Metal-Nitrate-Catalyzed Levulinic Acid Esterification with Alkyl Alcohols: A Simple Route to Produce Bioadditives

This work developed an efficient route to produce fuel bioadditive alkyl levulinates. Special attention was paid to butyl levulinate, which is a bioadditive with an adequate carbon chain size to be blended with liquid fuels such as diesel or gasoline. In this process, levulinic acid was esterified with butyl alcohol using cheap and commercially affordable metal nitrates as catalysts, producing bioadditives at more competitive costs. Iron (III) nitrate was the most active and selective catalyst toward butyl levulinate among the salts evaluated. In solvent-free conditions, with a low molar ratio and catalyst load (1:6 acid to alcohol, 3 mol% of Fe (NO3)3), conversion and selectivity greater than 90% after an 8 h reaction was achieved. A comparison of the iron (III) nitrate with other metal salts demonstrated that its superior performance can be assigned to the highest Lewis acidity of Fe3+ cations. Measurements of pH allow the conclusion that a cation with high Lewis acidity led to a greater H+ release, which results in a higher conversion. Butyl levulinate and pseudobuty levulinate were always the primary and secondary products, respectively. The consecutive character of reactions between butyl alcohol and levulinic acid (formation of the pseudobutyl levulinate and its conversion to butyl levulinate) was verified by assessing the reactions at different temperatures and conversion rates. A variation in Fe(NO3)3 catalyst load impacted the conversion much more than reaction selectivity. The same effect was verified when the reactions were carried out at different temperatures. The reactivity of alcohols with different structures depended more on steric hindrance on the hydroxyl group than the size of the carbon chain. A positive aspect of this work is the use of a commercial iron nitrate salt as the catalyst, which has advantages over traditional mineral acids such as sulfuric and hydrochloric acids. This solid catalyst is not corrosive and avoids neutralization steps after reactions, minimizing the generation of residues and effluents.