1. Introduction
Glycerol, a highly functionalized molecule, was identified as one of the top twelve most important bio-based chemicals in the world by the US Department of Energy [
1]. Glycerol has a wide range of applications, from the production of food additives to pharmaceuticals, cosmetics, personal care products and detergents, and it is also transformed into non-toxic solvents [
2,
3,
4,
5].
Nowadays, glycerol is mostly generated as an undesired byproduct (around 10% of the total volume) during the production of biodiesel, one of the most important and valuable alternative liquid biofuels in the transportation sector [
6,
7,
8]. In 2017, the production of biodiesel exceeded 21 million tons per year just in the EU [
9]. Thus, despite the wide market for glycerol, the increasing growth of the biodiesel industry leads to the problem how to utilize the glycerol glut. Moreover, the use of low-quality glycerol from biodiesel production involves complex and expensive purification processes. Therefore, adding value to glycerol could contribute to the commercial viability of biodiesel production.
Among the processes used to transform glycerol (oxidation/reduction, reaction with other molecules), selective oxidation by low-cost and environmentally-friendly heterogeneous catalytic methods allows glycerol to be converted into more valuable products. Using glycerol as a raw material can result in a range of useful oxygenated compounds, such as glyceric, tartronic, glycolic, lactic and hydroxypyruvic acids, and dihydroxyacetone. Hence, control of the product selectivity is crucial.
Selective oxidation of glycerol with molecular oxygen on supported precious metal catalysts, (Pd, Pt and notably Au) shows very high activity in the process [
10,
11,
12,
13,
14]. Furthermore, compared with catalysts based on metals of the platinum group, gold catalysts appear to be more resistant to oxygen poisoning under liquid-phase oxidation conditions using O
2 as the oxidant [
15]. However, to obtain significant glycerol conversion, the presence of an alkaline medium is necessary, because it contributes to the first step of the oxidation process, the deprotonation of glycerol, which is considered essential for the oxidation of primary alcohols [
16]. A gold catalyst alone cannot activate the hydroxyl group of glycerol at mild temperatures [
17].
The major oxidation products of glycerol obtained over gold-based catalysts in the presence of added bases are glyceric and glycolic acids and in some cases tartronic acid (
Table 1,
Scheme 1), which are produced by the sequential oxidation of glyceric acid. All these substances are valuable substrates for the chemical and pharmaceutical industry. Glyceric acid, is generally considered as the primary product from glycerol oxidation and is used in cosmetology as a carotolytic and as a base material for functional surfactants and monomer for oligoesters [
18]. However, semi-industrial methods for the production of glyceric acid have not been developed yet, even though the general approaches of enzymatic synthesis [
19,
20] and the traditional methods for producing α-hydroxy acids by acid hydrolysis of cyanohydrins are still applicable. Glycolic acid is used in the textile industry as a dyeing and tanning agent, in food processing as a flavoring agent and as a preservative, and in the pharmaceutical industry as a skin care agent [
21]. It is also used together with lactic acid, another high value glycerol oxidation product, to produce a co-polymer (poly (lactic-co-glycolic acid), PLGA) for medical application in drug delivery [
22]. Among these compounds, tartronic acid is a high value-added chemical with high biological activity used in the treatment of metabolic disorders, liver diseases, and osteoporosis. It is also an anti-corrosive protective agent and a monomer of biopolymers [
23,
24,
25,
26].
Table 1 briefly summarizes some of the catalytic results from research [
27,
28,
29,
30,
31,
32,
33,
34,
35] on glycerol oxidation with molecular oxygen under pressure over gold supported catalysts in the presence of a base under different reaction conditions.
Carretin et al. [
27] reported the selective oxidation of glycerol to glyceric acid (100% selectivity), probably via the initial formation of glyceraldehydes using gold supported on activated carbon or graphite under mild reaction conditions after 3 h. It was also noted that, with high concentrations of NaOH, exceptionally high selectivity to glyceric acid can be obtained. However, by decreasing the glycerol to gold ratio (R) from 540 to 214 and the oxygen concentration, an increase of glycerol conversion is obtained, with the formation of some tartronic acid via consecutive oxidation.
Porta and Prati [
28] obtained a high selectivity towards glyceric acid (92%) with a 90% conversion of glycerol on a Au/C catalyst by optimizing the temperature and a NaOH/glycerol ratio. The higher the temperature, the higher the amount of tartronic acid formed (however, no data on selectivity values were provided). Also, larger gold particles (30 nm size) that were obtained with immobilization methods, maintained constant selectivity while particles with a smaller mean size (6 nm) obtained with incipient wetness or impregnation methods showed higher activity with a rapid change in selectivity. Besides that, the authors established the existence of two main pathways one leading to hydroxyacetone and glyceric aldehyde as the main oxidation products, and the other to glycolic and oxalic acids as the final compounds. In addition, the rapid oxidation of glyceraldehyde favors the formation of glyceric acid, rather than that of hydroxyacetone (
Scheme 1).
Cai et al. [
29] observed high catalytic performance (90–99% conversion after 9 h) in glycerol oxidation with different selectivity values on Au NPs deposited on various supports (CeO
2, activated carbon and different Y type zeolites). However, it should be noted that a low ratio of glycerol to Au (R = 150) was used in all cases. Preferential formation of tartronic acid (from 44 to 82%) was observed when Y type zeolite was used as the support, while the primary products on Au/CeO
2 and Au/C were oxalic acid (55%) and glyceric acid (89%), respectively. The authors proposed that the main reason for the formation of tartronic acid was the small size of the Au nanoclusters (1 nm) on the HY zeolite support.
Villa et al. [
30] described high activity (full conversion) of PVA protected Au nanoparticles (NPs) supported on NiO for glycerol oxidation, but with lower selectivity (55%) to glycerate after 4 h of reaction. Under the same reaction conditions, Au/TiO
2 prepared the same way achieved 81% of glycerate selectivity but 64% for glycerol conversion. The improvement in activity by using NiO as the support was related to the stronger interaction between the support and the Au NPs. The XPS measurements revealed only Au
0 species on both support (NiO and TiO
2) surfaces.
Wang et al. [
31], investigated Au catalysts supported on nanofibers with different degrees of graphitization under the same reaction conditions used in [
30]. They found a similar size of Au NPs (3.5–3.8 nm) with a similar level of activity in glycerol oxidation (64–70%), but with different product distributions. The authors attributed this to the different shape and configuration of the Au particles. On Au/CNF-PS, 55% of glyceric acid (C3 product) and 45% of formic and glycolic acid (C1 + C2 products) were obtained, while 22% of glyceric acid and 77% of formic and glycolic acid were observed using Au/CNF-HT. The high selectivity of the latter catalyst to C1 and C2 products, which derives from the C-C bond cleavage, was supposedly associated with the exposure of low index Au planes surfaces caused by the direct contact between CNF-HT and the {111} surface of PVA Au NPs, while disordered carbon nanofiber surfaces (CNF-PS) led to random orientation of supported particles.
Sobczak et al. [
28] obtained a Au/Nb
2O
5 catalyst with catalytic properties comparable to Au/C, prepared by the gold-sol method and crystalline niobia. After 5 h, glycerol conversion was 67% with glyceric acid as the main product. However, Au on carbon showed a different behavior. Thus, it was concluded that oxidation of glycerol is a complex process and many parameters influence the activity and selectivity of the catalysts used. Au/Nb
2O
5 was also tested in a second glycerol oxidation run by simple solvent decantation after the first run, without any drying and washing, and a small decrease in the activity (9%) with no change in selectivity was observed. Total selectivity (<100%) could not be reached for several reasons: polymerization of the reaction products, oxidation of the reaction products to CO
2 or adsorption of the products on the support surface. It was noted that glycolic acid formation proceeds via cracking of the C-C bond by the acidic centers on the catalyst surface. The authors suggested that the higher yield of tartronic acid was caused by the slow desorption of glyceric acid. The Au-Nb
2O
5 catalyst was also investigated by Wolski [
33], who found that with Au NPs smaller than 3 nm, the catalyst ability of C-C bond cleavage was enhanced and promoted formation of C2 and C1 products.
Murthy and Selvam [
34] reported 82–84% glycerol conversion after 5 h on mesoporous carbon supported nano-gold catalysts synthesized by the sol-immobilization method, with 70% selectivity to glyceric acid. The remarkable performance of both fresh and regenerated catalysts (second cycle), was attributed to the presence of pore channels in mesoporous carbons, which act as nanoreactors preventing the agglomeration of nanoparticles.
Zope et al. [
35] studied the factors that influence the formation of diacids (tartronic and oxalic acids) in glycerol oxidation and of furandicarboxylic acid in 5-hydroxymethylfurfural (HMF) oxidation over gold supported catalysts (Au/TiO
2 and Au/C). Interestingly, hydrotalcite was used as an alternative to liquid bases for HMF reaction, which requires further neutralization. To effectively produce diacids, the use of a continuous reactor or high Au catalyst loadings in a semi-bath reactor was needed. Such conditions are necessary to prevent the formation of trace byproduct species from monoacid, since such species inhibit the rate of both glycerol oxidation and monoacid oxidation to diacid. Thus, the best results were obtained in the semi-bath reactor with R = 350: full conversion and 30% of diacid (25% of tartronic acid and 5% of oxalic acid) over Au/TiO
2 catalyst after 3 h at 60 °C under 11 bar of O
2.
After analyzing these works, it can be concluded that it is essential to control the activity and selectivity in the process of liquid-phase oxidation of glycerol, and a comprehensive approach is necessary. This includes taking into account the particle size and shape of gold, the choice of the support and reaction conditions, that is, the amount of base and gold added relative to alcohol, and reaction temperature.
The aim of this work was to study the influence of the nature of the support and the base additives on the catalytic performance of gold catalysts in the liquid phase oxidation of glycerol by molecular oxygen.
2. Materials and Methods
Gold catalysts with a nominal load of 4% were prepared, using HAuCl
4·4H
2O (Merck, Darmstadt, Germany) as a precursor, using the deposition-precipitation with urea (Merck, Darmstadt, Germany) method. Commercial oxides TiO
2, CeO
2, La
2O
3 and MgO (Aldrich), and titanium oxide modified by impregnation with aqueous solutions of La(NO
3)
3∙6H
2O, Ce(NO
3)
3∙6H
2O or Mg(NO
3)
2∙6H
2O (Merck, Darmstadt, Germany) in a molar ratio Ti/M (La, Ce, Mg) = 40, according to the procedure described in previous works [
36,
37,
38], were used as supports.
Pretreatment in a hydrogen atmosphere for 1 h at a temperature of 300 °C was used for the decomposition of the products of the hydrolysis of the complex of gold (III) with urea on the support surface [
39].
The catalysts were characterized by adsorption-desorption of N
2 at −196 °C on a Micromeritics 23x-Tristar 3000 Apparatus, Micromeritics Instrument Corporation (Norcross, GA, USA), X-ray diffraction (XRD) on a Philips XPert PRO diffractometer (Amsterdam, Netherlands), X-ray photoelectron spectroscopy (XPS), on a ESCALAB 200A, VG Scientific (Waltham, MA, USA), energy-dispersive X-ray spectroscopy (EDX), transmission electron microscopy (TEM), as well as scanning transmission electron microscopy-high angle annular dark field (STEM-HAADF) using one single microscope (JEOL JEM-2100F, JEOL Ltd., Tokyo, Japan) and the temperature-programmed carbon dioxide (CO
2-TPD) method on a “Chemosorb” chemisorption analyzer (Neosib, Novosibirsk, Russia) as previously reported in [
36,
37,
38,
40,
41,
42], where the detailed description of the applied procedures can be found.
The size of the gold NPs used in the (i.e., after the reaction test) catalysts was investigated by high resolution transmission electron microscopy (HRTEM) using a JEM-2100F instrument. The samples were ground to a fine powder and sonicated in hexane at room temperature. Then, a part of the suspension was placed on a lacey carbon-coated Cu grid. For each sample, at least 300 particles were counted.
The determination of the basic sites is described in detail in previous papers by our group [
37,
38]. Briefly, the CO
2-temperature-programmable desorption (TPD) method was applied using a “Chemosorb” chemisorption analyzer (Neosib, Novosibirsk, Russia), equipped with a thermal conductivity detector (TCD). After treatment in an inert atmosphere, samples were saturated with CO
2 for 1 h at 25 °C and the temperature was increased to 600 °C at a rate of 10 °C min
−1 under an inert atmosphere. Total basicity was calculated from the area of the desorption peaks.
The catalytic tests were carried out in a semi-batch reactor operated under 3 atm of oxygen at 50 °C under stirring at 1100 rpm. Typically, the catalyst sample was added in a glycerol/gold ratio R = 1000 mol/mol to 10 mL of 0.3 M glycerol (87 wt.% solution, Fluka, Maurice, NJ, USA) and 1.2 M NaOH aqueous solution (distilled water) in a glass reactor equipped with heater, mechanical stirrer, gas supply system and thermometer. Small aliquots of the reacting mixture were taken after 15, 30, 60, 120 and 180 min to monitor the reaction progress. Catalytic experiments with alkaline earth bases (MgO, SrO, CaO) were performed with Au/La2O3/TiO2 catalyst under the conditions described above (R = 1000, pO2 = 3 atm) with different glycerol/base molar ratios (4 or 12) and reaction temperatures (50, 80 or 95 °C),over a 6 h period.
The reactants and products were analyzed and quantified by high-performance liquid chromatography (HPLC, Agilent Technologies, 1220 Infinity, Santa Clara, CA, USA) using a column Alltech OA-10308 (L × i.d.: 300 mm × 7.8 mm, Fisher Scientific, Hampton, NH, USA) with ultraviolet (Varian 9050 UV, 210 nm) and refractive index (Waters RI) detectors, using 0.4 mL/min of 0.1% aqueous solution of H3PO4 as the eluent. Attribution of peaks was made by comparison with chromatograms of standard samples. No activity of oxidation of glycerol was observed in the absence of support/catalyst.
The conversion of glycerol and selectivity to products were calculated in terms of moles of C atoms, according to Equations (1) and (2), respectively:
Turnover frequency (TOF) was calculated with regard to the number of moles of gold during the first 15 min as follows:
The carbon balance in all the reported test data was within 100 ± 5%.
4. Conclusions
The efficiency of gold catalysts supported on pure oxides (TiO2, CeO2, La2O3 and MgO) or modified titania (CeO2/TiO2, La2O3/TiO2 and MgO/TiO2) was investigated in the aerobic oxidation of glycerol under mild (T = 50 °C, 3 atm of O2 and added base) conditions.
Gold catalysts were highly effective in the oxidation of glycerol in the presence of an alkaline base (NaOH). The order of the catalyst’s initial activity (TOF in 15 min) was found to be as follows: Au/MgO/TiO2 ≥ Au/La2O3/TiO2 > Au/CeO2 >Au/CeO2/TiO2 > Au/La2O3 > Au/TiO2 > Au/MgO. A combination of small particle size and high concentration of basic groups was proposed as requisite for the effective oxidation of glycerol.
The main product was sodium glycerate (38–72%). However, on the most active catalysts (Au/La2O3/TiO2, Au/CeO2, Au/MgO/TiO2 and Au/CeO2/TiO2) that exhibited full conversion, an increase in the formation sodium tartronate was observed with run time, and the selectivity to tartronate on these materials after 3 h (glycerol/Au = 1000) was as follows: 15, 19, 25 and 32% respectively. The tendency of these catalysts is as follows: the higher the growth of Au NPs after the reaction, the less formation of tartronate, which may indicate some deactivation of the catalysts, which prevents the further oxidation of glyceric acid to tartronic acid.
Although replacing traditional alkaline base (NaOH) with alkaline earth bases (CaO, SrO and MgO) did not provide higher activity, it led to the formation of free carboxylic acids in contrast to the salts formed in the case of NaOH. The highest conversion of 20% was achieved when MgO and Au/La2O3/TiO2 catalyst were used, giving a 52% selectivity to glyceric acid in 6 h at T = 95 °C, glycerol/MgO = 4 and glycerol/Au = 1000.