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The Center for Environmentally Beneficial Catalysis
Catalysis for Fine Chemicals &
Specialty Products Raghunath V. Chaudhari
Center for Environmentally Beneficial Catalysis
Department of Chemical and Petroleum Engineering
At Industrial catalysis & Catalytic Processes
Workshop at NCL, Pune
14 January, 2012
The Center for Environmentally Beneficial Catalysis
Impact of Catalysis in Life
• Catalysis contributed significantly to technological developments in various sectors of industry such as power, energy, materials, health & environment
• The 21st century has witnessed growth of Catalysis with a few serendipities, many patiently discovered facts and successful technological surprises
• Many future technological challenges will depend on breakthroughs in catalysis
Catalysis – A true multidisciplinary activity
The Center for Environmentally Beneficial Catalysis
Major Application Areas
Chemical Processes Hydrogenation, Dehydrogenation, Organic syntheses (Hydrogenolysis, Hydration, Reactive Partial Oxidation, Amination etc. ) Syn-gas Conversions and FT synthesis, Polymerizations and Oxidation
Petroleum Processes
Hydrodesulfurization, Hydrocracking, Hydrodenitrogenation, Hydrodemetalisation
Fine Chemicals and Pharmaceuticals
Hydrogenation, Carbonylation, Alkylation, Acylation, Oxidation, Amination, Hydroxylation, metathesis and C-C coupling reactions (Heck, Suzuki etc)
Biotechnology and Environmental Processes
Fermentation, Total oxidation, de-NOx, de-SOx, Auto- exhaust
The Center for Environmentally Beneficial Catalysis
Catalysts & Catalytic Processes: A Global Scenario
Products worth a Trillion Dollars are produced
annually using catalytic processes - More than GDP of
most of the countries. This excludes biocatalysts &
pollution control processes.
Value of Catalysts produced worldwide is more than US
$ 10 billion
Catalyst Usage
37 % Petroleum refining
34 % Chemical Processes
29 % Emission/Pollution control
80-90% of current Chemical Processes are based on
Catalysis
The Center for Environmentally Beneficial Catalysis
Catalysis & Green Chemistry
Growth of chemical industry has been associated
with generation of toxic and hazardous wastes
Our efforts in the last two decades in waste treatment, monitoring pollutants have improved pollution control, but, for pollution free processes Catalysis has a major role to play
Green approach in catalysis conceptualizes around use of green feedstock, high atom-efficiency & atom economy, recycling and diversification of downstream leftovers into value added products, green effluents
The Center for Environmentally Beneficial Catalysis
Green/Clean Technology Development
Major Challenges
• Replace hazardous and corrosive raw materials
/reagents
• Reduce waste products such as inorganic salts and/or
toxic co-products
• Substitute synthetic routes by catalytic ones
• Improve selectivity (atom efficiency) of desired
products
• Catalysis for processes under lower pressure and
temperatures
• Catalytic reaction engineering for optimization of
processes for higher productivity and safer operation
The Center for Environmentally Beneficial Catalysis
Examples of Catalysis in Clean Technologies
• Hydrogenation replacing stoichiometric reagents such as Fe-
HCl, NaBH4
• Oxidation using molecular oxygen or H2O2 to replace HNO3,
K2Cr2O7 type reagents
• Alkylation and acylation using solid acid catalysts to replace
Friedel-Craft synthesis with AlCl3
• Carbonylation reactions to produce carboxylic acid replacing
stoichiometric NaCN and HCN or HF/BF3
• Hydroformylation of olefins for synthesis of aldehydes and
alcohols
• Asymmetric catalysis for synthesis of enantiomerically pure
drugs, and agrochemicals, replacing the conventional optical
resolution methods
The Center for Environmentally Beneficial Catalysis
Application areas :
Fine & Specialty chemicals
Agricultural Chemicals Adhesives
Biocides Catalysts
Dyestuffs Electronic chemicals
Feed and food additives Flavors and fragrances
Industrial coatings Ind. & Inst. Cleaners
Lubricants & functional Fluids Paper additives
Pharmaceuticals Photographic chemicals
Pigments Plastics and polymers
Specialty surfactants Synthetic fibers & textiles
Sales > $ 140 billion
The Center for Environmentally Beneficial Catalysis
Fine Chemical Manufacturing Trends
The Center for Environmentally Beneficial Catalysis
Salient features of Fine chemicals
& pharmaceuticals Processes
Scale of production usually below 1000 TPA involving multiple organic synthesis
Batch processes are common
Varying market demands require product changeover
Stringent product specifications
Severe selectivity problems
Problems of corrosion, health hazards, safety, effluent disposal
Separation problems associated in the downstream processes
The Center for Environmentally Beneficial Catalysis
Key Business Aspects
Small manufacturing firms are starting up
Larger firms are expanding by
buying specialty companies
forming business alliances
establishing entrepreneurial divisions
Everyone is chasing chemistry professors
Product portfolios are expanding by “trees”
The Center for Environmentally Beneficial Catalysis
Examples of Catalytic Reactions in
Pharmaceuticals
Ibuprofen, by a three step catalytic route involving acylation, hydrogenation and carbonylation (3500 TPA, Hoechst Celanese Corporation)
Hydroformylation of diacetoxybutenes to 2-Methyl-4- acetoxybutenal (an intermediate for Vitamin-A, > 600 TPA, Hoffmann-La Roche & BASF)
Heck Coupling of 3-Bromopyridine & But-1-ene-3,4-diol followed by asymmetric hydrogenation to pyridine diol (intermediate for drugs in treatment of allergic conditions of eyes, nose and skin, optimized on multi-kg scale by AstraZeneca)
Oxidation of p-cresol to p-hydroxybenzaldehyde (intermediate for antibiotics like Amoxicillin, Cephalosporin)
Hydrogenation of butynediol to cis-butenediol (intermediate for Vitamin B6) Rev. Chem. Eng, 8, 1 (1992)
The Center for Environmentally Beneficial Catalysis
Examples of Catalytic Reactions in
Pharmaceuticals ….contd. Hydrogenation of,
nitrobenzene to p-amino phenol (An intermediate for paracetamol
(Mallinkrodt Process)
4-Acetoxy-3-methoxy-a-acetamido cinnamic acid to L-Dopa (drug for
Parkinson’s disease, >200 TPA, Monsanto)
branched C13 allylic alcohol to Vitamin E intermediate (Multi kg scale
process, Takasago)
C22-C23 double bond of bacterial metabolite Avermectin B1 to
Ivermectin (antiparasitic agent, useful for the treatment of
onchocerciasis; Manufactured by Merck)
1-hydroxy-2-propanone to (S)-1,2-propanediol (Intermediate for (S)-
oxfloxazin, bactericide; Manufactured by Takasago – 50 TPA)
substituted b-keto esters to b-hydroxy esters, (chiral building blocks,
e.g. carbapenem intermediate; Manufactured by Takasago – 120 TPA)
CHEMTECH., 18, 184 (1988)
The Center for Environmentally Beneficial Catalysis
Catalysis to Replace Phosgene
The Center for Environmentally Beneficial Catalysis
Goal: Eliminate phosgene use in
production of key chemical intermediates
Polycarbonate (PC)
Dimethyl Carbonate (DMC)
Diphenyl Carbonate (DPC)
Monomers for polyurethanes
- Methylene Diphenyl Diisocyanate (MDI)
- Toluene Diisocyanate (TDI)
Carbaryl (insecticide)
The Center for Environmentally Beneficial Catalysis
Polycarbonate (PC) Production via
the Phosgene Process
Global production ~1.2M tonnes/yr
Approximate cost $3-7 per kg
Important applications:
• Electronics: CDs, DVDs, computer parts
• Medical: Compatible with USP VI standard
• Packaging, shields
• Automotive and aviation: Light casings, instrument panels, interiors
Phosgene BPA Polycarbonate
n
The Center for Environmentally Beneficial Catalysis
Oxidative Carbonylation:
A Non-Phosgene Route
Alternative to phosgene for synthesis of
carbamates, carbonates and urea derivatives
Clean catalytic and atom efficient route
Eliminates corrosion problems
Development of selective catalysts is a major
challenge
The Center for Environmentally Beneficial Catalysis
Oxidative Carbonylation of Phenol to
Diphenyl Carbonate
• Typical Catalyst :Pd (OAc)2/Co catalyst and promoter
• Temperature :80 - 100 0C
• Pressure : 50 -100 atm
• Conversion : 50%
• Selectivity : 90%
US Patent No. : 5,399,734 (1995)
• Early studies showed promise of an oxidative carbonylation route
as an alternative to phosgene
• Catalysts to date suffer from low turnovers and stability problems
The Center for Environmentally Beneficial Catalysis
Oxidative Carbonylation of Bisphenol A
to Polycarbonate (Example 1)
Novel catalyst developed :
Pd(acac)2/Co(SMDPT)/Terpyridine/TEAB
Temperature: 100oC, Pressure : 1000 psig
Oligomer yield based on BPA charged : 90%
TON ~ 100
Single step non-phosgene
route for polycarbonate
US Patent No. 6,222,002
The Center for Environmentally Beneficial Catalysis
Single-Step Oxidative Carbonylation
of BPA to Polycarbonate
Ultimate low cost simple process
But, still needs catalyst improvements and
increased product purity
Low molecular weight PC [~3000] obtained
Catalyst TON of 100 achieved at 95% BPA conversion; oligomer yield 90%
Control oligomer weight by reactive separation with proper choice of solvents
Initially envisage two-step process with further polymerization of low MW oligomers
Future challenge: design a highly active/stable catalyst with minimal components
Current status
The Center for Environmentally Beneficial Catalysis
Synthesis and Use of Dimethyl Carbonate (DMC)
Trans-esterification of DMC with phenol to yield DPC
Oxidative carbonylation of Methanol
Conditions
CuCl/ KCl catalyst, T=130 oC, 2.4 Mpa, 35-250 g/l/h productivity
DPC used as a raw material for polycarbonates
The Center for Environmentally Beneficial Catalysis
Polycarbonate Synthesis by
Transesterification
Reaction uses trans-esterification catalysts and either phenol or
Bis-Phenol A as the reactant to obtain either DPC or PC
The Center for Environmentally Beneficial Catalysis
Exciting New Process: Asahi
Kasei’s CO2-based Non-Phosgene
Polycarbonate
• First process to use carbon dioxide as a starting material.
• 50,000 tonnes/yr plant operating in Taiwan since 2002.
The Center for Environmentally Beneficial Catalysis
Commercial Isocyanate Products
Monomeric MDI
Oligoisocyanate MDI
Monomeric TDI
4,4’-MDI 2,4’-MDI 2,2’-MDI
2,4-TDI 2,6-TDI
• MDI & TDI represent 90 % of the isocyanate market and are the key
monomers for polyurethanes (4M TPA in US)
• Diisocyanates are reacted with polyols to produce polyurethanes. The range
of polyurethane types, from flexible or rigid light weight foams to tough, stiff
elastomers, are used in a wide diversity of consumer and industrial
applications.
The Center for Environmentally Beneficial Catalysis
Applications of Polyurethanes
MDI-Polyurethanes
TDI-Polyurethanes
MDI-Polyurethane
Domestic
insulation
Multipurpose
adhesives
Automotive
interiors
Composite
wood products
Synthetic
leather
TDI-Polyurethane
The Center for Environmentally Beneficial Catalysis
Growth in MDI Demand
The Center for Environmentally Beneficial Catalysis
Conventional Process for MDI uses
Phosgene
Condensation
Neutralization
Phosgenation
Disadvantages
Handling of toxic and corrosive phosgene, used in high excess
Produces large quantity of HCl and NaCl
Poor selectivity to pure monomeric MDI
Difficulty in removal of hydrolysable chlorine compounds
Polyamine
Poly-MDI
The Center for Environmentally Beneficial Catalysis
Alternative: Oxidative Carbonylation
Route to MDI
-H2O
OR
NHCOOEt + 2CO2 2NO + 3CO + EtOH
(EPC)
3. Decomposition
+ 2 EtOH
( 4,4' - , and 2,4' - MDI)
NCO CH2OCNNHCOOEt CH2EtOCONH
Second Step : Intermolecular transfer reaction
+ EPC
( 4,4' -, and 2,4' - MDU)
EtOCONH 2CH NHCOOEt EPC+N CH2 NHCOOEt
COOEt
( N-benzyl compound)
2
First Step : Condensation
2. Condensation
(MDU)
COOEt
NHCOOEt N CH2NHCOOEt + HCHO
1. Carbonylation
(EPC)
NHCOOEt + H2OO22
1+ CO + EtOH + NH2
A clean catalytic
process without
using toxic and
corrosive phosgene
Requires cheaper
raw materials like
CO and O2, aniline
being common in all
the routes
Eliminates inorganic
salts and HCl
formation providing
environmentally
benign process
Novel Features of non-Phosgene Route
The Center for Environmentally Beneficial Catalysis
Heterogeneous Catalysts Work Well in
Oxidative Carbonylation
• Separable Catalysts
• Efficient catalysts with
high activity, selectivity
and recyclability
Conversion: 98.5%
Selectivity: 96.4%
TOF: 157 h-1
0
20
40
60
0 1 2 3 4
Recycle No.
Con
v/ Y
ield
, %
0
20
40
60
80
100
DP
U S
elec
tivit
y, %
ConversionYieldSelectivity
The Center for Environmentally Beneficial Catalysis
Reactions Conditions:
Catalyst: Supported Pd/NaI,
Temperature: 190oC
Total Pressure: 1000 psig, Yield of
Polycarbamate: 94%
Oxidative Carbonylation of Poly-DADPM
Single step non-phosgene process
Novel catalyst with high selectivity to Poly-MDU
Chaudhari et al, WO-01/47871 A2
The Center for Environmentally Beneficial Catalysis
• A non-phosgene route for the synthesis of methyl N-phenyl carbamate from dimethyl carbonate and N,N-diphenyl urea under mild conditions.
• A homogenous catalyst, sodium methoxide exhibited excellent activity in the synthesis of methyl N-phenyl carbamate under atmospheric pressure.
Green Chem., 2007
Synthesis of Methyl N-phenyl Carbamate
from CO2
The Center for Environmentally Beneficial Catalysis
2-Arylpropionic acids (NSAIDs):
Carbonylation Route
The Center for Environmentally Beneficial Catalysis
Profens: 2-Arylpropionic acids (non-steroidal anti-inflammatory drugs)
Ibuprofen
(Boots, Hoechst Celanese)
Naproxen
(Syntex) Ketoprofen
(Wyeth-Ayerst)
Indoprofen
(Farmitalia)
Fenoprofen
(Lilly)
Carprofen
(Hoffmann-LaRoche) Flurbiprofen
(Upjohn)
The Center for Environmentally Beneficial Catalysis
Ibuprofen – Classical Routes
Toxic NaCN required
Generation of large quantity of inorganic salts
Hazardous downstream effluent handling
6-step synthesis
Stoichiometric AlCl3 required
Enormous byproduct salts generated
Overall Atom Economy ~ 40%
OTHER STOICHIOMETRIC ROUTE
BOOTS PROCESS
The Center for Environmentally Beneficial Catalysis
Alternative: Catalytic Carbonylation Route for
Ibuprofen
Total world production of Ibuprofen is > 15,000 tpa*
Ibuprofen by Hoechst Celanese (Currently BASF) via the carbonylation route : ~ 3500 tpa
High regioselectivity (>95%) to the branched isomer (Ibuprofen) is attained but at high CO pressures (>160 bar)
Clean and eco-friendly process with ~77-99 % overall atom economy‡
* Myers R. L. The 100 Most Important Chemical Compounds: A Reference Guide, 150, 2007
‡ http://www.rsc.org/education/teachers/Resources/green/ibuprofen/home.htm
The Center for Environmentally Beneficial Catalysis
Catalyst Performance Improved with
Novel Low-Pressure Catalyst
Stud. Surf. Sci. Catal. 1998, Catal. Lett. 1999, Org. Lett., 2000
Catalyst
Biphasic
PdCl2(PPh3)2
/10% Aq. HCl
Homogeneous
PdCl2(PPh3)2/
HCl
Homogeneous
PdCl2(PPh3)2 /
TsOH-LiCl
Homogeneous
Pd(pyca)(PPh3)(O
Ts) /TsOH-LiCl
Temp, °C 130 115 115 115
CO Pressure,
bar
160 54 54 54
TOF, h-1 42 90 829 840
iso sel., % >95 93 96 99.5
CO, H2OCOOH
RR
COOH+
LiCl, TsOHR
OH
Major (iso) Minor (n)
Novel Pd(pyca)(PPh3)(OTs) complex showed distinct improvement
lower reaction temperature
CO pressure reduced from 160 to 54 bar
20-fold enhancement of TOF
Improvement of Catalyst Performance
The Center for Environmentally Beneficial Catalysis
Another Option: Aqueous Biphasic Catalyst Water-soluble [Pd(Pyca)(TPPTS)]+TsO- complex prepared
by exchanging PPh3 with TPPTS
Chem. Comm., 2000
Gas
phase
Organic
phase
Aqueous
phase
Substrate Product Conv
, %
TOF
, h-1
Regiosel,
%
Iso n
81 147 98 1.5
45 10 93 6.5
Temp = 388K, PCO = 5.4 MPa
CO
CO
CO
Li+
Cl- Higher activity than the BHC biphasic process
High iso-selectivity was observed
Catalyst active on recycles under CO atm only
The Center for Environmentally Beneficial Catalysis
Yet Another Option: Supported Pd Catalysts
LiCl-TsOH, PPh3 promoters used
Catalyst Conv
%
Regiosel
%
TOF
h-1
1% Pd-C 96 99.2 3375
1% Pd/ -alumina 92 99.5 2475
1% Pd/H ZSM 5 90 99.0 2285
1% Pt-C 90 99.2 550
Pd metal 97 99.3 90
Comments
High activity and selectivity observed
Pd-C catalyst recycled efficiently for at least 6 times
Active Pd-complex leaches out during reaction and re-adsorbed to support after reaction
Chem. Comm., 1999
The Center for Environmentally Beneficial Catalysis
Metal complex: Pd(pyca)(PPh3)(OTs)
Support: MCM-41, MCM- 48, SBA-15
Distinctions
High activity (TOF 450 h-1)
High selectivity ( 99% to iso)
Easily separable & recyclable
Highly stable (Pd leaching 10-4 %)
Still Another Option: Anchored Pd-complex
Catalysts in Mesoporous Supports
J. Am. Chem. Soc.,2002
The Center for Environmentally Beneficial Catalysis
Ossification of Pd-complexes
Aq. TPPTS
Aq. Ba(NO3)2
Catalytically active
Coordination sphere
Insoluble appendage
Facile synthesis steps
Making Aq. Soluble Pd-
complexes having –SO3-
groups
Simple admixing with Ba2+
ions
Stable intrinsically insoluble
metal complex formed
Wide applicability to all
similar aqueous soluble
catalysts to obtain solid
catalysts
The Center for Environmentally Beneficial Catalysis
Asymmetric Catalysis
The Center for Environmentally Beneficial Catalysis
A major advancement in synthesis of enantiopure chiral drugs, agrochemicals and flavoring agents by asymmetric hydrogenation, isomerization , oxidation and hydroformylation reactions.
Majority of the pharmaceutical products prescribed presently involve molecules with at least one chiral center and a stringent enantiopurity is required in 80% of products.
Asymmetric Catalysis
Drugs
Agrochemicals
Flavouring agents
The Center for Environmentally Beneficial Catalysis
Why Asymmetric Catalysis ?
The demand for single enantiomeric
products is increasing at > 9 %
annually with sales of $ 147 bn
Large differences in the activities of
individual enantiomers. In many cases,
one of the stereo isomer is either
inactive or toxic
Racemic switch : Product line
extension for existing racemates for
expired patents
Asymmetric catalysis provides a clean,
atom efficient route for synthesis of
single enantiomers involving minimum
synthesis steps and minimized waste
generation
The Center for Environmentally Beneficial Catalysis
Selectivity is Important
Chemo-Selectivity
The selective conversion of one functional group in the
presence of other dissimilar but reactive groups
Regio-Selectivity
The selective conversion of a functional group to a
desired regio-isomer
Stereo-Selectivity
The selective conversion to one stereo-isomer in
preference to another, represented as Enantiomeric
excess (ee) defined as : (R – S) /(R + S)
The Center for Environmentally Beneficial Catalysis
Asymmetric Hydrogenation of C=C Bonds
• Aroma compound (Both R & S isomers are useful fragrance compds)
• This reaction is H2-pressure dependent - low pressures trigger
isomerization to nirol
• Chirality of BINAP (R or S) and product configuration (R or S) are
reverse
• Commercialized by Takasago on 300t/a scale
ee 97 %; TOF-500 h-1
Noyori et al , JACS, 109, (1987) 1596
The Center for Environmentally Beneficial Catalysis
L-Dopa Synthesis by Asymmetric Hydrogenation
1 2
Hydrogenation is carried out in a slurry of substrate (S/C ratio = >20000:1)
Reaction involves simultaneous dissolution of H2 and sparingly soluble substrate followed by reaction to produce precipitating solid product
The precipitate, essentially optically pure is collected by filtration while the catalyst and the racemic product remain in solution
95% ee for L-Dopa derivative is obtained
Commercialized by Monsanto - > 2 tons/a
‘Asymmetric Catalysis on Industrial scale’ Ed. H.
U. Blaser, E. Schmidt WILEY-VCH 2004
drug for Parkinson’s disease
The Center for Environmentally Beneficial Catalysis
Metolachlor synthesis
• Metolachlor is the active ingredient of Dual® – One of the most
important grass herbicides
• Out of the four isomers, two isomers with (1’S) configuration account
for ~ 95 % of the herbicide activity of Metolachlor
• An example of Chiral Switch - It is marketed as a racemic mixture of
all 4 from 1976, but recently changed to (1’S) Metolachlor
• Racemic Metolachlor Synthesis: Pt catalyzed reductive alkylation of
2-methyl-5-ethyl aniline (MEA)
• (1’S) Metolachlor: Asymmetric hydrogenation of MEA imine
The Center for Environmentally Beneficial Catalysis
Asymmetric Hydrogenation of C=N Bond: Metolachlor Synthesis
• Rh-diphosphine: Low ee: 69%; Low TOF: 15h-1
• Ir-diphosphine: Good ee: 84%; Low TOF: 250 h-1
• Ferrocenyl diphosphines: New class of ligands was synthesised and found to be highly active e.g. Xyliphos
• Optimization of reaction conditions: - Acetic acid as solvent was found to be effective - Quaternary ammonium iodide (NBu4I) increased the rate by 5 times and
leads to 100 % conversion in 1/20th time
- ee values decreased from 83% at –10º C to 76% at 60º C - Optimum conditions: 50º C and 80 bar H2 pressure
The Center for Environmentally Beneficial Catalysis
Metolachlor Process
Syngenta’s Metolachlor plant - C & EN 82 (2004)
Important Issues: Synthesis of MEA imine in required purity Development of Xyliphos synthesis from g to kg scale in reproducible form and quality Catalyst instability: Liquid formulation developed for intermittent catalyst addition
Choice of reactor technology: A loop reactor was used for optimum mass and heat transfer
Process Features: ee: 84 %; TON: 1000000; TOF: 200000 h-1
Plant capacity: 10000 ton/a of (S)-NAA Largest scale catalytic enantio-selective hydrogenation plant in the world ‘Asymmetric Catalysis on Industrial scale’ Ed. H.
U. Blaser, E. Schmidt WILEY-VCH 2004
The Center for Environmentally Beneficial Catalysis
Challenges in Asymmetric Catalysis
Processes
While enantioselectivity is of prime importance, it is the overall rate of reaction that will decide industrial feasibility
The enantioselectivity is more sensitive to higher temperature than chemo selectivity or regioselectivity
Synthesis of chiral catalysts at lower cost on commercial scale
Catalyst-product separation is complex due to non-volatile and thermally sensitive products. Opportunity for development of Heterogenized chiral catalysts
Detailed kinetic analysis is required as, most reactions involve gas-liquid or gas-liquid -solid systems with complex chemistry
the reactivity of the intermediates of respective enantiomers differs radically in many cases
the Non-Linear Effect between ee of chiral auxiliaries and products
In some cases the individual enantiomers differ in their solubility properties e.g. L-Dopa
The Center for Environmentally Beneficial Catalysis
Catalyst Invention
Research Concept
Catalyst Synthesis
Catalyst Characterization
Rapid Catalyst Screening
Basic Rxn. Kinetics
Preliminary Process Economics
Market Input
Catalyst Modification
Catalyst Life Studies
More Detailed Kinetics
Detailed Process Economics
Lab Reactor Evaluations
Commercial Application
Pilot-Plant Evaluation
Catalyst Scale-Up
Discovery “Good Science”
Development Commercialization “Good Engineering”
- from Discovery to Commercialization -
P. L. Mills, J. F. Nicole and M. P. Harold, Stud. Surf. Sci. Catal. , Vol 133, 2001
The Center for Environmentally Beneficial Catalysis
New Trends in Green Technology
Development
• Novel synthetic routes & New Chemistry
One pot reactions
Tandem synthesis
Multifunctional catalysts
Immobilized catalysts
• Novel Reactor concepts
Batch to continuous operations
Microchannel reactors
• Green solvents or Solventless Processes
The Center for Environmentally Beneficial Catalysis
Center for Environmentally
Beneficial Catalysis
• Established in 2003 by NSF
• >$30 million invested
• World-class faculty;
• Modern laboratories
• Industry-guided research
• Revenue-generating projects
The Center for Environmentally Beneficial Catalysis 54
Core Projects: Some Recent Advances
4 L Spray Oxidation Reactor:
1st extended continuous runs
Inexpensive
soluble polymer
ligands for
hydroformylation
Nanofiltered:
soluble polymer-
bound methyltri-
oxorhenium for
oxidation
Cu-Pd/Graphene Nanocatalysts
for biomass conversions
Multi-
functional
mesoporous
catalysts
The Center for Environmentally Beneficial Catalysis
• ADM
• Chevron Phillips
• ConocoPhillips
• Dupont
• Evonik
• ExxonMobil
• P&G
• UOP
• Zeachem
• BASF Catalysts
• BP
• CritiTech, Inc
• Eastman
• Gevo
• KTEC
• Novozymes
• Pharma Roundtable
• SI Group
15 Industrial Partners Total
The Center for Environmentally Beneficial Catalysis
Current Industry Advisors
56
Former Partners BASF Catalysts
BP
CritiTech, Inc
Eastman
Gevo
KTEC
Novozymes
Pharma Roundtable
SI Group
Conclusions Advances in Catalysis are providing improved process
economics, environmental compatibilities, and product quality
replacing stoichiometric processes.
Wide ranging opportunities exist in the design of innovative
high-performance multicomponent catalyst systems and process
routes.
Asymmetric catalysis provides a cost effective, environmentally
acceptable alternative for synthesis of enantiopure products,
however, the success would largely depend on development of
lower cost chiral ligands and catalyst-product separation
technology
Enantioselectivity coupled with high productivity (TOF) and
stability is essential in catalyst development to expand the
applicability of Asymmetric Catalysis
The challenges can be met through integrated efforts in catalysis
science and engineering.