Scale-Up for the Conversion of Corn Stover-Derived Levulinic Acid into 2-Methyltetrahydrofuran

Abstract

Previous research has identified attractive chemical pathways to form levulinic–lactic acid mixtures from corn stover. Unfortunately, there is little market demand for levulinic acid, so conversion into more useful chemicals is needed. Presented herein are the results from a study to translate and optimize two lab-scale reactions that can be used to transform levulinic acid into a useful platform chemical, 2-methyltetrahydrofuran (2-MeTHF), to the continuous bench-scale. 2-MeTHF is an important monomer for the production of liquid polyols, which are used in polymer foam products. First, a hydrogenation reaction takes place, transforming levulinic acid into γ-valerolactone (GVL) by reaction with isopropanol using a Zr-β-zeolite catalyst. Next, the GVL is reacted with hydrogen to form 2-MeTHF utilizing a CuO/Al2O3 catalyst. Both reactions were optimized in bench-scale continuous flow reactors designed to produce 0.613 kg/h of 2-MeTHF from an initial feed of 1.02 kg/h of levulinic acid with a single pass conversion of 81 mol%.