The present invention relates to an electrochemical method for preparing vanillin or its derivatives.
Vanillin, of chemical name 4-hydroxy-3-methoxybenzaldehyde, is one of the most important aromatic flavor compounds used in foods, beverages, fragrances, pharmaceuticals and polymers. Vanillin was historically extracted from Vanilla planifolia, Vanilla tahitiensis and Vanilla pompona pods. The demand getting higher today, less than 5% of worldwide vanillin production comes from natural vanilla pods. Currently, chemical synthesis is the most important process for producing vanillin
Vanillin was first synthesized from eugenol, found in clove oil, in 1875. Less than 20 years after it was first identified and isolated. Vanillin was commercially produced from eugenol until the 1920s. Later it was synthesized from lignin-containing “brown liquor”, a byproduct of the sulfite process for making wood pulp. Counter-intuitively, even though it uses waste materials, the lignin process is no longer popular because of environmental concerns, and today most vanillin is produced from guaiacol. Several routes exist for synthesizing vanillin from guaiacol.
At present, the most significant of these is the two-step process, in which guaiacol reacts with glyoxylic acid by electrophilic aromatic substitution. The resulting vanillylmandelic acid is then converted via 4-hydroxy-3-methoxyphenylglyoxylic acid to vanillin by oxidative decarboxylation. For example, J. Am. Chem. Soc. 1998, 120, 3332-3339 illustrates an industrial process for the synthesis of vanillin performed in two steps involving an electrophilic aromatic substitution of glyoxylic acid on guaiacol followed by an oxidative decarboxylation. Disadvantageously, a lot of salt produced by using this process when the reaction of oxidative decarboxylation was performed with periodinate NaIO4.
Shenyang Huagong Daxue Xuebao (2010), 24(4), 289-293 teaches a method for preparing vanillin by electrochemical oxidation from 3-methoxy-4-hydroxymandelic acid. However, such reaction must be carried out in the presence of a base compound, such as sodium hydroxide. Hydrochloric acid was used to remove the base compound after the reaction. Similarly, salt was still formed by using this method. Furthermore, the reaction used high temperature ranging from 55-60 . It is also well known for the skilled person that high potential is always needed for this reaction.
There is still a need to develop a more environmental-friendly process to prepare vanillin or its derivatives under milder reaction conditions, which can overcome the drawbacks in prior arts.
The present invention therefore pertains to an electrochemical method for converting a compound of formula (I) to a compound of formula (II) in the presence of a solvent and a compound generating a mediator in reduced form in the solvent,
wherein:
Advantageously, the mediator can be recycled and reused without forming any salts, which makes the method more environmental-friendly. Furthermore, lower potentials are needed when the mediator is used by comparing to prior arts.
Throughout the description, including the claims, the term “comprising one” should be understood as being synonymous with the term “comprising at least one”, unless otherwise specified, and “between” should be understood as being inclusive of the limits.
As used herein, the terminology “(Cn-Cm)” in reference to an organic group, wherein n and m are each integers, indicates that the group may contain from n carbon atoms to m carbon atoms per group.
As used herein, the terminology “oxidative decarboxylation” reactions are oxidation reactions in which a carboxylate or carboxylic acid group is removed, forming carbon dioxide.
As used herein, the term “anode” means the electrode from which electrons migrate to the outside circuit and is the electrode where oxidation occurs.
As used herein, the term “cathode” means the electrode to which electrons migrate from the outside circuit and is the electrode where reduction occurs.
The articles “a”, “an” and “the” are used to refer to one or to more than one (i.e., to at least one) of the grammatical object of the article.
The term “and/or” includes the meanings “and”, “or” and also all the other possible combinations of the elements connected to this term.
It is specified that, in the continuation of the description, unless otherwise indicated, the values at the limits are included in the ranges of values which are given.
Ratios, concentrations, amounts, and other numerical data may be presented herein in a range format. It is to be understood that such range format is used merely for convenience and brevity and should be interpreted flexibly to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited.
As used herein, “mediator” is a redox substance that mediates electron transfer. In the present invention, this substance acts as electron shuttles between the oxidizing electrode and the compound of formula (I). The mediator is not particularly limited as long as it can shoulder the responsibility for transferring the electron between the oxidizing electrode and the compound of formula (I).
Examples of the compound generating a mediator in reduced form in the solvent are:
In some embodiments, sodium bromide (NaBr) or ammonium bromide (NH4Br) can be preferably used.
In some embodiments, environmental-friendly compound such as iron salts can be preferably used. Among all iron salts, iron(II) sulphate (FeSO4) is more preferable.
In the method according to the present invention, a mediator in reduced form is obtained when the compound above mentioned is dissolved in a solvent. It shall be understood by the skilled person that the mediator in reduced form is oxidized at the anode so as to obtain a mediator in oxidized form when the current is passed to the reactor. The mediator in oxidized form then oxidizes the compound of formula (I) and simultaneously forms a mediator in reduced form, which can be same as or different from the mediator reduced form obtained when the compound is dissolved.
Examples of the mediator in reduced form are:
Examples of the mediator in oxidized form are:
As defined above, MP+can be a metal cation. Preferably, p is 1 or 2. Examples of the metal cation are: K+, Li+, Na+ and Mg2+.
In some preferred embodiments, MP+ is H+.
As defined above, R1, R2, R3 and R4, independently from each other, are selected from the group consisting of: a hydrogen atom, an alkyl group, an alkoxy group, a hydroxyl group, a halogen atom, a haloalkyl group and a perhaloalkyl group.
In some embodiments, R1, R2, R3 and R4, independently from one another, may be a hydrogen atom or a C1-C6 alkyl group. More preferably, R1, R2, R3 and R4, independently from one another, are selected from the group consisting of: a hydrogen atom, methyl, ethyl, propyl and isopropyl.
In some embodiments, R1 or R3 may be an alkoxy group, which is selected from the group consisting of methoxy, ethoxy, propoxy and butoxy. R2 or R4 may be a hydrogen atom.
According to a specific aspect of the present invention, R5 is a hydrogen atom or an alkyl group.
The compound of formula (I) can be notably 4-hydroxy-3-methoxy mandelic acid or 4-hydroxy-3-ethoxy mandelic acid.
The compound of formula (II) can be notably 4-hydroxy-3 -methoxybenzaldehyde or 4-hydroxy-3-ethoxybenzaldehyde.
It is understood that the solvent shall have good solubility for both the compound of formula (I) and the compound generating the mediator in reduced form so that they can have sufficient contact in the solution. Such solvent can be alcohol, water or their combination. Preferably, the solvent is water.
pH value of the solution comprising the compound of formula (I), and the compound generating a mediator in reduced form depends on the mediator and is optionally adjusted by the skilled person. For example, pH value of the solution comprising compound of formula (I) and an iron salt shall be adjusted to below 4 and preferably below 3 to prevent the formation of iron(II)/(III) hydroxide. pH value of the solution comprising compound of formula (I) and an alkali metal bromide shall be adjusted to an acidic or slight basic solution to prevent the formation of the toxic Bra gas.
The method according to the present invention is carried out in such a preferred reactor comprising both an anode and a cathode.
The anode and/or the cathode preferably comprises a catalyst. The catalyst for the anode or the cathode may comprise metal element, which can be in the form of elemental metal, metal alloy, metal oxide or metal complex.
The anode catalyst may preferably comprise element selected from the group consisting of elements of Groups IIIA, IVA, VA of Periodic Table and Transition metals.
As used herein, metals of group IB, IIB, IIIB, IVB, VB, VIB, VIIB and VIIIB are often referred to as transition metals. This group comprises the elements with atomic number 21 to 30 (Sc to Zn), 39 to 48 (Y to Cd), 72 to 80 (Hf to Hg) and 104 to 112 (Rf to Cn).
Examples of the anode catalyst are notably:
Preferably, the anode catalyst is Pt.
The cathode catalyst may preferably comprise element selected from the group consisting of elements of Groups IA, IIA, IIIA, IVA, VA, VIA, VIIA of Periodic Table, Transition metals and Lanthanides.
Examples of the cathode catalyst are notably:
Preferably, the cathode catalyst is Ni or Cu and more preferably Cu.
The catalyst for the anode or the cathode mention above can be loaded on a support. The support is not particularly limited. Typical examples of support are carbon, alumina and silica.
In one embodiment, the anode or the cathode may comprise a catalyst mentioned above and a substrate.
Preferably, the anode and the cathode can be made with porous substrate structures.
The anode substrates can include, for example, stainless steel net, nickel foam, sintered nickel powder, etched aluminum-nickel mixtures, carbon fibers, and carbon cloth. Preferably, carbon materials and stainless steel are used as an anode substrate.
The cathode substrates can include stainless steel, nickel foam, sintered nickel powder, etched aluminum-nickel mixtures, metal screens, carbon fibers, and carbon cloth.
Methods for applying the anode catalyst to the anode substrate, and the cathode catalyst to the cathode substrate include, for example, spreading, wet spraying, powder deposition, electro- deposition, evaporative deposition, dry spraying, decaling, painting, sputtering, low pressure vapor deposition, electrochemical vapor deposition, tape casting, screen printing, hot pressing and other methods.
When substrates are used, preferred range of the catalyst loading may be comprised between 0.01 mg/cm−2 and 500 mg/cm−2. More preferably, the catalyst loading amount may be comprised between 1 mg/cm−2 and 20 mg/cm−2.
In a preferred embodiment, the electrochemical reactor used according to the invention has two independent compartments. The anode and the cathode reside in these two compartments separately. A membrane can be placed between the two compartments. Said membrane can be neutral or ion-exchange membrane. Preferably, the membrane is a nafion (a sulfonated tetrafluoroethylene based fluoropolymer-copolymer) cation exchange membrane.
Advantageously, the distance between the anode and the cathode is in the range of 1 mm to 10 cm and preferably 3 mm to 1 cm.
In one embodiment, the method according to the present invention comprises following steps:
Step(i)
The concentration of the compound generating a mediator in reduced form in the solution can be in the range of 0.05 M to 2 M and preferably 0.1 M to 0.5 M.
Step(iii)
Preferably, the reaction temperature can be from 0° C. to 100° C. and more preferably from 10° C. to 30° C. and most preferably room temperature.
According to the present invention, room temperature is between 15° C. and 25° C.
Preferably, the reaction can be run for 1 h to 144 h and more preferably 2 h to 50 h.
Preferably, the reaction can be run at a current density ranging from 0.1 mA/cm2 to 100 mA/cm2 and more preferably from 0.5 mA/cm2 to 15 mA/cm2.
Preferably, the reaction can be run at a potential ranging from 0.0001 V to 10 V and more preferably from 1.5 V to 4 V.
Step(iv)
The molar ratio of the compound of formula (I) in this step to the compound generating a mediator in reduced form in step (i) can be equal to or higher than 1 and preferably from 1 to 10 and more preferably from 1.5 to 5.0.
Preferably, the reaction temperature can be from 0° C. to 100° C. and more preferably from 10° C. to 30° C. and most preferably room temperature.
According to the present invention, room temperature is between 15° C. and 25° C.
The skilled person will use the proper reaction time based on the reaction parameters above mentioned.
In another embodiment, the method according to the present invention carried out in an electrochemical reactor comprising both an anode and a cathode has following steps:
Step a)
The molar ratio of the compound of formula (I) to the compound generating a mediator in reduced form can be equal to or higher than 1 and preferably from 1 to 10 and more preferably from 1.5 to 5.0.
The concentration of the compound generating a mediator in reduced form in Solution A can be in the range of 0.01 M to 1 M and preferably 0.05 M to 0.2 M.
The concentration of the compound of formula (I) in Solution A can be in the range of 0.1 M to 1 M and preferably 0.1 M to 0.3 M.
Step b)
The concentration of the compound generating a mediator in reduced form in Solution B can be in the range of 0.01 M to 1 M and preferably 0.05 M to 0.2 M.
As can be understood by one skilled in the art, the sequence of step a) and step b) may be reversed, or performed simultaneously.
Step d)
Preferably, the reaction temperature in this embodiment can be from 0° C. to 100° C. and more preferably from 10° C. to 30° C. and most preferably room temperature.
Preferably, the reaction in this embodiment can be run at a current density ranging from 0.1 mA/cm2 to 100 mA/cm2 and more preferably 1 mA/cm2 to 15 mA/cm2.
Preferably, the reaction can be run at a potential ranging from 0.0001 V to 10 V and more preferably 1.5 V to 4 V.
Preferably, the reaction can be run for 1 h to 144 h.
The following examples are included to illustrate embodiments of the invention. Needless to say, the invention is not limited to described examples.
Materials
Ex-situ Synthesis of Mediator
In order to prove that vanillin is formed by the mediator and not by electrochemistry, therefore in a first step BrO— will be formed by electrochemical oxidation of Br- in an H-Cell setup by electrochemistry. In a second step this solution will be added to 4-hydroxy-3-methoxy mandelic acid. Stirred for 4h.
Electrochemical decarboxylation of 4-hydroxy-3-methoxy mandelic acid with sodium bromide.
A 20 ml H-cell with a nafion cation exchange membrane is used as reactor. After the membrane is placed between the cells, water is filled in both sides in order to check the sealing. The anode side is equipped with a Pt mesh as working electrode: diameter=1 cm, height=2 cm. Surface area=6.3 cm2. The cathode side uses a 200 ppi Cu mesh as counter electrode. It is bent into cylindrical shape: length=4 cm, height=2 cm, surface area=8 cm2. The system is not stirred and no reference electrode is used.
Electrochemical decarboxylation of 4-hydroxy-3-methoxy mandelic acid with iron sulfate
Filing Document | Filing Date | Country | Kind |
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PCT/CN2019/120513 | 11/25/2019 | WO |