Intensifying cyclopentanone synthesis from furfural using supported copper catalysts

This work addresses catalytic strategies to intensify the synthesis of cyclopentanone, a bio-based platform chemical and a potential SAF precursor, via Cu-catalyzed furfural hydrogenation in aqueous media. When performed in a single step, using either uniform or staged catalytic bed configuration, high temperature and hydrogen pressures (180°C and 38 bar) are necessary for maximum CPO yields (37 and 49%, respectively). Parallel furanic ring hydrogenation of furfural and polymerisation of intermediates, namely furfuryl alcohol (FFA), limit CPO yields. Employing a two step configuration with optimal catalyst bed can curb this limitation. First, the furanic ring hydrogenation can be suppressed by using milder conditions (i.e., 150°C and 7 bar H2, and 14 seconds of residence time). Second, FFA hydrogenation using tandem catalysis, i.e., a mix of β-zeolite and Cu/ZrO2, at 180°C, 38 bar H2 and 0.6 gFFA g−1 cat hr−1, allows sufficient time for CPO formation and minimises polymerisation of FFA, thereby resulting in 60% CPO yield. Therefore, this work recommends a split strategy to produce CPO from furfural. Such modularity may aid in addressing flexible market needs.