A PROCESS FOR PREPARATION OF 2, 5-FURAN DICARBOXYLIC ACID FROM 5-HYDROXYMETHYL FURFURAL

Abstract

The present invention provides a process for the synthesis of furan dicarboxylic acid (FDCA) from glucose or crude hydroxy methyl furfural (HMF) using mixed metal oxides catalyst. The present invention further provides a process for preparation of the mixed metal oxides catalyst.

Claims

1. A process for synthesis of 2, 5-furan dicarboxylic acid from crude 5-hydroxymethyl furfural, the process comprising the steps of: a) reacting a glucose with a zeolite catalyst in a solvent at a temperature in the range of 165° C.-185° C. for a period of 5-6 hrs to obtain crude 5-hydroxymethyl furfural; b) optionally, purifying the crude 5-hydroxymethyl furfural as obtained in step (a) with a solvent by extraction method to obtain pure 5-hydroxymethyl furfural; c) reacting the 5-hydroxymethyl furfural as obtained in step (a) or (b) with a mixed metal oxide catalyst in a solvent at a temperature in the range of 12θ° C.-140° C. for 1-24 hrs under 10-20 bar O.sub.2/air pressure in the presence of a base to obtain 2,5-furan dicarboxylic acid.

2. The process as claimed in claim 1, wherein selectivity of the 2,5-furan dicarboxylic acid is in the range of 80 to 95% with 50 to 80% of yield; and wherein said crude 5-hydroxymethyl furfural used is with purity in the range from 80-90%.

3. The process as claimed in claim 1, wherein said zeolite catalyst used in step a) is selected from the group consisting of H-form of Mordenite, Faujasite, Beta zeolite, Mobil-type five and H-form of Zeolite Socony Mobil-5, and H-Beta type having Si/Al or Si/Heteroatom ratios in the range from 1 to 400, wherein the heteroatom is selected from Aluminum, Gallium and Boron.

4. The process as claimed in claim 1, wherein said solvent of step (a) or (b) is selected from the group consisting of water, methyl isobutyl ketone, dichloromethane, methyl isobutyl ketone, ethyl acetate, diethyl ether, hexane, tetrahydrofuran, dimethyl sulfoxide, toluene alone or combination thereof.

5. The process as claimed in claim 1, wherein said mixed metal oxide catalyst used in step c) is selected from mixture of oxides of metals comprising of Cobalt, Cerium, Iron, Vanadium, Copper, Zirconium, Titanium, Lanthanum, Manganese and a mixture thereof, wherein said metals are supported on support selected from Cerium(IV) oxide, activated Carbon, Silicon dioxide, Zirconium dioxide, Aluminum oxide, Titanium dioxide, Magnesium oxide, Calcium oxide, Strontium oxide, Barium oxide, Lanthanum oxide, Samarium(III) oxide, Yttrium oxide, Zinc oxide, Molybdenum trioxide, Thorium dioxide, Zinc oxide-Aluminum oxide, Magnesium oxide-Titanium dioxide, Caesium/Aluminum oxide, Sodium oxide, Potassium oxide, Caesium oxide/Aluminum oxide, Caesium/Silicon dioxide, Caesium oxide/Silicon dioxide, Sodium oxide/Magnesium oxide, hydrotalcite (Mg.sub.6Al.sub.2(OH).sub.16CO.sub.3.Math.4H.sub.2O), chrysolite (Mg.sub.3(Si.sub.2O.sub.5)O.sub.3(OH).sub.4), sepiolite (Mg.sub.4Si.sub.6O.sub.15(OH).sub.2, alkali ion-exchanged zeolites, alkali ion-added zeolites, lanthanide imide and nitride on zeolite, and metal oxynitrides.

6. The process as claimed in claim 1, wherein said base used in step c) is selected from the group consisting of sodium carbonate, sodium bicarbonate, potassium carbonate, potassium bicarbonate, sodium hydroxide and potassium hydroxide.

7. The process as claimed in claim 1, wherein ratio of the 5-hydroxymethyl furfural: mixed metal oxide catalyst used in step c) is in the range of 0.1-10.0.

8. The process as claimed in claim 1, wherein amount of said base used in step c) is 1-2 molar equivalent to complete 2, 5-furan dicarboxylic acid formation.

9. The process as claimed in claim 1, wherein the mixed metal oxide catalyst is selected from the group consisting of oxides of Cobalt-Manganese-Cerium, Cobalt-Manganese-Iron, Cobalt-Manganese-Iron-Zirconium and Cobalt-Manganese.

10. A process for preparing the mixed metal oxide catalyst as claimed in claim 1, comprising mixing and grinding metal precursors in the range of 0.1-1 molar ratio in presence of oxalic acid in the range of 0.5-0.75 at a temperature in the range of 25-35° C. for time period of 10-20 minutes to obtain a paste; drying the grinded paste in hot air oven at a temperature in the range of 50° C. to 150° C. for time period of 2-16 hrs followed by calcination at temperature between 300-800° C. in oven for a time period of 1-20 hrs in the presence of air to get the mixed metal oxide catalysts.

11. The process as claimed in claim 9, wherein said precursors used are selected from cobalt (II) acetate tetrahydrate, cereous nitrate hexahydrate, ferric nitrate nonahydrate, vanadium (III) chloride, copper (II) nitrate trihydrate, zirconyl nitrate, manganese (II) nitrate tetrahydrate and mixtures thereof.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0085] FIG. 1: SEM images of catalyst synthesized

[0086] FIG. 2: TEM images of catalyst synthesized

[0087] FIG. 3: XRD patterns for synthesized catalysts

[0088] FIG. 4: FT-IR spectrum for FDCA; FT-IR (v, cm-1): 3151, 3125 (—OH); 1701 (C═O); 1572, 1424 (C═C); 1276, 1229 (C—O); 962, 852, and 763 (═CH) groups respectively.

[0089] FIG. 5: .sup.1HNMR (6/ppm) spectrum for FDCA

[0090] FIG. 6: High Resolution Mass Spectroscopy analysis for FDCA.

DETAILED DESCRIPTION OF THE INVENTION

[0091] The invention will now be described in detail in connection with certain preferred and optional embodiments, so that various aspects thereof may be more fully understood and appreciated.

[0092] In the current invention, the inventors have overcome several drawbacks of prior arts by developing an oxidation reaction in the presence of non-precious metal-based catalysts, which operate under milder conditions and use high substrate concentrations.

[0093] Accordingly, to accomplish the objects of the invention, a process for the synthesis of 2, 5-furan dicarboxylic acid (FDCA) from crude 5-hydroxymethyl furfural (HMF) is provided; wherein the process comprising the steps of: [0094] a) synthesizing 5-hydroxymethyl furfural (HMF) from glucose by using a zeolite catalyst in a suitable solvent at a temperature in the range of 165° C.-185° C. for a period of 5-6 hr to afford crude 5-hydroxymethyl furfural (HMF); [0095] b) optionally, purifying the crude 5-hydroxymethyl furfural (HMF) with a suitable solvent obtained at step a) by extraction method to afford pure 5-hydroxymethyl furfural (HMF); [0096] c) reacting the 5-hydroxymethyl furfural (HMF) obtained at step b) with mixed metal oxide catalyst in a solvent at a temperature in the range of 120° C.-140° C. for 1-24 hr under 10-20 bar O.sub.2/Air pressure in the presence of a base to afford 2,5-furan dicarboxylic acid (FDCA).

[0097] The process of the present invention is depicted below in scheme-1:

##STR00001##

The zeolite catalyst used at step a) is selected from the group comprising of H-form mordenite, faujasite, beta, MFI, HMOR, HZSM-5, H-Beta type having varying Si/Al or Si/Heteroatom ratioscan vary from 1 to 400, wherein heteroatoms are selected from Al, Ga, B, which will retain zeolite framework.

[0098] The suitable solvent used at step a) and step b) may include polar solvent, ketone solvent, ether solvent, ester solvent, non-polar solvent, and mixtures thereof.

[0099] Polar solvents may include water, ammonia, sulfuric acid, deuterium oxide, ethanol, methanol, acetone, isopropanol, methyl ethyl ketone, n-propanol, acetonitrile, DMSO, and DMF and mixtures thereof.

[0100] Nonpolar solvents may include chloroform, pentane, hexane, benzene, toluene, octane, decane, dimethyl ether, and dichloromethane, and mixtures thereof.

[0101] Ketone solvent may include acetone, methyl ethyl ketone, methyl isobutyl ketone, and mixtures thereof.

[0102] Ether solvents may include tetrahydrofuran, diethyl ether, 1,4-dioxane, methyl tert-butyl ether, and mixtures thereof.

[0103] Ester solvents may include methyl acetate, ethyl acetate, isopropyl acetate, tert-butyl acetate, and mixtures thereof.

[0104] The solvent used in step a) is mixture of water and methyl isobutyl ketone in the range of range 0.1:1 to 1:0.1 v/v.

[0105] The solvent used in step b) is selected from dichloromethane, methyl isobutyl ketone, ethyl acetate, diethyl ether, hexane, tetrahydrofuran, dimethyl sulfoxide, toluene alone or combination therefrom.

[0106] The mixed metal oxide catalyst used at step c) is selected from the oxides of the metal group comprising of Co, Ce, Fe, V, Cu, Zr, Ti, La and Mn. Moreover, these metals also supported on various supports selected from CeO.sub.2, Activated Carbon, SiO.sub.2, ZrO.sub.2, Al.sub.2O.sub.3, TiO.sub.2, HT, MgO, NaY.

[0107] The metal oxides comprising the catalyst are optionally supported on basic supports selected form the group comprising of: [0108] (1) Single component metal oxides [0109] alkaline earth metal oxides (MgO, CaO, SrO, BaO etc.) [0110] rare earth oxides (La.sub.2O.sub.3, Sm.sub.2O.sub.3 etc.) [0111] other oxides (Al.sub.2O.sub.3, ZrO.sub.2, Y.sub.2O.sub.3, ZnO, TiO.sub.2, MoO.sub.3, ThO.sub.2, etc.) [0112] (2) Double components metal oxide (ZnO—Al.sub.2O.sub.3, MgO—TiO.sub.2 etc.) [0113] (3) Zeolites [0114] alkali ion-exchanged zeolites: Na-X, Cs-X (where X stands for zeolite type) [0115] alkali ion-added zeolites: Cs.sub.2O/Cs-X (where X stands for zeolite type) [0116] (4) Supported alkali metal compounds [0117] alkali metal compounds on alumina (Na or K or Cs/Al.sub.2O.sub.3, Na.sub.2O or K.sub.2O or Cs.sub.2O/Al.sub.2O.sub.3 etc.) [0118] alkali metal compound on silica (Na or K or Cs/SiO.sub.2, Na.sub.2O or K.sub.2O or Cs.sub.2O/SiO.sub.2 etc.) [0119] alkali metal ions on alkaline earth oxides (Na.sub.2O/MgO etc.) [0120] (5) Clay minerals [0121] hydrotalcite (for e.g. Mg.sub.6Al.sub.2(OH).sub.16CO.sub.3.Math.4H.sub.2O with varying metal content) [0122] chrysolite (for eg. Mg.sub.3(Si.sub.2O.sub.5)O.sub.3(OH).sub.4 with varying metal content) [0123] sepiolite (Mg.sub.4Si.sub.6O.sub.15(OH).sub.2 with varying metal content) [0124] (6) Non-oxide [0125] KF supported on alumina (for e.g. KF/Al.sub.2O.sub.3 etc.) [0126] lanthanide imide and nitride on zeolite [0127] metal oxynitrides: ALPON, VALPON etc.

[0128] The base used at step c) is selected from the group consisting of sodium carbonate, sodium bicarbonate, potassium carbonate, potassium bicarbonate, sodium hydroxide and potassium hydroxide.

[0129] In particularly useful embodiment, sodium carbonate is used as a base at step c).

[0130] The ratio of HMF:catalyst used at step c) is in the range of 0.1-10.0.

[0131] The amount of base used at step c) is 1-2 molar equivalent to complete FDCA formation.

[0132] The selectivity of the product 2,5-furan dicarboxylic acid (FDCA) is >80%, preferably 80 to 95% with >50%, preferably 50 to 80% yield.

[0133] In an embodiment of the invention, the HMF used is crude with purity in the range from 80-90%.

[0134] The mixed metal oxide catalyst is selected from Co—Mn—Ce, Co—Mn—Fe, Co—Mn—Fe—Zr, Cu—Mn.

[0135] In an aspect of the invention, the mixed metal oxide catalyst is synthesized by a simple, green process comprises mixing metal precursors in the range of 0.1-1 molar ratio and mixing with oxalic acid varying in the range of 0.5-0.75 at 25-35° C. for 10-20 minutes; drying the grinded paste in hot air oven at 50° C. to 150° C. for 2-16 h followed by calcination at 300-800° C. temperature in oven for a period of 1-20 hr in the presence of air to get mixed metal oxide catalysts.

[0136] Here, Oxalic acid was added for making material more porous.

[0137] The precursors used are selected from Cobalt (II) Acetate Tetrahydrate, Cerous Nitrate Hexahydrate, Ferric Nitrate Nonahydrate, Vanadium (III) Chloride, Copper (II) Nitrate Trihydrate, Zirconyl Nitrate and Manganese (II) Nitrate Tetrahydrate.

[0138] Metal precursors mixed in the range of 0.1-1 molar ratio and mixed with oxalic acid varying in the range of 0.5-0.75. Mixed metal precursor to oxalic acid ratio is 0.1:0.75M.

[0139] In a comparative embodiment, supported metal catalysts using noble metals like Ru (0.25 to 3 wt % loading) are prepared by wet impregnation method where mixed metal oxides are used as a support.

[0140] In an optional aspect, the catalysts are synthesized by processes selected from sol-gel process or wet impregnation process or incipient wetness method, physical mixture of metal oxides etc.

[0141] Several experiments have been conducted with different reaction parameters and by using different mixed metal oxides, solvents etc. Results from those experiments are summarized in the following tables.

TABLE-US-00001 TABLE 1 The results obtained by using different mixed metal oxides on crude HMF (80-90%) oxidation. Catalyst Press. FDCA HMF Sr. (M:M' mol Temp. Time O2 Sel. Conv. No. ratio) (° C.) (h) (bar) (%) (%) 1 Without catalyst 120 6 10 4 90 2 Co—Mn (1:4) 120 4 10 65 100 3 Co—Mn—Ce 120 4 10 30 78 4 (1:4:1) 6 53 96 5 8 52 98 6 Co—Mn—-Ce 120 4 10 67 95 7 (1:4:0.25) 6 75 100 8 140 6 6 80 100 9 Co—Mn—Fe 120 4 10 68 95 10 (1:4:1) 8 15 78 98 11 Co—Mn—Fe—-Zr 120 4 10 62 95 12 (1:4:0.5:0.5) 8 67 97 13 Cu—Mn (1:4) 120 4 10 75 92 14 8 15 90 100 15 Co—Mn—Zr 120 8 10 68 100 16 (1:4:1) 140 6 12 73 100 17 Mn—Fe—Cu 120 6 10 19 97 (4:1:1) 18 Mn—Fe—Ce 140 6 6 54 96 (4:1:0.25) 19 Co—Cu—Mn 120 10 10 42 100 (1:1:4) 20 Co—Mn—V (1:4:1) 120 6 10 2 53 21 Co—Cu—Mn—Ce 120 6 10 60 92 (1:1:4:0.25) 22 Co—Cu—Mn—Fe 62 95 (1:1:4:1) 23 Co—Mn/HT 52 92 24 Co—Mn—Ce/HT 59 96 25 Cu—Mn—Ce 49 88 (1:4:0.25) 26 Cu—Mn—Fe—Zr 54 93 (1:4:1:1) 27 Ru/Co—Mn (1:4) 120 6 10 75 95 28 Ru—Co—Mn—Ce 85 100 (1:4:0.25) 29 Ru—Cu—Mn (1:4) 83 100 30 .sup.#Ru/Carbon 4 93 100 31 Ru—Co—Mn—Ce/C 90 100 (1:4:0.25) 32 Co/NG 120 8 35 98 33 CuOx/MC 120 6 45 100 34 MnOx— 120 6 35 100 CoOx/MC 35 CuMn/NG 120 8 53 100 *Reaction condition: 0.5 wt % solution of crude HMF (Purity 80-90%), catalyst (0.5 g), Water (30 mL), Base (Na.sub.2CO.sub.3: 0.15 g). (MC = Mesoporous carbon, NG = Nitrogen doped graphene) .sup.#0.25 g catalyst. Note: When solid base is used in the reaction, homogeneous base is not used.

TABLE-US-00002 TABLE 2 The data of effect of time on the HMF oxidation reaction. Catalyst FDCA HMF Sr. (M:M′ mol Time, Selectivity Conversion No. ratio) (h) (%) (%) 1 Co—Mn—Ce 4 69 83 2 (1:4:0.25) 6 80 100 3 8 60 92 1 Co—Mn—Fe 2 38 78 2 (1:4:1) 4 68 95 3 6 73 96 4 8 78 98 1 Co—Mn—Fe—Zr 4 62 95 2 (1:4:0.5:0.5) 6 65 96 3 8 67 97 1 Cu—Mn 4 82 92 2 (1:4) 6 85 100 3 8 90 100 *Reaction condition: 0.5 wt % solution of crude HMF (Purity 80-90%), catalyst (0.5 g), Water (30 mL), Base (Na.sub.2CO.sub.3: 0.15 g), Temperature (120° C.), O.sub.2 Pressure (10-15 bar). Note: In case of Co—Mn—Ce (1:4:0.25) catalyst, reaction carried out at 6 bar oxygen and 140° C.

TABLE-US-00003 TABLE 3 The data of effect of HMF purity on the oxidation. Purification of lab synthesized HMF was done in the lab by solvent extraction technique. Catalyst Tem- FDCA Sr. (M:M' mol Purity of perature, Time, Pressure Selectivity No. ratio) HMF (%) (° C.) (h) O2 (bar) (%) 1 Co—Mn—Ce 50 120 12 20 50 2 (1:4:0.25) 60 120 12 15 51 3 80 120 8 10 78 4 90 140 6  6 80 5 98 140 6  6 91 (Commercial sample) 1 Co—Mn—Fe 50 140 12 15 56 2 (1:4:1) 60 140 8 15 54 3 80 120 6 10 76 4 90 120 8 15 78 5 98 120 8 10 37 (Commercial sample) 1 Co—Mn— 50 120 12 20 47 Fe—Zr 60 120 10 15 52 2 (1:4:0.5:0.5) 80 120 8 10 54 3 90 120 8 10 67 4 98 120 6 10 70 (Commercial sample) 1 Cu—Mn 50 120 12 20 53 (1:4) 60 120 12 20 68 2 80 120 8 15 75 3 90 120 8 10 90 4 98 120 8 15 92 (Commercial sample) *Reaction condition: catalyst (0.5 g), solvent (water: 30 mL), Base (Na.sub.2CO.sub.3: 0.15 g)

TABLE-US-00004 TABLE 4 Effect of reaction temperature on the HMF oxidation reaction. Catalyst Pressure FDCA Sr. (M:M′ mol Temperature, Time O2, Selectivity No. ratio) (° C.) (h) (bar) (%) 1 Co—Mn—Ce 100 6 6 19 2 (1:4:0.25) 120 6 6 62 3 140 6 6 80 1 Co—Mn—Fe 100 6 10 57 2 (1:4:1) 120 8 15 78 3 140 8 10 68 1 Co—Mn—Fe—Zr 100 6 15 49 2 (1:4:0.5:0.5) 120 8 10 67 3 140 8 10 56 1 Cu—Mn 100 6 15 75 2 (1:4) 120 8 15 90 3 140 8 15 80 *Reaction condition: 0.5 wt % solution of crude HMF (Purity 80-90%), catalyst (0.5 g), solvent (water: 30 mL), Base (Na.sub.2CO.sub.3: 0.15 g).

TABLE-US-00005 TABLE 5 Recyclability of the catalyst is studied by conducting several experiments. Catalyst FDCA Sr. (M:M′ mol Time, Selectivity No. ratio) Run No. (h) (%) 1 Co—Mn—Ce 1 6 80 2 (1:4:0.25) 2 6 61 3 3 6 50 4 4 6 48 1 Co—Mn—Fe 1 8 78 2 (1:4:1) 2 8 78 3 3 8 74 4 4 8 73 1 Co—Mn—Fe—Zr 1 8 67 2 (1:4:0.5:0.5) 2 8 63 3 3 8 63 4 4 8 61 1 Cu—Mn 1 8 90 2 (1:4) 2 8 62 3 3 8 55 4 4 8 51 *Reaction condition: 0.5 wt % solution of crude HMF (Purity 80-90%), catalyst (0.5 g), solvent (water: 30 mL), Base (Na.sub.2CO.sub.3: 0.15 g), Temperature (120° C.), Pressure (10-15 bar). Note: In case of Co—Mn—Ce (1:4:0.25) catalyst, reaction carried at 6 bar oxygen and 140° C.

TABLE-US-00006 TABLE 6 The results obtained by HMF concentration study. Catalyst HMF FDCA Sr. (M:M′ mol concentration Time, Selectivity No. ratio) (wt %) (h) (%) 1 Co—Mn—Ce 0.5 6 80 2 (1:4:0.25) 2.0 6 72 3 5.0 6 63 4 10.0 6 48 5 20.0 6 33 1 Co—Mn—Fe 0.5 8 78 2 (1:4:1) 2.0 8 71 3 5.0 8 59 4 10.0 8 43 5 20.0 8 39 1 Co—Mn—Fe—Zr 0.5 8 67 2 (1:4:0.5:0.5) 2.0 8 48 3 5.0 8 42 4 10.0 8 33 5 20.0 8 35 1 Cu—Mn 0.5 8 90 2 (1:4) 2.0 8 75 3 5.0 8 60 4 10.0 8 53 5 20.0 8 40 *Reaction condition: Crude HMF (Purity 80-90%), catalyst (0.5 g), solvent (water: 30 mL), Base (Na.sub.2CO.sub.3: 0.15 g), Temperature (120° C.), Pressure (10-15 bar). Note: In case of Co—Mn—Ce (1:4:0.25) catalyst, reaction carried at 6 bar oxygen and 140° C.

TABLE-US-00007 TABLE 7 The results obtained by study experiments to check effect of O2 and air oxidants against HMF purity. Catalyst Purity FDCA Sr. (M:M′ mol of HMF Pressure Time, Selectivity No. ratio) (%) (bar) (h) (%) 1 Co—Mn—Ce 90 O2 (6) 6 80 2 (1:4:0.25) 90 Air (15) 6 77 3 98 O2 (6) 6 91 4 98 Air (15) 6 80 1 Co—Mn—Fe 90 O2 (15) 8 78 2 (1:4:1) 90 Air (20) 8 79 3 98 O2 (10) 8 87 4 98 Air (20) 8 82 1 Co—Mn—Fe—Zr 90 O2 (10) 8 67 2 (1:4:0.5:0.5) 90 Air (15) 8 62 3 98 O2 (10) 8 75 4 98 Air (15) 8 73 1 Cu—Mn 90 O2 (15) 8 90 2 (1:4) 90 Air (20) 8 86 3 98 O2 (10) 8 92 4 98 Air (20) 8 93 *Reaction condition: 0.5 wt % solution of crude HMF, catalyst (0.5 g), solvent (water: 30 mL), Base (Na.sub.2CO.sub.3: 0.15 g), Temperature (120° C.). Note: In case of Co—Mn—Ce (1:4:0.25) catalyst, reaction carried at 6 bar oxygen and 140° C.

[0142] Reactions were also carried out in fixed bed reactor in a continuous mode with the employment of following reaction conditions: [0143] Substrate solution: 1 wt % HMF solution in water [0144] Flow: 1 mL/min [0145] Catalyst loading: 1 g [0146] Temperature: 150° C. [0147] Oxygen pressure: 15 bar [0148] Conversion of HMF: 73% [0149] Yield of FDCA: 50%

EXAMPLES

[0150] Following examples are given by way of illustration therefore should not be construed to limit the scope of the invention.

Example 1: Preparation of Mixed Metal Oxide Catalyst Co—Mn—Ce (1:4:0.25) M: M: M Ratio

[0151] Typical synthesis procedure: added Cobalt (II) Acetate Tetrahydrate, Manganese (II) Nitrate Tetrahydrate and Cerous Nitrate Hexahydrate with molar ratio (1:4:0.25 M) given precursors mixed thoroughly and grind with the help of mortar-pestle till fine textured formation seen. Oxalic acid is added to desired precursor in 1:0.75M ratio and manually grind at 27° C. for 20 min. Here, Oxalic acid was added for making material more porous. Then, the grinded paste was subjected for drying in hot air oven at 60° C. for 16 h. After complete drying of powder, it was calcined at 300° C. for 3 hours in oven in presence of air to get mixed metal oxide catalysts denoted as Co—Mn—Ce.

Example 2: Preparation of Mixed Metal Oxide Catalyst Co—Mn—Fe: (1:4:1) M:M:M Ratio

[0152] Typical synthesis procedure added Cobalt (II) Acetate Tetrahydrate, Manganese (II) Nitrate Tetrahydrate and Ferric Nitrate Nonahydrate with molar ratio (1:4:1 M) given precursors mixed thoroughly and grind with the help of mortar-pestle till fine textured formation seen. Oxalic acid is added to desired precursor in 1:0.75M ratio and manually grind at 27° C. for 20 min. Here, Oxalic acid was added for making material more porous. Then, the grinded paste was subjected for drying in hot air oven at 60° C. for 16 h. After complete drying of powder, it was calcined at 300° C. for 3 hours in oven in presence of air to get mixed metal oxide catalysts denoted as Co—Mn—Fe.

Example 3: Preparation of Mixed Metal Oxide Catalyst Co—Mn—Fe—Zr (1:4:0.5:0.5) M:M:M:M Ratio

[0153] Typical synthesis procedure added Cobalt (II) Acetate Tetrahydrate, Manganese (II) Nitrate Tetrahydrate, Ferric Nitrate Nonahydrate and Zirconyl Nitrate with molar ratio (1:4:0.5:0.5 M) mixed thoroughly and grind with the help of mortar-pestle till fine textured formation seen.

[0154] Oxalic acid is added to desired precursor in 1:0.75M ratio and manually grind at 27° C. for 20 min. Here, Oxalic acid was added for making material more porous. Then, the grinded paste was subjected for drying in hot air oven at 60° C. for 16 h. After complete drying of powder, it was calcined at 300° C. for 3 hours in oven in presence of air to get mixed metal oxide catalysts denoted as Co—Mn—Fe—Zr.

Example 4: Preparation of Mixed Metal Oxide Catalyst Cu—Mn: (1:4) M:M Ratio

[0155] Typical synthesis procedure added Copper (II) Nitrate Trihydrate and Manganese (II) Nitrate Tetrahydrate with molar ratio (1:4 M) given precursors mixed thoroughly and grind with the help of mortar-pestle till fine textured formation seen. Oxalic acid is added to desired precursor in 1:0.75M ratio and manually grind at 27° C. for 20 min. Here, Oxalic acid was added for making material more porous. Then, the grinded paste was subjected for drying in hot air oven at 60° C. for 16 h. After complete drying of powder, it was calcined at 500° C. for 17 hoursin oven in presence of air to get mixed metal oxide catalysts denoted as Cu—Mn.

[0156] Catalyst Characterization

[0157] Scanning Electron Microscopy

[0158] Scanning electron micrograph images (FIG. 1) show the morphology of prepared samples. Catalyst Co—Mn—Ce (1:4:0.25) (FIG. 1b) and Co—Mn—Fe—Zr (1:4:0.5:0.5) (FIG. 1d) shows agglomerated particles. Spherical and rounded shape particles are seen in case of Cu—Mn (FIG. 1a) mixed oxides while flake shaped particles are observed in case of Co—Mn—Fe mixed oxide (FIG. 1c).

[0159] Transmission Electron Microscopy

[0160] TEM images (FIG. 2) show the morphological properties of Co—Mn—Ce (1:4:0.25) and Cu—Mn (1:4) (FIG. 2a). It has been clearly seen the particle lattice fringes in case of Co—Mn—Ce (FIG. 2b). The segregated particles with fringes are clearly visible in case of Cu—Mn (1:4) mixed oxide catalyst. All the synthesized catalysts were analysed by TEM and showed lattice fringes.

[0161] XRD Patterns for Synthesized Catalysts.

[0162] The XRD pattern (FIG. 3) of Cu—Mn (1:4) (FIG. 3a) shows the characteristic peaks of the spinel CuMn2O4. Traces of CuO were also detected in the XRD pattern. Peaks for MnOx, along with Mn3O4 also has major contribution.

[0163] In case of Co—Mn—Ce (1:4:0.25) (FIG. 3b) the XRD pattern showed diffraction peaks of CeO.sub.2 at 2θ=(28.6°, 33.1°, 47.6° and 56.5°). Peaks at 59.120 (222), 69.490 (400), and 76.820 (331) also contributes to CeO.sub.2. High intense peak of Mn.sub.3O.sub.4 has seen at 2θ=36.1°.

[0164] FIGS. 3c and 3d of Co—Mn—Fe (1:4:1) and Co—Mn—Fe—Zr, respectively clearly show the diffraction pattern of various phases like Fe.sub.2O.sub.3, Fe.sub.3O.sub.4, Co.sub.3O.sub.4, CoFe.sub.2O.sub.4, Mn.sub.2O.sub.3, CoMnO.sub.4, CoMnO.sub.3. From the data obtained, it seems reasonable to see the peak of tetragonal ZrO.sub.2 at 2θ=30.2°, 35.2°, 50.3,60.2° and 62.8°. [0165] Fe.sub.2O.sub.3, 2θ=18°, 30.5°, 36°,49°,54° and 62.5° [0166] Fe.sub.3O.sub.4 (Cubic), 2θ=18°, 30.5°, 36°,54° and 62.5° [0167] Co.sub.3O.sub.4 (Cubic), 2θ=33.5°, 38.5°, 41°, 540 [0168] CoFe.sub.2O.sub.4(Cubic), 2θ=30.5°, 36°, 41°, 62.5° [0169] Mn.sub.2O.sub.3(Cubic), 2θ=18°,33.5°, 36°, 41°,54° [0170] CoMnO.sub.4 (Cubic), 2θ=38.5°, 61°, 62.5° [0171] CoMnO.sub.3 (rhombohedral), 2θ=41°, 54°, 65°.

Example 5: Synthesis of Crude HMF

[0172] Reactions were carried out in a batch mode reactor, with glucose or starch (10 wt % with respect to water) as a substrate in the presence of HMOR (H-form mordenite) catalyst (0.143 g) at 1750° C. for 6 h. Water: methyl isobutyl ketone (MIBK) (1:5 v/v) was used as solvent (30 mL) and 41% yield of HMF with 53% selectivity and 77% HMF conversion was achieved.

Example 6: Purification of HMF

[0173] A 20 g of reaction mixture (HMF in organic solvent) was taken and solvent was evaporated to obtain semi-solid mass containing HMF. Water was added to this semi-solid mass and subsequently extraction of HMF with aforesaid solvent was done. If required to achieve higher purity of HMF, repeated extraction procedures were carried out to get highly purified 5-HMF (˜purity±90%).

Example 7: Synthesis of FDCA

[0174] In a batch mode reactor, 5-hydroxymethyl furfural (HMF), Solvent (Water) and catalyst (different mixed metal oxide) were added. Reactor was flushed and pressurized with O.sub.2/Air and desired pressure was filled. Then reaction mixture was stirred at desired temperature for definite time. Reactions are done in the temperature range of 12θ° C. for 8 h using 10-20 bar O.sub.2/Air pressure. The reaction mixture was centrifuged and filtered through 0.22 μm filter and analysed using HPLC equipped with a HC-75 H+column (300*7.8 mm) and refractive index detector.

Advantages of the Invention

[0175] Precious metals (like Au, Pt, Ag, etc.) avoided. [0176] New combination of catalysts employed. [0177] Lesser amounts of pressure required. [0178] Crude HMF used. [0179] Economically significant. [0180] Environmental friendly process which avoids use of solvent, organic and mineral aids and mineral bases