compounds of Formula I can then be converted to one or more compounds of Formula II or III in step (d) of method E. In some embodiments of method E, the method produces one or more compounds of Formula II. In certain embodiments, the one or more compounds of Formula II may include pentanol, heptanol, nonanol and undecanol. In some, it includes linear or branched pentanol, linear or branched heptanol, linear or branched nonanol, linear or branched undecanol, linear or branched tridecanol and / or linear or branched pentadecanol.
In some embodiments, the one or more compounds of Formula II may include 2-pentanol, 4-heptanol, 2-heptanol, 4-nonanol, 2-methyl-4-nonanol, 6-undecanol, 5-ethylundecan-6-ol, 5,7-diethylundecan-6-ol, 5,7-dibutylundecan-6-ol, 9-ethyltridecan-6-ol, 5,11-diethylpentadecan-8-ol, 5-butylundecan-6-ol or 5-butyl- 7-ethylundecan-6-ol. In certain embodiments, the one or more compounds of Formula II may include 2-pentanol, 4-heptanol, 2-heptanol, 4-nonanol, 2-methyl-4-nonanol and 6-undecanol. In still other embodiments, the one or more compounds of Formula II may include 5-ethylundecan-6-ol, 5,7-diethylundecan-6-ol, 5,7-dibutylundecan-6-ol, 9-ethyltridecan-6-ol , 5,11-diethylpentadecan-8-ol, 5-butylundecan-6-ol and 5-butyl-7-ethylundecan-6-ol.
In some embodiments, the one or more compounds of Formula II is a mixture of compounds selected from 2-pentanol, 4-heptanol, 2-heptanol, 4-nonanol, 2-methyl-4-nonanol, 6-undecanol, 5-ethylundecan -6-ol, 5,7-diethylundecan-diethylpentadecan-8-ol, 5-butylundecan-6-ol and / or 5-butyl-7-ethylundecan-6-ol.
In some embodiments of method E, the method produces one or more compounds of Formula III. In certain embodiments, the one or more compounds of Formula III comprise pentane, heptane, nonane and undecane. In certain embodiments, the one or more compounds of Formula III may include linear or branched pentane, linear or branched heptane, linear or branched nonane, linear or branched undecane, linear or branched tridecane and / or linear or branched pentadecane.
In some embodiments, the one or more compounds of Formula III may include pentane, heptane, nonane, 2-methylnonane, undecane, 5-ethylundecane, 5,7-diethylundecane, 5,7-dibutylundecane, 9-ethyltridecane, 5,11- diethyl pentadecane, 5-butylundecane and / or 5-butyl-7-ethylundecane. In certain embodiments, the one or more compounds of Formula III may include pentane, heptane, nonane, 2-methylnonane and undecane. In still other embodiments, the one or more compounds of Formula I may include 5-ethylundecane, 5,7-diethylundecane, 5,7-dibutylundecane, 9-ethyltridecane, 5,11-diethylpentadecane, 5-butylundecane and / or 5-butyl -7-ethylundecane.
In some embodiments, the one or more compounds of Formula III is a mixture of compounds selected from pentane, heptane, nonane, 2-methylnonane, undecane, 5-ethylundecane, 5,7-diethylundecane, 5,7-dibutylundecane, 9-ethyltridecane , 5,11-diethylpentadecane, 5-butylundecane and / or 5-butyl-7-ethylundecane.
In another embodiment that can be combined with any of the previous embodiments of method E, steps (a) - (d) are performed as a multi-step process in a container. In other modalities of method E, a second metal-based catalyst is added in step (d) for hydrogenation, deformylation, isomerization, hydrodeoxygenation or catalytic reform of one or more compounds of the Formula. In some embodiments, the second metal-based catalyst includes a metal selected from the group consisting of platinum, nickel, molybdenum, tungsten, cobalt and combinations of these metals. In certain embodiments, the second metal-based catalyst includes platinum, nickel-molybdenum (Ni-Mo), nickel-tungsten (Ni-W), cobalt-molybdenum (Co-Mo) and combinations of these metals. In specific embodiments, the second metal-based catalyst can be Pd / C, Ni0-Mo03 / A1203, Pt / SiO2-A12O3 or combinations of these catalysts.
In some embodiments, a fuel or lubricant is produced by method E,
In some of the previous embodiments, the disclosed methods are carried out as a reaction in "a container". In one embodiment, for example, the one or more compounds of Formula I formed in the synthesis are not isolated from the reaction mixture or purified. Instead, the entire reaction mixture is used in the next step of the process, in which the one or more compounds of Formula I are converted to the corresponding alcohols or alkanes. The reaction of a vessel eliminates the effort and expense of isolating one or more Formula I compounds. It should be understood, however, that the one or more Formula I compounds can be isolated from the reaction mixture before proceeding with the next reaction step to produce the corresponding alcohols or alkanes. In some of the previous modalities, the methods are carried out in a single reaction vessel. In some of the foregoing embodiments, the one or more compounds of Formula I are used in the next step of the process without isolation or purification. In some of the previous embodiments, the reaction steps are carried out in a reaction vessel.
Another aspect of the present disclosure provides a method F of producing a mixture of alkanones, by: a) providing a mixture of fermentation product that includes acetone and one or more optionally substituted alcohols; b) combining the fermentation product mixture with a metal based catalyst in the presence of a base; and c) producing a mixture of alkanones, wherein at least a part of the alkanones in the mixture is double-alkylated. In some modalities of method F, at least 20%, 25%, 30%, 40%, 50%, 60%, 70%, 75%, 80%, 90% or 95% of the alkanones are double alkylated.
In certain embodiments, the method further includes separating each of the alkanones in the mixture. Each of the separate alkanones can be further converted to alcohols by hydrogenation, deformylation, isomerization, hydrodeoxygenation or catalytic reform of the alkanone. Each of the separate alkanones can be further converted to alkanes by hydrogenation, deformylation, isomerization, hydrodeoxygenation or catalytic reform of the alkanone.
In other embodiments of method F, the mixture of alkanones is a mixture of C5-C20 alkanones. In certain embodiments, at least 20%, 30%, 40%, 50%, 60%, 70%, 80% or 90% of the mixture comprises C7-C20 alkanones. In certain embodiments, at least 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80% or 90% of the mixture comprises C11-C20 alkanones.
In some embodiments that can be combined with any of the previous embodiments of method F, providing the fermentation product mixture includes: providing a saccharide; placing the saccharide in contact with a fermentation agent to produce the fermentation product mixture. In some embodiments, the saccharide may include C5 saccharides, Ce saccharides or a mixture thereof. In certain embodiments, the saccharide may include glucose, sucrose, cellobiose and xylose, or a combination thereof. In certain embodiments, saccharides can be derived from biomass, which can include cellulose, hemicellulose and / or lignin. In certain embodiments, the delivery of the fermentation product mixture also includes contacting the saccharide and the fermenting agent with an extractor. In some embodiments, the extractor has one or more of the following properties: i) it is non-toxic to the fermentation agent (for example, Clostirdium); ii) has partition coefficients for acetone and butanol equal to or greater than 1; and iii) it has a partition coefficient for ethanol less than 0.5. In other modalities, the extractor is selected from glyceryl tributyrate, glyceryl tripropionate, oleyl alcohol and polypropylene glycol, or a combination thereof. In still other embodiments, the fermentation product mixture has less than about 5% by weight, about 4% by weight, about 3% by weight, about 2% by weight or about 1% by weight of water .
In some embodiments of method F, the one or more optionally substituted alcohols is a substituted alcohol that can be branched or linear. In other embodiments, the one or more alcohols optionally substituted in the fermentation product mixture is an optionally substituted alcohol. In still other embodiments, the one or more optionally substituted alcohols of the fermentation product mixture are two optionally substituted alcohols. In still other embodiments, the one or more optionally substituted alcohols of the fermentation product mixture are two or more optionally substituted alcohols. In certain embodiments, the optionally substituted alcohols are C1-C14 alcohols. In other embodiments, the fermentation product mixture is composed of acetone and two or more optionally substituted C1-C8 alcohols. In still other embodiments, the fermentation product mixture is composed of acetone and two or more optionally substituted C1-C4 alcohols. In still other embodiments, the one or more optionally substituted alcohols of the fermentation product mixture are two optionally substituted alcohols. In still other embodiments, the fermentation product mixture is composed of acetone, a first C1-C4 alcohol and a second Cl-C4 alcohol. In other embodiments, the fermentation product mixture is composed of acetone, butanol and ethanol.
In certain embodiments, acetone, butanol and ethanol are present in the fermentation product mixture in a weight ratio of about 2 to 4 acetone to about 5 to 7 butanol to about 0.01 to 2 ethanol. In other embodiments, acetone, butanol and ethanol are present in the fermentation product mixture in a weight ratio of about 3 to about 6 to about 0.01 to 1. In still other embodiments, acetone, butanol and ethanol are present in the fermentation product mixture in a weight ratio of about 3 to about 6 to about 1.
In some embodiments that can be combined with any of the previous embodiments of method F, the metal-based catalyst can include nickel, ruthenium, rhodium, palladium, rhenium, iridium, platinum, copper or combinations of these metals. In certain embodiments, the metal-based catalyst can be [Ir (COD) Cl] 2, RUC12 (COD), PtCl2 (COD), [Rh (COD) Cl] 2, Ni / Si-Alumina, Ru / C, Rh / C, Pt / C or Pd / C, or a combination of these metal based catalysts. In still other embodiments, the metal-based catalyst may include a palladium-based catalyst, such as Pd (OAc) 2, Pd2 (dba) 3, Pd (OH) 2 / C, Pd / C, Pd / CaCO3, Pd / Alumina or Pd-polyethylenimines on silica, or a combination of these palladium-based catalysts.
In some embodiments that can be combined with any of the previous modalities of method F, the base can be K3PO4, KOH, Ba (OH) 2.8H2O, K2CO3, KOAc, KH2PO4, Na2HPO4, pyridine or Et3N, or a combination of these bases.
In other embodiments that can be combined with any of the previous embodiments of method F, the method further includes combining the fermentation product mixture in step (c) with a solvent. In some embodiments, the solvent is an organic solvent. In certain embodiments, the solvent may be toluene, ethyl acetate, diethylene glycol dimethyl ether, monoglyph, butanol, diethylene glycol butyl ether, oleyl alcohol, dibutyl phthalate or mixtures of these solvents. In still other modalities, the method is carried out pure.
In some embodiments that can be combined with any of the previous embodiments of method F, the method further includes heating the reaction mixture from step (c) to a temperature sufficient to form the one or more compounds of Formula I. In certain embodiments, the temperature is between 100 ° C and 200 ° C. In other modalities, the temperature is between 110 ° C and 180 ° C. In still other modalities, the temperature is between 110 ° C and 145 ° C. In still other modalities, the temperature is between 140 ° C and 220 ° C.
In some embodiments that can be combined with any of the previous embodiments of method F, the alkanones of the mixture are linear, branched or a mixture thereof. In some embodiments, the alkanones of the mixture are selected from linear or branched pentanone, linear or branched heptanone, linear or branched nonanone, linear or branched undecanone, linear or branched tridecanone and / or linear or branched pentadecanone. In other embodiments, the alkanones of the mixture are selected from linear or branched pentanone, linear or branched heptanone, linear or branched nonanone and linear or branched undecanone, or a combination thereof. In still others the alkanones of the mixture are selected from linear or branched undecanone, linear or branched tridecanone and / or linear or branched pentadecanone. In certain embodiments, the alkanones in the mixture are selected from 2-pentanone, 4-heptanone, 2-heptanone, 4-nonanone, 2-methyl-4-nonanone, 6-undecanone, 5-ethylundecan-6-one, 5 , 7-diethylundecan-6-one, 5,7-dibutylundecan-6-one, 9-ethyltridecan-6-one, 5,11-diethylpentadecan-8-one, 5-butylundecan-6-one and 5-butyl-7 -ethilundecan-6-one. In other embodiments, the alkanones in the mixture are selected from 2-pentanone, 4-heptanone, 2-heptanone, 4-nonanone, 2-methyl-4-nonanone and 6-undecanone. In still other embodiments, the alkanones in the mixture are selected from 5-ethylundecan-6-one, 5,7-diethylundecan-6-one, 5,7-dibutylundecan-6-one, 9-ethyltridecan-6-one, 5, ll-diethylpentadecan-8-one, 5-butylundecan-6-one and 5-butyl-7-ethylundecan-6-one.
In other embodiments that can be combined with any of the previous embodiments of method F, one or more alkanones of the mixture can serve as one or more precursors for fuel additives.
In another embodiment that can be combined with any of the previous embodiments of method F, steps (a) - (c) are performed as a multi-step process in a container. In other modalities of method F, a second metal-based catalyst is added to the mixture of step (c) of alkanones for hydrogenation, deformation, isomerization, hydrodeoxygenation or catalytic reform of one of the most alkanoates in the mixture. In some embodiments, the second metal-based catalyst includes a metal selected from the group consisting of platinum, nickel, molybdenum, tungsten, cobalt and combinations of these metals. In certain embodiments, the second metal-based catalyst includes platinum, nickel-molybdenum (Ni-Mo), nickel-tungsten (Ni-W), cobalt-molybdenum (Co-Mo) and combinations of these metals. In specific embodiments, the second metal-based catalyst can be Pd / C, NIO-M0O3 / AI2O3 or Pt / SiO2-Al2O3, or a combination of these catalysts.
In some embodiments, a fuel or lubricant is produced by the F method.
In another aspect, a method of producing a mixture of alcohols suitable for use as a fuel or lubricant is provided by: a) preparing the mixture of alkanones according to method F; and b) converting the mixture of alkanones to a mixture of alcohols by hydrogenation, deformylation, isomerization, hydrodeoxygenation or catalytic reform of the mixture of alkanones.
In certain embodiments, the mixture of alcohols is selected from pentanol, heptanol, nonanol and undecanol. In certain embodiments, the mixture of alcohols is selected from linear or branched pentanol, linear or branched heptanol, linear or branched nonanol, linear or branched undecanol, linear or branched tridecanol and / or linear or branched pentadecanol. In some embodiments, the alcohol mixture is selected from 2-pentanol, 4-heptanol, 2-heptanol, 4-nonanol, 2-methyl-4-nonanol, 6-undecanol, 5-ethylundecan-6-ol, 5,7 -dietilundecan-6-ol, 5,7-dibutylundecan-6-ol, 9-ethyltridecan-6-ol, 5,1l-diethylpentadecan-8-ol, 5-butylundecan-6-ol and / or 5-butyl-7 -ethilundecan-6-ol. In other embodiments, the alcohol mixture is selected from 2-pentanol, 4-heptanol, 2-heptanol, 4-nonanol, 2-methyl-4-nonanol and 6-undecanol. In still other embodiments, the alcohol mixture is selected from 5-ethylundecan-6-ol, 5,7-diethylundecan-6-ol, 5,7-dibutylundecan-6-ol, 9-ethyltridecan-6-ol, 5, 1l-diethylpentadecan-8-ol, 5-butylundecan-6-ol and 5-butyl-7-ethylundecan-6-ol.
In yet another aspect, a method of producing a mixture of alkanes suitable for use as a fuel or lubricant is provided by: a) preparing the mixture of alkanones according to method F; and b) converting the mixture of alkanones to a mixture of alkanes by hydrogenation, deformylation, isomerization, hydrodeoxygenation or catalytic reform of the mixture of alkanones.
In certain embodiments, the mixture of alkanes is selected from pentane, heptane, nonane and undecane. In certain embodiments, the mixture of alkanes is selected from linear or branched pentane, linear or branched heptane, linear or branched nonane, linear or branched undecane, linear or branched tridecane and / or linear or branched pentadecane. In some embodiments, the alkane mixture is selected from pentane, heptane, nonane, 2-methylnonane, undecane, 5-ethylundecane, 5,7-diethylundecane, 5,7-dibutylundecane, 9-ethyltridecane, 5,11-diethylpentadecane, 5 - butylundecane and / or 5-butyl-7-ethylundecane. In still other embodiments, the mixture of alkanes is selected from pentane, heptane, nonane, 2-methylnonane and undecane. In still other embodiments, the alkane mixture is selected from 5-ethylundecane, 5,7-diethylundecane, 5,7-dibutylundecane, 9-ethyltridecane, 5,11-diethylpentadecane, 5-butylundecane and / or 5-butyl-7- ethylundecane. DESCRIPTION OF THE FIGURES
The present application can be understood by reference to the description below considered together with the figures of the attached drawings, in which equal parts can be referred to by equal numbers:
FIGURE 1 depicts an exemplary reaction for the production of C5-C11 ketones from an ABE mixture using a palladium on carbon (Pd / C) catalyst;
FIGURE 2 depicts several exemplary products that can be derived from converting an ABE mixture to double alkylated ketones;
FIGURE 3 is a graph showing the yield of products A to F from the variation of metal-based catalysts on the acetone alkylation in the ABE mixture;
FIGURE 4 is a graph showing the yield of products A to F from the variation of the base in the alkylation of acetone in the ABE mixture;
FIGURE 5 is a graph showing the yield of products A to F from the variation of the palladium-based catalyst in the acetone alkylation in the ABE mixture;
FIGURES 6A and 6B are graphs representing the yield of products A to F from the variation of the temperature and the amount of base, respectively, in the acetone alkylation in the ABE mixture;
FIGURE 7 is a graph showing the yield of products A to F from the variation of solvent in the alkylation of acetone in the ABE mixture;
FIGURE 8 is a graph showing the product distribution of products from A to F at specific times, from 15 to 1200 minutes;
FIGURE 9 is a graph showing the yield of ketones and alcohols from the variation in the amount of base (% in mol of K3PO4);
FIGURE 10 is a graph showing the yield of ketones (products A to F) from the recycling of the catalyst (Pd / C) through three cycles;
FIGURE 11 is an exemplary reaction scheme for the production of C11-C27 ketones from an ABE mixture;
FIGURE 12 is a schematic depicting three exemplary reactions for the production of biodiesel from an ABE mixture;
FIGURE 13 is a flow chart for an exemplary process for converting the mixture of products from an ABE fermentation to C5-C11 ketones;
FIGURE 14 depicts the time course of product formation in a glucose fermentation extraction in an exemplary feed batch with glyceryl tributyrate, in which the upper graph shows the product formation in the extracting phase and the lower graph shows the formation production in the aqueous phase;
FIGURE 15 depicts the time course of product formation in a glucose fermentation extraction in an exemplary feed batch with glyceryl tributyrate, in which the upper graph shows the product formation in the extraction phase and the lower graph shows the formation production in the aqueous phase;
FIGURE 16 is a graph showing the effect of adding water on the alkylation reactions of an ABE mixture;
FIGURE 17 is a graph showing the distribution of product over time during an exemplary palladium-catalyzed alkylation reaction of an ABE mixture, where "o" represents 2-pentanone, "Δ" represents 4-heptanone, represents 2- heptanone, represents 4-nonanone, If • 1! represents 2-methyl-4-nonanone, undecanone; and e "A" represents 6-
FIGURE 18 is a graph showing the effect of inhibitors on ABE fermentation without an extractor based on the amount of acetone, butanol and ethanol produced. DETAILED DESCRIPTION
The following description establishes numerous exemplary process configurations and parameters, among other things. It should be recognized, however, that such a description is not intended to be a limitation on the scope of the present disclosure, but instead it is provided as a description of exemplary modalities.
As used in this document, "fuel" refers to a composition made up of a compound that contains at least one carbon-hydrogen bond, which produces heat and energy when burned. The fuel can be produced using biomass of plant origin as a raw material, for example, from the lignin cellulose lignin biopolymer. Fuel can also contain more than one type of compound and includes mixtures of compounds. As used in this document, the term "transportation fuel" refers to a fuel that is suitable for use as an energy source for transportation vehicles.
As used herein, the terms "alkyl", "alkenyl" and "alkynyl" include straight-chain and branched-chain monovalent hydrocarbyl radicals, and combinations thereof, which contain only C and H, when they are not substituted. Examples include methyl, ethyl, propyl, isopropyl, butyl, 2-propenyl, 3-butynyl and the like. The total number of carbon atoms in each such group is sometimes described in this document, for example, when the group can contain up to ten carbon atoms, it can be represented as 1-lOC, C1-C10 or Cl-10 . When heteroatoms (usually N, O and S) replace carbon atoms, as in heteroalkyl groups, for example, the numbers describing the group, although they are still written as, for example, C1-C6, represent the sum of the number of atoms of carbon in the group plus the number of such heteroatoms that are included as substitutions for the carbon atoms in the ring or chain being described.
Alkyl, alkenyl and alkynyl groups are commonly substituted to the extent that such a substitution makes chemical sense. Typical substituents may include, for example, halo, = 0, = N-CN, = N-OR, = NR, OR, NR2, SR, SO2R, SO2NR2, NRSO2R, NRCONR2, NRCOOR, NRCOR, CN, COOR, CONR2, OOCR, COR and NO2, where each R is independently H, C4-C10 alkyl C-heterocyclylalkyl, C1-C8 acyl, C2-C8 heteroacyl, C2-C8 alkenyl, C2-C8 heteroalkenyl, C2-C8 alkynyl, C2- heteroalkynyl C8, C6-C10 aryl, or C5-C10 heteroaryl, and each R is optionally substituted with halo, = 0, = N-CN, = N-OR ', = NR', OR ', NR'2, SR', SO2R ', SO2NR'2, NR'SO2R', NR'CONR'2, NR'COOR ', NR'COR', CN, COOR ', CONR'2, OOCR', COR 'and NO2, where each R' is independently H, C1-C8 alkyl, C2-C8 heteroalkyl, C3-C8 heterocyclyl, C4-C10 heterocyclylalkyl, C1-C8 acyl, C2-C8 heteroacyl, C6-C10 aryl or C5-C10 heteroaryl. The alkyl, alkenyl and alkynyl groups can also be replaced by C1-C8 acyl, C2-C8 heteroacyl, C6-C10 aryl or C5-C10 heteroaryl, each of which can be substituted by substituents that are appropriate for the particular group. Where a substituent group contains two groups R or R 'at the same or adjacent atoms (for example, -NR2OU -NR-C (O) R), THE two groups R or R' can optionally be taken together with the atoms in the substituent group to which they are attached to form a 5- to 8-membered ring in the ring, which can be substituted as allowed for the R or R 'itself, and can contain an additional hetero atom (N, 0 or S) as a member of the ring.
"Alcanone" refers to a ketone compound in a linear or branched arrangement. Examples of alkanones include pentanone, heptanone, heptanone, nonanone and undecanone. In certain embodiments, the alkanones have a linear arrangement, such as 2-pentanone, 4-heptanone, 2-heptanone, 4-nonanone and 6-undecanone. In other embodiments, the alkanones have a branched arrangement, such as 2-methyl-4-nonanone. Preferred alkanes include those with at least five carbons (C5 + alkanones), at least seven carbons (C7 + alkanones), at least nine carbons (C9 + alkanones) or at least where carbons (C11 + alkanones), or between five and twenty carbons (C5-C20 alkanones), between seven and twenty carbons (C7-C20 alkanones) or between eleven and twenty carbons (C11-C20 alkanones). In other embodiments, the alkanone can be replaced with substituents that are suitable for the alkyl group, as described above.
"Heteroalkyl", "heteroalkenyl" and "heteroalkynyl" and the like are defined in the same way as the corresponding hydrocarbyl groups (alkyl, alkenyl and alkynyl), but the term "hetero" refers to groups containing 1 to 3 heteroatoms O, S or N, or combinations thereof in the residue of the structure; thus, at least one carbon atom of a corresponding alkyl, alkenyl or alkynyl group is replaced by one of the specified heteroatoms to form a heteroalkyl, heteroalkenyl or heteroalkynyl group. The typical and preferred sizes for the heteroforms of the alkyl, alkenyl and alkynyl groups are generally the same as the corresponding hydrocarbyl groups, and the substituents that may be present in the heteroforms are the same as those described above for the hydrocarbyl groups. For reasons of chemical stability, it also understands that, unless otherwise specified, such groups do not include more than two contiguous heteroatoms, except where an oxo group is present in N or S as in a nitro or sulfonyl group.
"Cycloalkyl" can be used in the present invention to describe a carbocyclic non-aromatic group that is connected through a ring carbon atom, and "cycloalkylalkyl" can be used to describe a carbocyclic non-aromatic group that is attached to the molecule through a alkyl binder. Examples of cycloalkyl substituents can include cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, adamantyl and decahydronaphthalenyl. Likewise, "heterocyclyl" can be used to describe a non-aromatic cyclic group that contains at least one heteroatom as a ring member and that is attached to the molecule through a ring atom, which can be either C or N; and "heterocyclylalkyl" can be used to describe such a group that is connected to another molecule via a linker. The sizes and substituents that are suitable for the cycloalkyl, cycloalkylalkyl, heterocyclyl and heterocyclylalkyl groups are the same as those described above for alkyl groups. As used in this document, these terms also include rings that contain one or two double bonds, as long as the ring is not aromatic.
"Arylalkyl" groups, as used herein, are hydrocarbyl groups and can be described by the total number of carbon atoms in the ring and alkylene binder or similar. Thus, a benzyl group is a C7 arylalkyl group and phenylethyl is C8-arylalkyl.
"Heteroarylalkyl", as described above, refers to a moiety that includes an aryl group that is linked through a linking group and that differs from "arylalkyl" in that at least one atom in the aryl ring or an atom in the linking group being a heteroatom, selected from N, O and S. The heteroarylalkyl groups are described in the present invention according to the total number of atoms in the combined ring and linker, and they include aryl groups linked via a linker heteroalkyl; heteroaryl groups linked through a hydrocarbyl linker, such as alkylene; and heteroaryl groups linked through a heteroalkyl linker. Thus, for example, C7 heteroarylalkyl could include pyridylmethyl, phenoxy and N-pyrrolylmethoxy.
In general, any alkyl, cycloalkyl, alkenyl, alkynyl or arylalkyl group, or any heteroform of one of those groups that is contained in a substituent, can itself be optionally substituted by additional substituents. The nature of these substituents is similar to those cited in relation to the primary substituents themselves, if the substituents are not otherwise described. However, alkyl substituted by aryl, amino, alkoxy, = 0 and the like would be included within the scope of the invention, and the atoms of these substituent groups are not counted in the number used to describe the alkyl, alkenyl group, etc. that is being described. When no number of substituents is specified, each such alkyl, alkenyl, alkynyl or aryl group can be replaced with a number of substituents according to their available valences; in particular, any of these groups can be replaced with fluorine atoms in any or all of its available valences, for example.
"Heteroform", as used in the present invention, refers to a derivative of a group such as alkyl, aryl or acyl, in which at least one carbon atom of the designated carbocyclic group has been replaced by a heteroatom selected from N, O and S Thus, the alkyl, alkenyl, alkynyl, acyl, aryl and arylalkyl heteroforms are heteroalkyl, heteroalkenyl, heteroalkynyl, heteroacyl, heteroaryl and heteroarylalkyl, respectively. It is understood that no more than two N, O or S atoms are normally linked in sequence, except where an oxo group is attached to N or S to form a nitro or sulfonyl group.
"Optionally substituted", as used in this document, indicates that the particular group or groups being described may have no substituents other than hydrogen, or the group or groups may have one or more different substituents for hydrogen. If not specified otherwise, the total number of such substituents that may be present is equal to the number of H atoms present in the unsubstituted form of the group being described. Where an optional substituent is attached via a double bond, such as carbonyl oxygen (= 0), the group occupies two available valences, so that the total number of substituents that can be included is reduced according to the number of available valences.
"Halo", as used in the present invention, includes fluorine, chlorine, bromine and iodine.
"Amino", as used in the present invention, is described as "substituted" or "optionally substituted", the term includes NR'R ", where each R 'and R" can be independently H, or is an alkyl, alkenyl group , alkynyl acyl, aryl or arylalkyl or a heteroform of one of these groups, and each of the alkyl, alkenyl, alkynyl acyl, aryl or arylalkyl groups, or heteroforms of one of these groups, is optionally substituted with the substituents described as suitable for the group corresponding. The term also includes forms in which R 'and R "are linked together to form a 3-8 membered ring that can be saturated, unsaturated or aromatic containing 1 to 3 heteroatoms selected independently from N, 0 and S as members of the ring, and which is optionally substituted with the substituents described as appropriate for alkyl groups or, if NR'R "is an aromatic group, it is optionally substituted with the substituents described as typical for heteroaryl groups.
As used herein, "primary alcohol" refers to an alcohol where the carbon that carries the -OH group is only attached to an alkyl group. Examples of primary alcohols can include methanol, ethanol, 1-propanol, 2-methyl-1-propanol, butanol and pentanol. As used herein, "secondary alcohol" refers to an alcohol where the carbon that carries the -OH group is attached to two alkyl groups. Examples of secondary alcohols can include 2-propanol and cyclohexanol. As used herein, "tertiary alcohol" refers to an alcohol where the carbon that carries the -OH group is attached to three alkyl groups. Examples of tertiary alcohols can include 2-methyl-2-butanol.
As used in this document, the term "yield" refers to the total amount of the product in relation to the amount of ketone present in the fermentation product mixture. For example, with reference to FIGURE 1, the overall reaction yield refers to the combined molar yields of products A to F, calculated in relation to the molar amount of acetone present as a starting material in the fermentation product mixture.
As used in this document, the term "about" refers to an approximation of a declared value within an acceptable range. Preferably, the range is +/- 10% of the declared value.
The following description refers to a process for converting a fermentation product mixture produced from sugars derived from biomass (eg, glucose, sucrose, cellobiose, xylose) into fuels using metal-catalyzed alkylation. With reference to Figure 1, reaction 100 is an exemplary modality for the production of C5-C11 ketones suitable for use in fuels. The starting materials 102 comprise an acetone-butanol-ethanol (ABE) mixture produced by fermenting sugars derived from biomass using bacteria of the genus Clostridium. This fermentation process produces an ABE mixture in a mass ratio of 3: 6: 1 , respectively (or a molar ratio of 2.3: 3.7: 1). The acetone in the ABE mixture undergoes mono and double alkylation in the presence of the metal-based catalyst 104 (ie Pd / C) and base 106 (ie K3PO4) in solvent 108 (ie toluene) at a reaction temperature 145 ° C for 20 hours.
These reaction conditions produce 110 products which include 2-pentanone (A), 4-heptanone (B), 2-heptanone (C), 4-nonanone (D), 2-methyl-4-nonanone (E) and 6-undecanone (F). Among these products, B, D and F are produced by double-alkylation of acetone.
Under the reaction conditions described herein, in some preferred embodiments, the formation of one or more Guerbet products (e.g., aldehydes) in the product mixture is minimized. In certain preferred embodiments, ketone alkylation predominates, which produces a greater proportion of double alkylated compounds in the product mixture. The reaction conditions described here allow for greater kinetic control of the alkylation reaction to produce ketones with higher molecular weight that are suitable for aviation fuel and diesel compounds (for example, C5-C20 alkanones).
The process described in this document employs several components, including a fermentation product mixture obtained from a fermentation process, a metal-based catalyst, a base and a solvent to perform the alkylation of a ketone, such as acetone, in the presence of two or more alcohols to produce one or more products suitable for use as fuels and other chemicals. The Fermentation Product Mix
The fermentation product mixture described in this document can be derived from renewable sources, such as biomass. In some embodiments, biomass is first converted to sugars, which are then used as a raw material to produce the fermentation product mixture. Sugars suitable for use as a raw material to produce the fermentation product mixture may include, for example, monosaccharides, disaccharides or oligosaccharides. In certain embodiments, sugars can include any C5 or C6 saccharides, or a combination of C5 and C6 saccharides. In other embodiments, sugars may include arabinose, lixose, ribose, xylose, ribulose, xylulose, alose, altrose, glucose, sucrose, cellobiose, mannose, gulose, idose, galactose, thalose, psychosis, fructose, sorbose or tagatose, or mixture of them. In one embodiment, sugars can include glucose, sucrose or xylose, or a mixture thereof. In another embodiment, sugars may include glucose or sucrose, or a mixture thereof. Any methods known in the art can be employed to produce sugars from biomass. For example, biomass can undergo pretreatment processes known in the art to more effectively release sugars from biomass. Biomass is generally composed of organic compounds that are relatively rich in oxygen, such as carbohydrates, and can also contain a wide variety of other organic compounds. In some modalities, biomass is composed of cellulose, hemicellulose and / or lignin.
It must be understood, however, that in other modalities the sugars used as raw material in the fermentation process can be derived from non-renewable sources, or from renewable and non-renewable sources.
The fermentation product mixture can include a ketone and one or more alcohols. In certain embodiments, the fermentation product mixture can include a ketone and an alcohol, or a ketone and two alcohols. In certain embodiments, the ketone is acetone. The fermentation product mixture can be an ABE mixture produced by fermenting sugars using any host capable of producing hydrocarbons (for example, ethanol and heavier hydrocarbons). For example, in some embodiments, the fermentation agent is a bacterium from the Clostridia family (for example, Clostridium acetobutylicum, Clostridium beijerinckii), Clostridial bacteria have the ability to convert biomass-derived carbohydrates into an ABE mixture from hexoses and pentoses. It should be understood, however, that any fermentation agent capable of converting sugars into a mixture of a ketone and one or more alcohols can be employed to supply the raw materials for the process described herein.
In some embodiments, the fermentation product mixture can be used without further purification or isolation steps after the fermentation process. In other embodiments, the fermentation product mixture is isolated after the fermentation process. Any techniques known in the art can be used to isolate the fermentation product mixture (for example, ABE mixture) after the fermentation process.
While an ABE mixture is used as starting materials in reaction 100, the raw materials used in the process described here are not limited to butanol and ethanol like alcohols. Alcohols can be of any length. In some embodiments, the fermentation product mixture may include primary alcohols including, for example, methanol, ethanol, propanol, 2-methylpropan-1-ol, butanol, pentanol and 2-ethyl-1-hexanol.
While the ABE mixture in reaction 100 has a mass ratio of 3: 6: 1, the ratio of acetone to two or more primary alcohols can vary. For example, the fermentation process can be optimized to reduce the amount of ethanol produced, in order to maximize the yield of butanol.
Additional ketones and alcohols can be added to the fermentation product mixture to vary the range of molecular weights and structures obtained from the process described here. In some embodiments, these additional ketones and alcohols can be added to the fermentation product mixture prior to use in the reaction with the catalyst and the base. In other embodiments, these additional ketones and alcohols can be added during the reaction. These additions to the fermentation product mixture can be useful to improve the properties of the product for specific applications, such as biodiesel or lubricants. The alcohols and ketones added to the fermentation product mixture can be saturated or unsaturated. For example, oleyl alcohol can be added to the fermentation product mixture to adjust the molecular weight of the products produced by the methods described for use as lubricants.
The fermentation product mixture can also include bioderivated ketones through the ketonation of volatile fatty acids. For example, acetic acid can be ketonized through fermentation to form acetone, which can be converted into a mixture of higher ketones using the methods described in the present invention to produce gasoline and gasoline precursors. Propionic acid can also be ketonized by fermentation to form 3-pentanone, which can be converted into a mixture of higher ketones using the methods described in this document to produce gasoline and gasoline precursors.
In addition, in some embodiments, an extractor can also be used to selectively extract the fermentation product mixture from the aqueous phase in an organic phase (immiscible in water). In some embodiments, an extractor is a chemical used to recover certain products from the fermentation broth. For example, in one embodiment, an extractor is a chemical used to recover acetone and butanol from the fermentation broth.
Suitable extractors may include tributyrin (also known as glyceryl tributyrate), oleyl alcohol, polypropylene glycol (of different molecular weights) or mixtures of these extractors. In some embodiments, the extractor does not inhibit the growth of microorganisms by producing the fermentation product mixture, or decrease the rate of formation of fermentation products. In certain embodiments, the extractor can be chosen from a class of materials that (a) are not inhibitory to microorganisms (b) have very low solubility in water and (c) have very low solubility in water, referring to the amount of water which can be dissolved in the extractor.
In certain embodiments, extraction in situ can be carried out during fermentation and can reduce the inhibitory effect of some of the products generated from the fermentation process. For example, the fermentation process described above can produce metabolites that have inherent toxicity that can affect the catalysis of the alkylation reaction under aqueous conditions. The use of a selective, non-toxic and water immiscible extractor can remove inhibitory metabolites in situ produced during fermentation. Removing such inhibitory products can increase solvent titers and yields, reduce distillation costs and reduce water use and reactor sizes. When used during fermentation, the extractor used must be non-inhibitory.
In other embodiments, an extractor can be used in the fermentation product mixture after fermentation has taken place to selectively extract certain components of the aqueous phase fermentation product mixture in the organic phase. For example, in one embodiment, an extractor such as tributyrin can be used to mix fermentation product in relative amounts of acetone and butanol in the fermentation product mixture used in the alkylation reactions described herein. Such fermentation products can be recovered from the extractor by distillation. When the boiling points of the extractors used are much higher than those of fermentation products, the energy needs for distillation can be reduced. Since extractors have very little water solubility, almost no water is present in the extractor, leaving mainly fermentation products.
Thus, in some embodiments, an extractor can selectively separate acetone and butanol from an ABE mixture in ratios suitable for subsequent alkylation reactions to produce fuel products and minimize the amount of ethanol extracted. Minimizing the amount of ethanol in the ABE mixture subjected to alkylation may, in some cases, be desirable to control the molecular weight of the products, as well as to produce products with longer chains. The addition of an extractor to the fermentation culture can, in certain modalities, reduce the formation of the Guerbet product. In certain embodiments, the addition of an extractor to the fermentation culture produces at least 40%, 50%, 60%, 70%, 80% or 90% of double-alkylated products.
The use of an extractor, in certain modalities, allows the simultaneous removal of residual inhibitors and the desired product during the fermentation of biofuel, a great advantage over existing recovery technologies.
Other techniques known in the art can be used to selectively separate ketones and alcohols from a fermentation mixture (e.g., acetone and butanol from an ABE mixture) for subsequent alkylation reactions to produce fuel products. For example, pervaporation is a membrane separation technique that can be used to separate liquid mixtures across a membrane using a solution-diffusion mechanism. First, permeation through the membrane occurs and then the permeate is collected as a vapor on the other side of the membrane. Evaporation of the permeate on the permeate side of the membrane creates the driving force for the transfer of the permeate. The pervaporation membrane acts as a selective barrier between the feed and the permeate; therefore, the selection of the pervaporation membrane is crucial to achieve high selectivity and flows. The permeability of components across the membrane is the multiplication of their diffusion and solubility in the membrane material. For example, for the pervaporation of alcohol-water mixtures, the diffusivity of water is greater than the diffusivity of alcohol due to the smaller size of the water molecule. Therefore, a membrane material with greater alcohol solubility must be selected to obtain permesselectivity of higher alcohol. Polydimethylsiloxane (PDMS) is known as a membrane material for the separation of ethanol from the diluted aqueous ethanol mixture due to its hydrophobic nature and the high free volume that allows excellent selectivity and high flows.
Thus, in some embodiments, the methods described in this document also include providing a pervaporation membrane and bringing the fermentation product mixture into contact with the pervaporation membrane to selectively separate the ketone and certain alcohols. An incarnation, the pervaporation membrane is PDMS. In another embodiment, the pervaporation membrane is a triblock copolymer of poly (styrene-b-dialkylsiloxane-b-styrene) that has a polydialkylsiloxane block and polystyrene end blocks. In certain embodiments, the triblock copolymer has a molecular weight in the range of about 110 kg / mol to about 1000 kg / mol. In other embodiments, the triblock copolymer has a molecular weight in the range of about 110 kg / mol to about 500 kg / mol. In some embodiments, the triblock copolymer has a molecular weight in the range of about 120 kg / mol to about 300 kg / mol. In some embodiments, the triblock copolymer has a molecular weight in the range of about 130 kg / mol to about 300 kg / mol. In some modalities, the triblock copolymer has morphology, and in which the morphology is cylindrical, lamellar, double diamond or thyroid. In some embodiments, the triblock copolymer has a morphology, which is cylindrical or lamellar. In some embodiments, the triblock copolymer has a morphology that is cylindrical. In some embodiments, the triblock copolymer has a domain spacing (d), and in which the domain spacing is in the range of about 20 to about 90 nanometers. In some embodiments, the triblock copolymer loses about 5% by weight at a temperature in the range of about 290 ° C to about 350 ° C. In some embodiments, polyalkylsiloxane is polydimethylsiloxane. In some embodiments, the polydialkylsiloxane block has a volume fraction of about 0.6 to about 0.95 with respect to the polystyrene end blocks. The Metal-Based Catalyst
While Pd / C is used as a metal-based catalyst 104 in reaction 100, any metal-based catalyst that can catalyze the alkylation of a ketone, while reducing the oligomerization of the ketone and the formation of the Guerbet product can be employed in the process described in this document. In other embodiments, any metal-based catalyst that can catalyze the double alkylation of acetone while reducing the acetone oligomerization and the formation of the Guerbet product can be employed in the process described in this document. For example, the metal-based catalyst may include transition metals, such as nickel, ruthenium, rhodium, palladium, rhenium, iridium or platinum. In other embodiments, the metal-based catalyst includes palladium or platinum. In certain embodiments, the metal-based catalyst is [Ir (COD) Cl] 2, RUC12 (COD), PtCl2 (COD), [Rh (COD) Cl] 2, Ni / Si-Alumina, Ru / C, Rh / C, Pt / C or Pd / C.
In still other embodiments, the metal-based catalyst is a palladium-based catalyst. Palladium-based catalysts can include palladium metal and suitable ligand complexes, including those containing P and / or N atoms to coordinate with palladium atoms, and other simple palladium salts in the presence or absence of ligands. Palladium-based catalysts can also include palladium and palladium complexes supported or bound on solid supports, such as palladium on carbon (Pd / C), as well as palladium black, palladium groups or palladium groups containing other metals. Suitable examples of palladium-based catalysts can include Pd (OAc) 2, Pd2 (dba) 3, Pd (OH) 2 / C, Pd / C, Pd / CaCO3, Pd / Alumina and Pd-polyethylenimines on silica.
The metal-based catalyst can be recycled in the methods described in this document. For example, the additional fermentation product mixture (for example, ABE mixture) can be added to the reaction vessel to further increase the overall product yield. The base
While K-.PO4 is employed as base 106 in reaction 100, any base that promotes the alkylation of the ketone can be used. In certain embodiments, any base that promotes double alkylation of acetone. In other modalities, the base can also promote the reduction of ketone oligomerization and the formation of the Guerbet product.
Suitable bases can include inorganic bases (for example, alkali and alkaline earth metal hydroxides) and organic bases. Examples of inorganic bases can include potassium hydroxide, barium hydroxide, cesium hydroxide, sodium hydroxide, strontium hydroxide, calcium hydroxide, lithium hydroxide, rubidium hydroxide and magnesium hydroxide. Examples of organic bases can include triethylamine, trimethylamine, pyridine and methylamine. In some embodiments, the base is KOH, Ba (OH) 2.8H2O, K2CO2, KOAc, KH2PO4, Na2HPO2, pyridine or Et2N.
The type of base used can be determined by the desired strength of the base and its ability to promote the alkylation of a ketone without producing undesirable side reactions or side products. The amount of base selected can affect the overall reaction yield and the proportion of alkylated products. In certain embodiments, the type of base used can be determined by the desired strength of the base and its ability to promote double alkylation of acetone without producing undesirable side reactions or by-products. The amount of base selected can affect the overall reaction yield and the proportion of double alkylated products. For example, increasing the base increases the overall reaction yield as well as the selectivity for double alkylation. In some embodiments, at least 0.3 mol equivalent of base is used. In other embodiments, between 0.32 to 1.3 mol of base equivalents is used. In still other embodiments, between 0.9 to 1.5 mol of base equivalents is used. In still other embodiments, between 0.95 to 1.3 mol of base equivalents is used. In certain embodiments, 0.95 mol of base equivalent is used.
In still other embodiments, the base used can be calcined. In such embodiments, the base can be pre-treated at an elevated temperature to obtain a more active material. For example, in a modality where K3PO4 is the base used, K3PO4 can be heated to about 600 ° C to obtain a material that is more active in promoting the alkylation reaction described here. The Solvent
Although toluene is used as solvent 108 in reaction 100, it must be recognized that, in some modalities, the reaction can be carried out pure, that is, without the addition of a solvent. In other embodiments, the reaction can be carried out with a solvent. Any solvent that promotes the alkylation of the ketone can be employed in the process described in the present invention. In certain embodiments, any solvent that promotes double alkylation of acetone can be used in the process described in this document. For example, the solvent can be an organic solvent. Organic solvents can include hydrocarbons (for example, toluene, benzene), ketones (for example, acetone or methyl ethyl ketone), acetates (for example, ethyl acetate or isopropyl acetate), nitriles (for example, acetonitrile), alcohols (for example , butanol, ethanol, isopropanol) or ethers (for example, diglyme, monoglyme, diglibu, THF). As used in this document, "diglyme" refers to diethylene glycol dimethyl ether. As used in this document, "diglibu" refers to diethylene glycol tributyl ether.
A suitable solvent in the process described in the present invention is one that can be used in the fermentation process, can be used in extracting the fermentation product mixture from the fermentation process or can be mixed directly with the fermentation process products. Other considerations include promoting the reaction rate, forming the reaction products and reducing the Guerbet product and ketone oligomerization (eg, acetone). In some embodiments, the solvent may include toluene, ethyl acetate, diglyme, monoglyme, butanol, diglibu, oleyl alcohol, dibutyl phthalate or mixtures of these solvents. Reaction Conditions a) Reaction Temperature
While the reaction mixture 100 was heated to 145 ° C, the temperature at which the rational mixture is heated can vary. In some embodiments, the reaction mixture is heated to reflux. In other embodiments, the reaction mixture is heated to an appropriate temperature to increase selectivity for double alkylated products.
The preferred temperature range can vary depending on the solvent, base, and catalyst used. For example, in a reaction mixture with toluene as a solvent, the preferred reaction temperature range is between about 110 ° C to 145 ° C. In other embodiments, the reaction temperature range can be increased to, for example, 140 ° C to 180 ° C to increase selectivity for double alkylated products. b) Reaction time
While reaction mixture 100 reacted for 20 hours, the reaction time will also vary with the reaction conditions and the desired yield. In some embodiments, the reaction time is determined by the conversion rate of the starting material. In other embodiments, the reaction time is determined by the rate of double alkylation of the starting material. In other embodiments, the reaction mixture is heated for 10 to 30 hours. In other embodiments, the reaction mixture is heated for 10 to 20 hours. In still other embodiments, the reaction mixture is heated for 1 to 10 hours. In still other embodiments, the reaction mixture is heated for 5 to 10 hours.
In addition, it must be understood that the reaction can be adjusted to produce gasoline versus aviation / diesel products. In some embodiments, gasoline products may include shorter chain products, such as 2-pentanone, 4-heptanone and 2-heptanone. In other embodiments, aviation / diesel products may include products with a heavier chain, such as 4-nonanone, 2-methyl-4-nonanone and 6-undecanone.
With reference to FIGURES 6A, 6B and 17, in some embodiments, gasoline products can be produced at lower temperatures, lower base loads and shorter reaction times. In some embodiments, gasoline products can be produced at higher yields than aviation / diesel products when one or more of the following conditions occur: (a) temperature is between 90 ° C and 170 ° C; (b) between 1 and 3 moles of base equivalents are used; and (c) the reaction mixture is heated for less than 90 minutes. In other embodiments, gasoline products can be produced with higher yields compared to aviation / diesel products when one or more of the following conditions occur: (a) temperature is between 100 ° C and 120 ° C; (b) between 1.2 and 1.7 mol equivalents of base are used; and (c) the reaction mixture is heated for less than about 60 minutes. In yet other embodiments, gasoline products can be produced at higher yields than aviation / diesel products when one or more of the following conditions occur: (a) the temperature is around 110 ° C; (b) about 1.5 mol of base equivalent is used; and (c) the reaction mixture is heated between 10 and 60 minutes. In some embodiments, two or more of the conditions may occur to produce gasoline products at higher yields than aviation / diesel fuel products. In other modalities, all three conditions can occur to produce gasoline products with higher yields compared to aviation / diesel products.
In addition, it should be understood that, in other modalities, aviation / diesel products can be produced at higher temperatures, with higher base loads and longer reaction times. In some embodiments, aviation / diesel products can be produced with higher yields than gasoline products when one or more of the following conditions occur: (a) the temperature is above 170 ° C; (b) between 3 and 9 moles of base equivalents are used; and (c) the reaction mixture is heated for more than about 90 minutes. In other modalities, aviation / diesel products can be produced with higher yields compared to gasoline products when one or more of the following conditions occur: (a) the temperature is between 180 ° C and 240 ° C; (b) between 4.5 and 6 moles of base equivalents are used; and (c) the reaction mixture is heated for between 2 and 25 hours. In still other modalities, aviation / diesel products can be produced with higher yields compared to gasoline products when one or more of the following conditions occur: (a) the temperature is about 180 ° C; (b) about 6 moles of base equivalent are used; and (c) the reaction mixture is heated for between 90 and 200 minutes. In some modalities, two or more of the conditions may occur to produce aviation / diesel products with higher yields compared to gasoline products. In other modalities, all three conditions can occur to produce aviation / diesel products with higher yields compared to gasoline products. Ketones and Their Uses
The reaction conditions described here allow greater control of the molecular weight of the ketones (for example, alkanones) produced. In certain embodiments, the reaction conditions produce alkanones with molecular weights suitable for use as fuels. Alcanones suitable for use as fuels may include those with at least 5 carbons, at least 7 carbons or at least 11 carbons. In certain embodiments, the alkanones produced using the methods described in the present invention are linear. In other embodiments, the alkanones produced are branched.
While reaction 100 produces products 110 which are composed of products A to F, double-alkylated products such as 4-heptanone (B), 4-nonanone (D) and 6-undecanone (F), it must be understood that the mixture of products may vary depending on the composition of the fermentation product mixture and the reaction conditions used in the process described in this document.
In certain embodiments, R1 and R2 may be independently substituted or unsubstituted alkyls. The alkyls can be of any length. In some modalities, each Ri and R2 is independently methyl, ethyl, propyl, isopropyl, butyl, pentyl, hexyl or heptyl.
In other embodiments, the one or more compounds of Formula I are C5-C19 ketones. In other embodiments, the one or more compounds of Formula I are C5-C11 ketones. In still other embodiments, the one or more compounds of Formula I are C11-C19 ketones.
In certain embodiments, the one or more compounds of Formula I may include


While monoalkylated products can be produced according to the process described in this document, in certain embodiments, at least one of one or more compounds of Formula I is a double-alkylated product. In some embodiments, at least 50% of the product mixture is composed of one or more double alkylated products. In other modalities, less than 20% of the product mix is made up of one or more monoalkylated products.
After the production of one or more compounds of Formula I, these one or more compounds can be further hydrogenated, deformed, isomerized, hydrodeoxygenated or catalytically reformed. Double-alkylated products can later be converted into corresponding alcohols or alkanes, suitable for the manufacture of a fuel or lubricant.
Examples of alcohols produced using methods described in this document include:


Examples of alcohols produced using methods


In some embodiments, the one or more compounds of Formula I can be converted to their corresponding alcohols in the presence of a metal-based catalyst. In certain embodiments, the metal-based catalyst includes platinum. In a specific embodiment, the second metal-based catalyst is palladium on carbon (Pd / C).
In other embodiments, the one or more compounds of Formula I can be converted to their corresponding alcohols in the presence of a metal-based catalyst. In certain embodiments, the metal-based catalyst includes platinum, nickel-molybdenum (Ni-Mo), nickel-tungsten (Ni-W), cobalt-molybdenum (Co-Mo) or combinations of these metals. In specific embodiments, the second metal-based catalyst is NIO-M0O3 / AI2O3, Pt / SiO2-Al2C> 3 or combinations of these catalysts.
FIGURE 2 depicts an exemplary embodiment of C7-C11 alkanes produced by double-alkylation of the ABE mixture using the process described in the present invention that can be converted into a fuel or lubricant. For example, 4-heptanone, 4-nonanone and 6-undecanone can be further deoxygenated to produce heptane, nonane and undecane, respectively. These alkanes can be mixed into diesel and aviation fuel, or they can be used independently as fuels after a small conversion to a refinery. In some embodiments, the double-alkylated products obtained from the process described herein may be suitable for use as fuels that can power transport vehicles (for example, airplanes, diesel vehicles) and other combustion turbine applications.
It should be understood that the methods described in the present invention can produce a mixture of compounds of Formula I, or a mixture of alkanones. In certain embodiments, each of the compounds of Formula I, or each of the alkanones in the product mixture can be separated prior to use in the production of the corresponding alcohol or alkane. Other Reactions to Produce Biodiesel
Alkylation of the fermentation product mixture using the methods described in this document can produce an amount of Guerbet product. As shown in FIGURE 11, an exemplary reaction scheme, butanol dimerization via Guerbet reaction can be followed by alkylation with acetone or 2-butanone in a two-step process in a container to produce one or more ketones ranging from Cl- C27.
Referring to Figure 12, exemplary reactions 1200, 1210 and 1220 are depicted. In reaction 1200, a starting material 1202 can be reacted with butanol to produce biodiesel and various precursors or biofuel related products. In reaction 1210, starting material 1202 can be reacted with acetone and / or butanol to produce biodiesel and various precursors or biofuel related products. In reaction 1220, starting material 1222 can be reacted with acetone and / or butanol to produce biodiesel and various precursors or biofuel related products. EXAMPLES
The following examples are illustrative only and are not intended to limit any aspect of this disclosure in any way.
All reactions were performed in a closed system using a 12 Q tube (pressure tube) in a parallel optimizer. All metal sources were purchased from Aldrich or Stem Chemicals and used as received. Acetone, ethanol and butanol, as well as other chemicals, were obtained from Aldrich and used without further purification. All reactions were analyzed by gas chromatography, using dodecane as an internal standard. Gas chromatography (GC) analysis was performed on a Varian CP-3800 instrument with a FID detector and VF5ms column (5% phenyl and 95% methyl polysiloxane) using helium as the carrier gas. Example 1
Alkylation catalyzed by acetone metal using ABE mixture
A metal-based catalyst (0.01 mmol) selected from the list in Table 1 below, K3PO4 (954 mg, 4.5 mmol) and a magnetic stir bar were added to 12 mL Q tube (pressure tube) . To each tube, 1.5 ml of toluene was added. Then, acetone (0.17 ml, 2.3 mmol), ethanol (60 pL, 1 mmol) and butanol (0.34 ml, 3.7 mmol) were also added to each tube. Each tube was sealed and kept at 145 ° C in a preheated metal block. Each reaction mixture was stirred for 20 hours at 145 ° C and then cooled to room temperature. Subsequently, dodecane (internal standard) was added and diluted with ethyl acetate. GC analysis of each reaction mixture produced the ratio of AF products in Table 1 below and as described in FIGURE 3. Yields were determined based on acetone. Table 1. Variation of metal-based catalysts in acetone alkylation in ABE mixture
Example 2
Alkylation of acetone using the multi-base ABE mixture
5% palladium on carbon (containing 50% water, 42 mg, .01 mmol), a base (4.5 mmol) selected from the list in Table 2 below and a magnetic stir bar were added to a 12-inch Q tube mL (pressure tube). To each tube, 1.5 ml of toluene was added. Then, acetone (0.17 ml, 2.3 mmol), ethanol (60 pL, 1 mmol) and butanol (0.34 ml, 3.7 mmol) were also added to each tube. Each tube was sealed and kept at 145 ° C in a preheated metal block. The reaction mixture was stirred for 20 hours at 145 ° C and then cooled to room temperature. Subsequently, dodecane (internal standard) was added and diluted with ethyl acetate. GC analysis of each reaction mixture produced the ratio of AF products in Table 2 and as described in FIGURE 4. Yields were determined based on acetone. Table 2. Base variation in acetone alkylation in the ABE mixture
Example 3
Alkylation of acetone using the ABE mixture with various palladium-based catalysts
A palladium-based catalyst (0.01 mmol) selected from the list in Table 3 below, K - PO4 (3 mmol) and a magnetic stir bar were added to a 12 mL Q tube (pressure tube). To each tube, 1.5 ml of toluene was added. Then, acetone (0.17 ml, 2.3 mmol), ethanol (60 pL, 1 mmol) and butanol (0.34 ml, 3.7 mmol) were also added to each tube. Each tube was sealed and maintained at 110 ° C in a preheated metal block. The reaction mixture was stirred for 20 hours at 110 ° C and then cooled to room temperature. Subsequently, dodecane (internal standard) was added and diluted with ethyl acetate. GC analysis of each reaction mixture produced the ratio of AF products in Table 3 below and as described in FIGURE 5. Yields were determined based on acetone. Table 3. Variation of palladium-based catalysts in the alkylation of acetone in the ABE mixture
Example 4
Alkylation of acetone using the ABE mixture at various reaction temperatures
5% palladium on carbon (containing 50% water, 42 mg, 0.01 mmol), K3PO4 (3 mmol) and a magnetic stir bar were added to a 12 mL Q tube (pressure tube). To each tube, 1.5 ml of toluene was added. Then, acetone (0.17 ml, 2.3 mmol), ethanol (60 pL, 1 mmol) and butanol (0.34 ml, 3.7 mmol) were also added to each tube. Each tube was sealed and kept in a pre-heated metal block at one of the temperatures listed in Table 4 below. Each reaction mixture was stirred for 20 hours at that temperature and then cooled to room temperature. Subsequently, dodecane (internal standard) was added and diluted with ethyl acetate. GC analysis of each reaction mixture produced the ratio of AF products in Table 4 below and as described in FIGURE. 6A. Yields were determined based on acetone. Table 4. Temperature variation in the alkylation of 15 acetone in the ABE mixture
Example 5
Alkylation of acetone using the ABE mixture with different amounts of K3PO4.
5% palladium on carbon (containing 50% water, 42 mg, 0.01 mmol), K3PO4 (mmol varied according to the amounts in Table 5), and a magnetic stir bar was added to a Q tube of 12 mL (pressure tube), 1.5 mL of toluene was added to each tube. Then, acetone (0.17 ml, 2.3 mmol), ethanol (60 pL, 1 mmol) and butanol (0.34 ml, 3.7 mmol) were also added to each tube. Each tube was sealed and kept at 145 ° C in a preheated metal block. The reaction mixture was stirred for 20 hours at 145 ° C and then cooled to room temperature. Subsequently, dodecane (internal standard) was added and diluted with ethyl acetate. GC analysis of the reaction mixture produced the ratio of AF products in Table 5 below and as described in FIGURE 6B. Yields were determined based on acetone. Table 5. Variation in the amount of K3PO4 in acetone alkylation in the ABE mixture

It should be understood that 1.5 to 6 mmol of K3PO4 was used in this Example, which is 32 to 128 mol%, or 0.32 to 5 1.3 mol equivalent in the amount of alcohol used in the reaction. For example, 1.5 mmol of K3PO4 to 4.7 mmol of alcohols is equal to 0.32 mol of equivalent (or 32 mol%) of K3PO4. Example 6
Alkylation of acetone using the ABE mixture with various solvents
5% palladium on carbon (containing 50% water, 42 mg, 0.01 mmol), K3PO4 (4.5 mmol) and a magnetic stir bar were added to a 12 mL Q tube (pressure tube). To each tube, 1.5 ml of solvent selected from Table 6 below was added. The solvents were selected for use in this Example based on their suitability for extracting starting materials from the fermentation process, or for direct mixing with the products of the fermentation process. For example, ethyl acetate can be produced from biomass. Monoglime and diglyme can be used after fermentation to separate the ABE mixture from the water. Butanol can be mixed directly with biobutanol produced by fermentation.
Then, acetone (0.17 ml, 2.3 mmol), ethanol (60 pL, 1 mmol) and butanol (0.34 ml, 3.7 mmol) were also added to each tube. Each tube was sealed and kept at 145 ° C in a preheated metal block. Each reaction mixture was stirred for 20 hours at 145 ° C and then cooled to room temperature. Subsequently, dodecane (internal standard) was added and diluted with ethyl acetate. GC analysis of each reaction mixture produced the ratio of AF products in Table 6 below. Yields were determined based on acetone. Table 6. Variation of solvent in acetone alkylation in ABE mixture
Example 7
Alkylation of acetone using the ABE mixture at various reaction temperatures to form monoalkylated products
5% palladium on carbon (containing 50% in water, 42 mg, 0.01 mmol), K3PO4 (1.5 mmol) and a magnetic stir bar were added to a 12 mL Q tube (pressure tube). To each tube, 1.5 ml of toluene was added. Then, acetone (0.17 mL, 2.3 mmol), ethanol (60 pL, 1 mmol) and butanol 146 (0.34 mL, 3.7 mmol) were also added to each tube. Each tube was sealed and kept in a pre-heated metal block at one of the temperatures listed in Table 7 below. Each reaction mixture was stirred for 20 hours at that temperature and then cooled to room temperature. Subsequently, dodecane (internal standard) was added and diluted with ethyl acetate. GC analysis of each reaction mixture produced the ratio of AF products in Table 7 below. Yields were determined based on acetone. Table 7. Temperature variation in acetone alkylation in the ABE mixture to form monoalkylated products
Example 8
Alkylation of acetone using the ABE mixture over time
5% palladium on carbon (0.02 mmol), K3PO4 (9 mmol), and a magnetic stir bar were added to a 12 mL Q tube (pressure tube). To each tube, 3 ml of toluene was added. Then, acetone (4.6 mmol), ethanol (2 mmol) and butanol (7.4 mmol) were also added to each tube. Each tube was sealed and kept at 145 ° C in a preheated metal block. Each reaction mixture was stirred at 145 ° C for 20 hours. The samples were collected during 20 hours according to the times listed in table 8. Each sample was cooled to room temperature. To each sample, dodecane (internal standard) was added and diluted with ethyl acetate. The GC analysis of each reaction sample produced the ratio of the AF products in Table 8 below and as described in FIGURE 8. Yields were determined based on acetone. Table 8. Distribution of products during the reaction at the reported times
Example 9
Alkylation in a vessel and hydrogenation using the ABE mixture
5% palladium on carbon (0.01 mmol), K3PO4 (4.5 mmol) and a magnetic stir bar were added to a high pressure reaction vessel (parallel HEL synthesizer), 1.5 mL toluene to the tube. was added. Then, acetone (2.3 mmol), ethanol (1 mmol) and butanol (3.7 mmol) were also added to the tube. The tube was sealed and kept at 145 ° C in a pre-heated metal block. The reaction mixture was stirred at 145 ° C for 20 hours. A sample of the reaction mixture was collected for analysis by GC.
To this reaction mixture, 5% platinum on carbon (0.02 mmol) was added, and the reaction vessel was pressurized with H2 gas (150 psi). The reaction mixture was stirred at 110 ° C for 14 hours, and then it was cooled to room temperature. GC analysis of the reaction mixture produced the ratio of products A'-F 'as shown in the above reaction scheme. Yields were determined based on acetone. The yields in parentheses indicate the corresponding yields for ketones. Example 10
Alkylation in a vessel and hydrogenation using the ABE mixture with different amounts of base, temperature and H2 gas to produce the corresponding alcohols
5% palladium on carbon (0.01 mmol), K3PO4 (mol% varied according to the amounts in Table 9) and a magnetic stir bar were added to a high pressure reaction vessel (HEL parallel synthesizer). To each tube, 1.5 ml of toluene was added. Then, acetone (2.3 mmol), ethanol (1 mmol) and butanol (3.7 mmol) were also added to each vial. Each container was sealed and kept at 145 ° C in a preheated metal block. Each reaction mixture was stirred at 145 ° C for 20 hours.
To this reaction mixture, 5% platinum on carbon (0.02 mmol) was added and the reaction vessel was pressurized with H2 gas (pressure as shown in Table 9). Each reaction mixture was stirred at one of the temperatures listed in Table 9 below for 14 hours and then cooled to room temperature. Note that reactions 4, 8 and 12 were carried out pure. GC analysis of each final reaction mixture produced the ratio of ketones and A'-F products in Table 9. FIGURE 9 also shows the effect of varying the base concentration used on the yield of ketones and alcohols. Table 9. Distribution of the alcohol product from ketones produced from the alkylation of acetone in the ABE mixture

Example 11
Alkylation in a container of the ABE mixture and reduction of the ketones to produce the corresponding alkanes
5% palladium on carbon (0.01 mmol), K3PO4 (4.5 mmol) and a magnetic stir bar are added to two 12 mL Q tubes (pressure tubes). In both tubes, acetone (2.3 mmol), ethanol (1 mmol) and butanol (3.7 mmol) are added. Each tube is veined and kept at 145 ° C in a preheated metal block. Each reaction mixture is stirred at 145 ° C for 20 hours.
Then, the reaction mixture from each tube is filtered and the liquid products are collected. The first reaction mixture containing ketone is added to a reactor containing sulfated NIO-M0O3 / AI2O3. The reactor is pressurized to 40 bar with hydrogen gas and heated to 250 ° C. After 10 hours the reactor is cooled to room temperature and the products analyzed by GC for yields of products A "-F". The second reaction mixture containing ketone is passed in Pt / SiO2-AI2O3 in a piston bed reactor at 200 ° C with a hydrogen pressure of 30 bar. GC analysis of the reactor effluent revealed the yield of products A "-F". Example 12 Recycling of catalysts to convert the ABE mixture into ketones
5% palladium on carbon, K3PO_4 (96 mol%), and a magnetic stir bar were added to a 12 mL Q tube (pressure tube). To the tube, 3 ml of toluene was added. Then, acetone (4.6 mmol), ethanol (2 mmol), and butanol (7.4 mmol) were also added to the tube. The tube was sealed and maintained at 145 ° C.
In 10, 20 and 30 hours, 100 mol% of excess ABE mixture was added to the tube. Samples were collected at 10, 20 and 30 hours. Each sample was cooled to room temperature. To each sample, dodecane (internal standard) was added and diluted with ethyl acetate. GC analysis was performed on each reaction sample. Total yields were determined at 10, 20 and 30 hours. The total yield based on the total acetone feed for each time point was: 80% in 10 hours, 72% in 20 hours and 61% in 30 hours. This demonstrated that the metal and base catalysts remained active and continued to convert each new aliquot of the starting material.
The procedures described in this example were repeated by adding excess ABE mixture in 5 and 10.5 hours. Total yields were determined based on each time point and the results are described in FIGURE 10. Example 13
Butanol palladium-catalyzed Guerbet reaction
5% palladium on carbon (x mmol), K3PO4 (y% by mol) and a magnetic stir bar were added to a 12 mL Q tube (pressure tube). To each tube, 1.5 ml of toluene and butanol (5 mmol) was added and stirred at 145 ° C for 24 hours. Each sample was cooled to room temperature. GC analysis was performed with an internal standard (dodecane) on each reaction sample to determine product yield. The yields provided in Table 10 below correspond to product G, that is, 2-ethyl-1-hexanol. Table 10: Palladium catalyzed Guerbet reaction of butanol
Example 14 Extraction using glyceryl tributyrate
The simulated clostridia fermentation medium was made with the following components: glucose (20 g / L), yeast extract (5 g / L), ammonium acetate (2 g / L), butyric acid (2 g / L) , acetoin (3 g / L), ethanol (20 g / L), acetone (20 g / L), 1-butanol (20 g / L) and lactic acid (10 g / L). 5 ml of the simulated fermentation medium was combined with 5 ml of glyceryl tributyrate and mixed for 5 minutes by inversion. The mixtures were then decanted by centrifugation at 5300 rpm for 5 minutes and the extraction phase was removed for analysis by GC. The distribution coefficients were calculated based on the following equation:

ABE extraction experiments were performed in quadruplicate. Miscanthus giganteus, obtained from the University of Illinois, Urbana-Champaign, was first crushed and placed in a 4 mm sieve. 5% w / w of Miscanthus giganteus was mixed with 1% H2SO4 in sealed Teflon tubes and reacted under the following conditions: 30 ramp of 6 minutes at 180 ° C, 2 minutes at 180 ° C. The liquid hydrolyzate was adjusted to pH 5.0 using concentrated KOH. 3 mL of hydrolyzate was combined with 3 mL of glyceryl tributyrate and mixed thoroughly for 5 minutes by inversion. The mixtures were then centrifuged for 5 minutes at 5300 rpm and the aqueous phase was removed. The inhibitors that remained in the aqueous phase were measured through the first extraction in ethyl acetate, followed by drying with Na2SO1. The dry solution was then incubated with bis ((trimethylsilyl) trifluoracetamide at 70 ° C for 30 minutes. Inhibitor concentrations were analyzed by GC / MS with isopropylphenol as an internal standard.
Glyceryl tributyrate recovered acetone (KD = 1.1) and 1-butanol (KD = 2.6) from the aqueous solution. Ethanol, however, remained in the aqueous phase (KD = 0.2). In addition, glyceryl tributyrate removed several of the biofuel fermentation inhibitors found in acid-pretreated lignocellulosic biomass (as summarized in Table 11 below). Table 11: Extraction of inhibitors generated by pre-treatment with acid from lignocellulosic biomass


Thus, the use of glyceryl tributyrate allows the simultaneous removal of residual inhibitors and the desired product (for example, acetone and butanol) during the fermentation of biofuel, a major advantage over existing recovery technologies. Example 15 Toxicity studies on Clostridium acetobutylicum
Growth inhibition and cell viability was examined in a study using ratios of up to 1: 1 in volume of extractor to medium. This study showed that glyceryl tributyrate was non-toxic to Clostridium acetobutylicum. Example 16 Effect of glyceryl tributyrate on glucose fermentation 15
A fermentation of 2 L at 60 hours of Clostridium acetobutylicum in glucose with a volume ratio of 1: 1 volume of medium and glyceryl tributyrate was performed and observed to produce 40.8 grams of solvents with 16.4 g of 1-butanol , 3.7 g of acetone and 0.8 g of ethanol, respectively, partitioning in the extractor phase. With reference to Figure 13, these solvents were produced from 105 g of glucose and 1.6 g of acetate, reaching a total yield by weight of ABE of 90% of the theoretical maximum.
In a separate reactor, 5% palladium on carbon, K3PO4 (954 mg, 4.5 mmol) and a magnetic stir bar were added to a 12 mL Q tube (pressure tube). To the tube, 1.5 ml of toluene was added. Then, acetone, ethanol and butanol prepared from the fermentation described above were also added to the reactor. The reaction mixture was stirred for 20 hours at 145 ° C and then cooled to room temperature. The reaction mixture was diluted in tetrahydrofuran and GC analysis was performed on the reaction mixture.
FIGURE 13 illustrates the yields of the reaction products. The total molar yield based on acetone was 93%, which represented a 97% conversion. In particular, 17% of upper alkylated products and 0% of alcohol and related products were observed, as determined using the FID response factor. Product yields are further summarized in Table 12 below. The values of total mass (g) were based on fermentative production and recovery of 153.5 mmol of acetone, 333.8 mmol of butanol and 158.7 mmol of ethanol. Assuming the complete recovery of acetone, butanol and ethanol from both phases, 20 g of C7 and superior products were produced. 15 g of low molecular weight products were also produced. Table 12. Summary of the amount of alkylated products (C7 +) produced.

In contrast, FIGURE 18 illustrates the effect of inhibitors on ABE fermentation without an extractor. Example 17 Extractive fermentation in batch fed with glucose using glyceryl tributyrate
Clostridium acetobutylicum ATCC824 was grown in clostridial growth medium (CGM) as described in Example 14 above. The fed batch fermentations were carried out in 3-L bioreactors (Bioengineering AG, Switzerland) with a working volume of 2L. More glucose and yeast extract were added intermittently to the culture using a concentrated solution of 450 g / L and 50 g / L, respectively. Cultures were grown at 37 ° C anaerobically by spraying 100 mL / min of N2 gas until solvent production was started. The pH of the culture was adjusted to 5.5 before inoculation. After inoculation, the pH of the bioreactor was controlled to a pH of at least 4.8.
Sugars and main metabolites (glucose, sucrose, lactate, acetate, butyrate, acetoin, ethanol, acetone and 1-butanol) were measured in the aqueous phase, using an Agilent HPLC system (Santa Clara, CA) equipped with UV / Vis detectors and refractive index. An Bio-Rad ion exchange column (Hercules, CA) Arninex HPX-87H was used with a Cation H pre-column at 30 ° C, with a 0.05 mM sulfuric acid mobile phase, and a flow rate of 0.7 mL.min'1. The concentrations of acetone, 1-butanol and ethanol in the extracting phase were measured by GC / FID.
FIGURE 14 depicts product formation in batch extractive fermentation fed glucose with glyceryl tributyrate for 60 hours. With reference to Figure 14, glyceryl tributyrate was observed to extract mainly butanol and acetone from the aqueous phase to the extracting phase. Example 18 Extractive fermentation in sucrose-fed batch using glyceryl tributyrate
The fed batch extractive fermentation process described in Example 17 above was performed using sucrose instead of glucose as the primary carbon source. The initial sucrose concentration was 60 g / L. Specifically, sucrose extractive fermentation was carried out in 100 ml shake flasks with 25 ml of clostridia growth medium inoculated with 2mL cells in OD6OO (0.6 to 1.0). Cultures were grown at 37 ° C in an anaerobic chamber and pH adjusted to 4.8 using 1M KOH during the first 12 hours of growth. After 16 hours, 25 mL of glyceryl tributyrate was added to the culture.
FIGURE 15 depicts product formation in batch extractive fermentation fed with sucrose with glyceryl tributyrate for 60 hours. With reference to Figure 15, glyceryl tributyrate was observed to extract mainly butanol and acetone from the aqueous phase to the extracting phase. Example 19 Effect of water on the alkylation reaction of the ABE mixture
5% palladium on carbon (containing 50% water, 42 mg, 0.01 mmol), tribasic potassium phosphate (954 mg, 4.5 mmol) and a magnetic stir bar were added to a 12mL Q tube ( pressure tube). To the tube, 1.5 ml of toluene was added. Then, acetone (0.17 ml, 2.3 mmol), ethanol (60 pL, 1 mmol) and butanol (0.34 ml, 3.7 mmol) were also added to the tube. Water was also added to each tube in the amount (% w: v), shown in FIGURE 16. Each tube was sealed and kept at 145 ° C in a preheated metal block. The reaction mixture was stirred for 20 hours at 145 ° C and then cooled to room temperature. Subsequently, dodecane (internal standard) was added and diluted with ethyl acetate. GC analysis of each reaction mixture produced the amount of products as shown in Figure 16. Yields were determined based on acetone.
As seen in Figure 16, it was observed that the presence of water decreases the overall reaction rate, resulting in less double alkylation and lower overall yield. Example 20 Alkylation reaction of the ABE mixture in pure condition
5% palladium on carbon (which contains 50% water, mmol varied according to the amounts in Table 13), K3PO4 (mmol varied according to the amounts in Table 13), and a magnetic stir bar was added to a 12 mL Q tube (pressure tube). To each tube, acetone (4.6 mmol), ethanol (2 mmol) and butanol (7.4 mmol) were also added. Each tube was sealed and kept in a pre-heated metal block at one of the temperatures listed in Table 13 below. Each reaction mixture was stirred for 20 hours at that temperature and then cooled to room temperature. Subsequently, dodecane (internal standard) was added and diluted with ethyl acetate. GC analysis of each reaction mixture produced the ratio of C5-C11 and Cn + products in Table 13 below. Yields were determined based on acetone.
Table 13: Alkylation reaction products in pure condition
Example 21 Distribution of Products in the Course of Time
5% palladium on carbon (which contains 50% water, 0.02 mmol), K3PO4 (9 mmol), and a magnetic stir bar were added to a 12 mL Q tube (pressure tube). To the tube, toluene (3 mL), acetone (4.6 mmol), ethanol (2 mmol) and butanol (7.4 mmol) were added. The tube was sealed and kept in a metal block preheated to 145 ° C. The reaction mixture was stirred up to 1200 minutes and then cooled to room temperature. Subsequently, dodecane (internal standard) was added and diluted with ethyl acetate. GC analysis was performed on the reaction mixture to determine the yield of the products. Yields were determined based on acetone. FIGURE 17A shows the distribution of products over time.
As seen in Figure 17A, acetone monoalkylation with butanol and ethanol was observed to occur within the first 1-1.5 hours of the reaction to produce 2-pentanone and 2-heptanone. It was then observed that these species were subjected to additional reaction to form double, double alkylated products. Surprisingly, no aldehydes were observed during the reaction, suggesting that the aldehyde intermediates were present in very low concentrations and reacted quickly with acetone and other ketones. Therefore, it was observed that the formation of the Guerbet products was minimized and the alkylation of acetone was observed as predominant. Example 22 Double alkylation reactions to produce C11-C19 products

In a 12 mL Q tube, 5 wt% palladium on carbon (0.011 g, 0.0026 mmol, water up to 50%), tribasic potassium phosphate (0.034 g, 0.16 mmol) and a magnetic stir bar were placed. To the reaction mixture, acetone (0.058 g, 1 mmol), 2-ethyl-1-hexanol (1.30 g, 10 mmol), butanol (0.22 g, 3 mmol) and 1 ml of toluene were added in sequence. The Q tube was sealed and the reaction mixture was stirred for 20 hours at 200 ° C, in a preheated metal block. The reaction mixture was cooled to room temperature and dodecane (internal standard) was added. The reaction mixture was diluted with tetrahydrofuran and GC analysis of the reaction mixture was performed (85% overall yield, 2-Cll: 4%, 6-C11: 22%, C15: 37%, C19: 22%). Thus, this example showed the selective production of the Guerbet product (2-ethylhexanol) in the presence of acetone. Example 23 Double alkylation reactions to produce the Cl9 product

5% palladium on carbon (which contains 50% water, 0.05 mol%), tribasic potassium phosphate (0.16 mol%) and a magnetic stir bar were added to a 12 mL Q tube ( pressure tube). To the reaction mixture, acetone (0.058 g, 1 mmol), 2-ethyl-1-hexanol (0.326 g, 2.5 mmol) and toluene (1 mL) were added sequentially. The Q tube was sealed and the reaction mixture was stirred for 20 hours at 200 ° C, in a preheated metal block. The reaction mixture was cooled to room temperature and dodecane (internal standard) was added. The reaction mixture was diluted with tetrahydrofuran and the GC analysis was performed (72% yield).
Example 24 Variation of the alkylation reaction conditions of the ABE mixture to control the molecular weight of the products

The alkylation of an ABE mixture was carried out under different reaction conditions to control the production of higher molecular weight compounds. In particular, the ABE ratio, the amount of base and the temperature varied. The distillation of the ABE mixture with an extractor was also carried out in one of the reactions described below.
In the first reaction, 5% palladium on carbon (containing 50% water, 1 mol%), K3PO4 (0.95 equiv.), And a magnetic stir bar were added to a 12 mL Q tube ( pressure). To each tube, acetone (2.3 mmol), ethanol (1 mmol), and butanol (3.7 mmol) were also added. The tube was sealed and kept in a metal block preheated to a temperature between 190 ° C and 210 ° C. The reaction mixture was stirred for 20 hours and then cooled to room temperature. Subsequently, dodecane (internal standard) was added and diluted with ethyl acetate. GC analysis was performed on the reaction mixture. Overall yield (57%; C5-C11: 57%; 015: small amount).
In the second reaction, 5% palladium on carbon (containing 50% water, 1 mol%), K3PO4 (1.3 equiv), and a magnetic stir bar were added to a 12 mL Q tube (pressure tube ). To the reaction tube, acetone (1.6 mmol), ethanol (1.7 mmol) and butanol (3.7 mmol) were added. The tube was sealed and kept in a metal block preheated to a temperature of about 145 ° C. The reaction mixture was stirred for 20 hours and then cooled to room temperature. Subsequently, dodecane (internal standard) was added and diluted with ethyl acetate. GC analysis was performed on the reaction mixture. Overall yield (78%; C5-C11: 72%; C13 (5-ethylundecan-6-one): 4%, C15: 2%).
In the third reaction, 5% palladium on carbon (containing 50% water, 1 mol%), K3PO4 (0.95 equiv.), And a magnetic stir bar were added to a 12 mL Q tube ( pressure). To each tube, acetone (2.3 mmol), ethanol (1 mmol), and butanol (3.7 mmol) were also added. The tube was sealed and kept in a metal block preheated to a temperature of about 145 ° C. The reaction mixture was stirred for 20 hours and then cooled to room temperature. Subsequently, dodecane (internal standard) was added and diluted with ethyl acetate. GC analysis was performed on the reaction mixture. Overall yield (79%; C5-C11: 77%; C13: 2%).
In the fourth reaction, the reaction conditions of the third reaction described above were repeated, except that the ABE mixture was first distilled with an extractor (tributyrin). Distillation with the extractor produced an ABE mixture that mainly included acetone and butanol, which were used in the alkylation reaction. Total yield (93%; C5-C11: 67.3%, higher alkylated products: 17%, alcohol and related products: 9%).
All yields described above were determined based on acetone.
Example 25 Ir-catalyzed ABE condensation reaction
An iridium catalyst (x mol%) listed in Table 14 below, K3PO4 (0.94 mmol) and a magnetic stir bar were added to a 12 mL Q tube (pressure tube). To each tube, 1.5 ml of toluene and acetone (2.3 mmol), ethanol (1 mmol) and butanol (3.7 mmol) were added. Each tube was sealed and kept in a metal block preheated to a temperature of about 145 ° C. The reaction mixture was stirred for 20 hours and then cooled to room temperature. GC analysis was performed with an internal standard (dodecane) on each reaction sample 10 to determine the yields of the AF products, as shown in the above reaction scheme. Yields were determined based on acetone. Table 14. Variation of the type and amount of iridium catalyst

Example 26Pd-catalyzed ABE reaction - recycling experiment using calcined base
The K3PO4 used in this example was first calcined at 600 ° C for 24 hours before being used. 5% palladium on carbon (which contains 50% water, 0.01 mmol), K3PO4 (6.98 mmol), and a magnetic stir bar were added to a 12 mL Q tube (pressure tube). To each tube, acetone (2.3 mmol), ethanol (1 mmol), butanol (3.7 mmol) and toluene (2.5 ml) were added. Each tube was sealed and kept in a metal block preheated to a temperature of about 145 ° C. The reaction mixture was stirred for 10 hours (i.e., Cycle 1 in Table 15 below). More acetone (2.3 mmol), ethanol (1 mmol) and butanol (3.7 mmol) were added twice at 10 hour intervals to the reaction mixture (i.e., cycles 2 and 3, respectively, in Table 15 below) to show that the base-metal mixture can be recycled. The GC analysis of the samples at the end of each cycle was performed with an internal standard (dodecane) in each reaction sample to determine the yields of the AF products, as shown in the above reaction scheme. Yields were determined based on acetone. Table 15. Results of recycling the base-metal mixture

权利要求:
Claims (15)
[0001]
1. Method of producing two or more compounds of Formula I,
[0002]
2. Method according to claim 1, characterized by the fact that each R2 and R2 is, independently, an optionally substituted C2-C20 alkyl.
[0003]
Method according to claim 1 or 2, characterized in that the fermentation product mixture has less than 5% by weight of water.
[0004]
Method according to any one of claims 1 to 3, characterized in that the fermentation product mixture comprises acetone, butanol and ethanol.
[0005]
Method according to any one of claims 1 to 4, characterized in that the metal-based catalyst comprises palladium supported or bonded to a solid support.
[0006]
Method according to any one of claims 1 to 5, characterized in that the metal-based catalyst is Pd (OAc) 2, Pd2 (dba) 3, Pd (OH) 2 / C, Pd / C , Pd / CaCO3, Pd / Alumina or Pd-polyethylenimines on silica.
[0007]
Method according to any one of claims 1 to 6, characterized in that the base is K3PO4, KOH, Ba (OH) 2.8H2O, K2CO3, KOAC, KH2PO, Na2HPO4, pyridine or Et3N.
[0008]
Method according to any one of claims 1 to 7, characterized in that the yield of the two or more compounds of Formula I in relation to the amount of acetone present in the fermentation product mixture is at least 10%.
[0009]
9. Method according to any one of claims 1 to 8, characterized by the fact that the biomass or sugars and the fermentation host are further contacted with an extractor that has one or more of the following properties: i) it is not toxic to Clostirdium; ii) has partition coefficients for acetone and butanol equal to or greater than 1; and iii) it has a partition coefficient for ethanol less than 0.5.
[0010]
10. Method according to claim 11, characterized by the fact that the extractor is glyceryl tributyrate, glyceryl tripropionate, oleyl alcohol or polypropylene glycol.
[0011]
11. Composition characterized by the fact that it comprises: a mixture of fermentation product comprising acetone and two or more substituted or unsubstituted alcohols; a metal-based catalyst, wherein the metal-based catalyst comprises nickel, ruthenium, rhodium, palladium, rhenium, iridium, or platinum; and base; wherein acetone, the first substituted or unsubstituted primary alcohol and the second substituted or unsubstituted primary alcohol are present in the fermentation product mixture in a weight ratio of 2 to 4 acetone to 5 to 7 of the first primary alcohol substituted or unsubstituted to 0.01 to 2 of the second substituted or unsubstituted primary alcohol; wherein the base is present in an amount of at least 0.3 moles of equivalent with respect to the two or more substituted or unsubstituted alcohols.
[0012]
12. Composition according to claim 11, characterized by the fact that the fermentation product mixture comprises acetone, butanol and ethanol.
[0013]
13. Composition according to claim 11 or 12, characterized in that the metal-based catalyst comprises palladium supported or bonded on a solid support.
[0014]
14. Composition according to claim 11 or 12, characterized by the fact that the metal-based catalyst is Pd (OAc) 2, Pd2 (dba) 3, Pd (OH) 2 / C, Pd / C, Pd / CaCO3, Pd / Alumina or Pd-polyethylenimines on silica.
[0015]
15. Composition according to any one of claims 11 to 14, characterized in that the base is K3PO4, KOH, Ba (OH) 2.8H2O, K2CO3, KOAC, KH2PO4, Na2HPO4, pyridine or EtsN.

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同族专利:

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公开号 | 公开日

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WO2012166267A3|2013-04-04|

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CA2834979A1|2012-12-06|

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AU2012262901A1|2013-11-07|

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JP2014518629A|2014-08-07|

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EA201391808A1|2015-03-31|

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EA032615B1|2019-06-28|

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US9856427B2|2018-01-02|

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MX2013013555A|2014-02-27|

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BR112013030207A2|2016-11-29|

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WO2012166267A2|2012-12-06|

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US20140137465A1|2014-05-22|

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法律状态:
2019-03-06| B07A| Application suspended after technical examination (opinion) [chapter 7.1 patent gazette]|

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2020-03-31| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2020-10-20| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 26/04/2012, OBSERVADAS AS CONDICOES LEGAIS. |

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2022-02-22| B21F| Lapse acc. art. 78, item iv - on non-payment of the annual fees in time|Free format text: REFERENTE A 10A ANUIDADE. |

优先权:

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申请号 | 申请日 | 专利标题

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US201161491141P| true| 2011-05-27|2011-05-27|

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US61/491,141|2011-05-27|

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PCT/US2012/035306|WO2012166267A2|2011-05-27|2012-04-26|Method to convert fermentation mixture into fuels|

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