Patent Application
20140171614
This disclosure relates to a method of producing an organic acid derived from a biomass resource.
Due to the growing concern over a rise in the prices of petroleum resources and their depletion, recent interest has focused on production of polymer materials using biomass resources, which are renewable resources, as raw materials. In particular, organic acids, which can be used as raw materials for polyesters and the like, are drawing attention. Examples of the method of producing such biomass resource-derived organic acids include methods in which an organic acid is obtained by direct chemical synthesis from a biomass-derived compound, and methods in which an organic acid is obtained by fermentation culture of a microorganism with a biomass-derived compound. However, in those methods, the produced organic acid needs to be processed by a combination of laborious purification steps such as crystallization, membrane separation and/or distillation to remove many kinds of impurities derived from the biomass resource and, especially, among such impurities, colored impurities, even in very small amounts, cause coloration of the polymer in a later step. Polymers obtained using colored organic acids are also colored, and this may lead to not only low commercial values but also low physical properties due to the influence of small amounts of causative agents of the coloration contained in the polymers.
As a method of removing colored impurities contained in a biomass resource-derived organic acid, a processing method using a reducing agent for an aqueous lactic acid solution containing pyruvic acid obtained by fermentation is known (JP 3880175 B). It has been suggested that, by this method, a lactic acid solution that does not contain pyruvic acid and is hardly colored can be obtained, and that a high-molecular-weight polylactic acid can be obtained using the solution.
We discovered that, in cases where colored impurities (for example, pyruvic acid) contained in biomass resource-derived lactic acid are removed by reduction treatment, which is a conventional method, racemic lactic acid is produced as the reduction treatment of pyruvic acid proceeds. This is problematic since there is a concern of a low optical purity of the obtained lactic acid and a low melting point of the polylactic acid obtained by polymerization of the lactic acid. Thus, it could be helpful to provide a processing method that allows, without influencing physical properties of organic acids derived from biomass resources, more efficient reduction in colored impurities.
We focused our attention on oxidizing agents used as reaction reagents in organic synthesis reactions. We then discovered that oxidation treatment of an organic acid derived from a biomass resource containing colored impurities enables reduction in the degree of coloration without deteriorating the physical properties of the organic acid.
We thus provide (1) to (7):
A high-purity organic acid with a lower degree of coloration, derived from a biomass resource, can be obtained. Further, since obtained organic acids do not suffer from deterioration of their physical properties by the process of removal of colored impurities, polymers produced by polymerization of the organic acids have better properties in, for example, color, the weight average molecular weight, the melting point and the weight reduction rate upon heating, compared to polymers produced by polymerization of organic acids obtained by conventional methods.
Specific examples of the organic acid derived from a biomass resource (hereinafter simply referred to as organic acid) include products produced by fermentation culture of micro-organisms capable of utilizing raw materials derived from biomass resources such as polysaccharides including cellulose, and monosaccharides including glucose and xylose; products produced from biomass resource-derived raw materials by known synthesis/degradation reactions; and products produced by combination of these methods. Production of an organic acid obtained by fermentation culture of a microorganism capable of utilizing a biomass resource is especially preferred. The organic acid is not limited, and the subject is preferably a polymer material (monomers) for which there is a concern of deterioration of the quality due to colored components derived from a biomass resource. Examples of the organic acid as the polymer material include lactic acid, hydroxybutyric acid, 3-hydroxypropionic acid, itaconic acid, glycolic acid, adipic acid, muconic acid, acrylic acid, succinic acid, sebacic acid, 2,5-furandicarboxylic acid and terephthalic acid, and one or more of these may be used as the subject.
Examples of the method of producing an organic acid by fermentation culture of a microorganism capable of utilizing a biomass resource include the method described in JP 2008-029329 A, in which lactic acid is produced by fermentation culture of a microorganism; the method described in JP 6-38775 A, in which 3-hydroxybutyric acid is produced by fermentation culture of a microorganism; the method described in JP 4490628 B, in which 3-hydroxypropionic acid is produced by fermentation culture of a microorganism; the method described in JP 1913914 B, in which itaconic acid is produced by fermentation culture of a microorganism; the method described in JP 2008-56654 A, in which glycolic acid is produced by fermentation culture of a microorganism; the method described in JP 4380654 B, in which succinic acid is produced by fermentation culture of a microorganism; the method in which, as described in Enzyme and Microbial Technology, 27, 205 (2000), sebacic acid is produced by a microorganism having a capacity to produce sebacic acid using decanoic acid as a raw material; and the method described in WO2011/094131, in which terephthalic acid is produced by fermentation culture of a microorganism.
Examples of the method of producing an organic acid from a biomass resource by combination of known chemical synthesis reactions include the method described in JP 2011-84540 A, in which glucose or fructose is converted to 5-hydroxymethylfurfural by acid treatment or the like, and this is followed by oxidation to produce 2,5-furandicarboxylic acid, which can be used as a raw material for polyesters. Examples of the method of producing an organic acid by thermal decomposition of a biomass include, as described in Science, 330, 1222 (2010), a method in which a cellulose biomass such as wood waste is subjected to heat pressurization treatment under hydrogen atmosphere to obtain xylene, and this is followed by oxidation by a known method to produce terephthalic acid, which can be used as a raw material for polyesters.
Examples of the method of producing an organic acid by subjecting a product obtained by fermentation culture of a microorganism capable of utilizing a biomass resource to chemical synthesis reaction include the method described in U.S. Pat. No. 5,487,987 B, in which muconic acid is produced by fermentation culture of a microorganism having a capacity of muconic acid fermentation, and the product is then subjected to hydrogen reduction to produce adipic acid, which can be used as a raw material for nylons; and the method described in JP 4490628 B, in which 3-hydroxypropionic acid is produced by fermentation culture of a microorganism having a capacity of muconic acid fermentation, and the product is then subjected to dehydration reaction to produce acrylic acid.
Although it is known that colored impurities are contained in the organic acids obtained by the methods described above, we discovered that the colored impurities are decomposed by oxidation reaction with an oxidizing agent. The details of the process are described below.
The oxidizing agent is not limited, and oxidizing agents used in general chemical reactions can be used. Preferred examples of the oxidizing agent include hydrogen peroxide and aqueous solutions thereof, sodium hypochlorite and aqueous solutions thereof, sodium chlorite, tert-butylhydroperoxide and aqueous solutions thereof, ozone and aqueous solutions thereof, oxygen, 2-iodoxybenzoic acid, manganese dioxide, Dess-Martin periodinane and 2,3-dicyano-5,6-dichloro-1,4-benzoquinone. More preferred examples of the oxidizing agent include hydrogen peroxide and aqueous solutions thereof, sodium hypochlorite and aqueous solutions thereof, sodium chlorite, tert-butylhydroperoxide and aqueous solutions thereof, and ozone and aqueous solutions thereof. Each of these oxidizing agents may be used alone, or two or more of these may be used.
When the colored impurities contained in the organic acid is subjected to oxidation treatment using an oxidizing agent, the organic acid is preferably in the state where the organic acid is dissolved in a solvent, but may also be in the state where the organic acid containing colored substances derived from a biomass is not completely dissolved in a solvent, or in the state of a slurry. Either an aqueous or organic solvent system may be applied as the solvent for the organic acid, and an aqueous solvent is preferably employed.
The method of adding the oxidizing agent to the organic acid is not limited. In cases where the oxidizing agent is a solid or liquid, the agent may be added to the organic acid directly or as a solution, and, in cases where the oxidizing agent is in the form of a gas, the agent may be added by a method in which the agent is directly blown into an organic acid solution, or by a method in which the oxidizing agent in the form of a gas is first dissolved in water or dispersed in water as microbubbles, and then fed to an organic acid solution.
Further, to rapidly obtain the effect of reducing colored components, heat treatment is preferably carried out in combination. The heat treatment herein means heating at a temperature of not less than 35° C., and the temperature is preferably 35 to 200° C., more preferably 50 to 180° C., still more preferably 60 to 180° C. The heat treatment may be carried out before the oxidation treatment, or the oxidation treatment may be carried out under heat.
In cases where the heat treatment is carried out before the oxidation treatment, the degree of coloration of the reaction solution (liquid to be treated) increases, but the degree of coloration decreases by the oxidation treatment of the solution.
In cases where the oxidation treatment is carried out under heat, the method is not limited to methods by simply heating the reaction solution. For example, in cases where distillation is carried out in a later step, the heating operation in the distillation operation may be regarded as the heat treatment. That is, in such cases, distillation of the reaction solution is carried out in the presence of the oxidizing agent. Since, in this method, the oxidation treatment and the heat treatment, in addition to isolation of the organic acid with a decreased degree of coloration, can be simultaneously carried out, the method is preferably applied.
The oxidation treatment may be combined with another purification operation. Depending on the type of the oxidizing agent employed, the agent may be dissolved or precipitated in the solution after reaction with coloring substances. The method of isolating the substances from the organic acid of interest is not limited, and examples of the method include ion exchange, filtration and distillation. In particular, in cases where the purification operation to be carried out in combination is distillation, the operation can be carried out simultaneously with the heat treatment, which is efficient and hence preferred.
The oxidizing agent treatment is finished when the color no longer changes. The length of time required for the color to stop changing varies depending on the type of the oxidizing agent employed and the amount of the agent added.
Whether or not the colored components derived from a biomass, contained in the organic acid, were reduced is evaluated by measuring the color of the organic acid before the oxidation treatment and after the oxidation treatment in terms of the APHA unit color number (JIS K 0071-1, established on Oct. 20, 1998; hereinafter referred to as the APHA value). That is, when the treatment was carried out under the same conditions except for the oxidation treatment, in cases where the APHA value after the oxidation treatment is lower than the APHA value before the oxidation treatment, it is judged that the effect of our method was obtained.
Using the obtained organic acid, an organic acid polymer can be produced by a known polymerization method. The organic acid polymer means a polymer produced by polymerization using an organic acid as monomers. Specific examples of the organic acid polymer include the organic acid polyesters and organic acid polyamides described below.
For example, in cases of a bifunctional oxycarboxylic acid containing a hydroxyl group in the molecule such as lactic acid, glycolic acid or hydroxybutyric acid, it may be polymerized alone to obtain a polyester. Examples of the polymerization method of production of a polyester include a two-step polymerization method in which a cyclic dimer such as lactide in the cases of polylactic acid, or glycolide in the cases of glycolic acid, is first produced, and ring-opening polymerization is then carried out; and a single-step direct polymerization method in which the organic acid is directly subjected to dehydration polycondensation in a solvent or under solvent-free conditions. Specific examples of the polyester include polylactic acid, polyglycolic acid, polyhydroxypropionic acid and polyhydroxybutyric acid.
Further, a polyester or polyamide can be produced using an organic acid having two carboxyl groups in the molecule (dicarboxylic acid) such as adipic acid, muconic acid, succinic acid, sebacic acid, itaconic acid, 2,5-furandicarboxylic acid or terephthalic acid. Production of a polyester or polyamide using a dicarboxylic acid as a raw material requires a diol or diamine, respectively, and these may be derived from either a biomass resource or petroleum.
As a method of producing a polyester using a dicarboxylic acid as a raw material, a known method may be used as it is, and, for example, the polyester can be produced by esterification reaction or ester exchange reaction of a dicarboxylic acid or a dicarboxylic acid composed of its ester-forming derivative with a diol, followed by polycondensation reaction. Either a solution reaction using a solvent or a melting reaction by heat melting may be employed, and a melting reaction is preferred in view of efficiently obtaining a high-quality polyester. The catalyst and the solvent used for the reaction may be optimized for the diol and the dicarboxylic acid. Further, for the esterification reaction or ester exchange reaction, and the subsequent polycondensation reaction, either a batch method or continuous method may be employed. In each reaction, the reaction vessel is not limited, and examples of the reaction vessel that may be used include stirring-vessel-type reaction vessels, mixer type reaction vessels, tower type reaction vessels and extruder type reaction vessels. Two or more of these reaction vessels may be used in combination.
In the esterification reaction or ester exchange reaction, and the subsequent polycondensation reaction, a catalyst may be used for promoting the reaction. Preferred specific examples of a compound that may be used as the catalyst include titanium compounds, tin compounds, aluminum compounds, calcium compounds, lithium compounds, magnesium compounds, cobalt compounds, manganese compounds, antimony compounds, germanium compounds and zinc compounds, with which high reaction activity can be achieved and the reaction rate and the yield of the obtained polyester can be increased. Examples of the ester exchange catalyst include alkali metal acetates. Examples of the polymerization catalyst include antimony oxide hardly containing germanium oxide, bismuth or the like; compounds of a transition metal such as cobalt; and alkoxy titanates. In particular, in view of reducing the reaction time to allow efficient production, titanium compounds, tin compounds, aluminum compounds, antimony compounds and germanium compounds are preferred; in view of obtaining a polyester whose crystallization property can be easily controlled and which is excellent in qualities such as thermal stability, hydrolysis resistance and thermal conductivity, titanium compounds and/or tin compounds are more preferred; and in view of decreasing the environmental stress, titanium compounds are still more preferred. Examples of the titanium compounds include titanate esters such as tetra-n-propyl ester, tetra-n-butyl ester, tetraisopropyl ester, tetraisobutyl ester, tetra-tert-butyl ester, cyclohexyl ester, phenyl ester, benzyl ester and tolyl ester, and mixed esters thereof. In particular, tetrapropyl titanate, tetrabutyl titanate and tetraisopropyl titanate are preferred in view of efficient production of polyester resins, and tetra-n-butyl titanate and the like are especially preferably used. Examples of the tin compounds include monobutyltin oxide, dibutyltin oxide, methylphenyltin oxide, tetraethyltin oxide, hexaethylditin oxide, cyclohexahexylditin oxide, didodecyltin oxide, triethyltin hydroxide, triphenyltin hydroxide, triisobutyltin acetate, dibutyltin diacetate, diphenyltin dilaurate, monobutyltin trichloride, dibutyltin dichloride, tributyltin chloride, dibutyltin sulfide and butylhydroxytin oxide, and methylstannoic acid, ethylstannoic acid and butylstannoic acid. Among these, in view of efficient production of polyesters, monoalkyltin compounds are especially preferably used. Each of these compounds as catalysts may be used alone, or two or more of these may be used in combination, in the esterification reaction or ester exchange reaction, and the subsequent polycondensation reaction. In terms of the timing of addition of the compound(s), the compound(s) may be added by any of a method in which the compound(s) is/are added immediately after addition of the raw material, a method in which the compound(s) is/are added at the same time as the raw material, and a method in which the compound(s) is/are added during the reaction. In cases where the compound to be used as a catalyst is a titanium compound, the amount of the compound added is preferably 0.01 to 0.3 part by weight with respect to 100 parts by weight of the polyester produced, and, in view of the thermal stability, color and reactivity of the polymer, the amount is more preferably 0.02 to 0.2 part by weight, still more preferably 0.03 to 0.15 part by weight.
Specific examples of the organic acid polyester include the following polyesters.
Examples of polyesters produced using as a raw material a dicarboxylic acid composition comprising succinic acid as a major component include polyesters with ethylene glycol (polyethylene succinate), polyesters with 1,2-propanediol, polyesters with 1,3-propanediol (polytrimethylene succinate), polyesters with 1,4-butanediol (polybutylene succinate), and polyesters with 2,3-propanediol.
Examples of polyesters produced using as a raw material a dicarboxylic acid composition comprising adipic acid as a major component include polyesters with ethylene glycol (polyethylene adipate), polyesters with 1,2-propanediol, polyesters with 1,3-propanediol (polytrimethylene adipate), polyesters with 1,4-butanediol (polybutylene adipate), and polyesters with 2,3-propanediol.
Examples of polyesters produced using as a raw material a dicarboxylic acid composition comprising sebacic acid as a major component include polyesters with ethylene glycol (polyethylene sebacinate), polyesters with 1,2-propanediol, polyesters with 1,3-propanediol (polytrimethylene sebacinate), polyesters with 1,4-butanediol (polybutylene sebacinate), and polyesters with 2,3-propanediol.
Examples of polyesters produced using as a raw material a dicarboxylic acid composition comprising 2,5-furandicarboxylic acid as a major component include polyesters with ethylene glycol, polyesters with 1,2-propanediol, polyesters with 1,3-propanediol, polyesters with 1,4-butanediol, and polyesters with 2,3-propanediol.
Examples of polyesters produced using as a raw material a dicarboxylic acid composition comprising itaconic acid as a major component include polyesters with ethylene glycol, polyesters with 1,2-propanediol, polyesters with 1,3-propanediol, polyesters with 1,4-butanediol, and polyesters with 2,3-propanediol.
Examples of polyesters produced using as a raw material a dicarboxylic acid composition comprising terephthalic acid as a major component include polyesters with ethylene glycol (polyethylene terephthalate), polyesters with 1,2-propanediol, polyesters with 1,3-propanediol (polytrimethylene terephthalate), polyesters with 1,4-butanediol (polybutylene terephthalate), and polyesters with 2,3-propanediol.
As the method of producing an organic acid polyamide using an obtained organic acid as a raw material, a known method may be used as it is and, more specifically, a method in which the above-described dicarboxylic acid and diamine are polycondensed is applied (see Osamu Fukumoto ed., “Polyamide Resin Handbook”, Nikkan Kogyo Shimbun, Ltd. (January, 1998) or JP 2004-75932 A).
Specific examples of the organic acid polyamide include the following polyamides.
Examples of polyamides produced using as a raw material a dicarboxylic acid composition comprising succinic acid as a major component include polyamides with hexamethylenediamine (polyhexamethylene succinamide, nylon 64), polyamides with 1,5-pentanediamine (polypentamethylene succinamide, nylon 54), polyamides with 1,4-butanediamine (polytetramethylene succinamide, nylon 44), polyamides with 1,3-propanediamine (polytrimethylene succinamide, nylon 34), polyamides with 1,2-propanediamine, polyamides with 1,2-ethylenediamine (polyethylene succinamide, nylon 24), and polyamides with o-phenylenediamine, m-phenylenediamine or p-phenylenediamine.
Examples of polyamides produced using as a raw material a dicarboxylic acid composition comprising adipic acid as a major component include polyamides with hexamethylenediamine (polyhexamethylene adipamide, nylon 66), polyamides with 1,5-pentanediamine (polypentamethylene adipamide, nylon 56), polyamides with 1,4-butanediamine (polytetramethylene adipamide, nylon 46), polyamides with 1,3-propanediamine (polytrimethylene adipamide, nylon 36), polyamides with 1,2-propanediamine, polyamides with 1,2-ethylenediamine (polyethylene adipamide, nylon 26), and polyamides with o-phenylenediamine, m-phenylenediamine or p-phenylenediamine.
Examples of polyamides produced using as a raw material a dicarboxylic acid composition comprising sebacic acid as a major component include polyamides with hexamethylenediamine (polyhexamethylene sebacimide, nylon 610), polyamides with 1,5-pentanediamine (polypentamethylene sebacimide, nylon 510), polyamides with 1,4-butanediamine (polytetramethylene sebacimide, nylon 410), polyamides with 1,3-propanediamine (polytrimethylene sebacimide, nylon 310), polyamides with 1,2-propanediamine, polyamides with 1,2-ethylenediamine (polyethylene sebacimide, nylon 210), and polyamides with o-phenylenediamine, m-phenylenediamine or p-phenylenediamine.
Examples of polyamides produced using as a raw material a dicarboxylic acid composition comprising 2,5-furandicarboxylic acid as a major component include polyamides with hexamethylenediamine, polyamides with 1,5-pentanediamine, polyamides with 1,4-butanediamine, polyamides with 1,3-propanediamine, polyamides with 1,2-propanediamine, polyamides with 1,2-ethylenediamine, and polyamides with o-phenylenediamine, m-phenylenediamine or p-phenylenediamine.
Examples of polyamides produced using as a raw material a dicarboxylic acid composition comprising itaconic acid as a major component include polyamides with hexamethylenediamine, polyamides with 1,5-pentanediamine, polyamides with 1,4-butanediamine, polyamides with 1,3-propanediamine, polyamides with 1,2-propanediamine, polyamides with 1,2-ethylenediamine, and polyamides with o-phenylenediamine, m-phenylenediamine or p-phenylenediamine.
Examples of polyamides produced using as a raw material a dicarboxylic acid composition comprising terephthalic acid as a major component include polyamides with hexamethylenediamine (polyhexamethylene terephthalamide, nylon 6T), polyamides with 1,5-pentanediamine (polypentamethylene terephthalamide, nylon 5T), polyamides with 1,4-butanediamine (polytetramethylene terephthalamide, nylon 4T), polyamides with 1,3-propanediamine (polytrimethylene terephthalamide, nylon 3T), polyamides with 1,2-propanediamine, polyamides with 1,2-ethylenediamine (polyethylene terephthalamide, nylon 2T), and polyamides with o-phenylenediamine, m-phenylenediamine or p-phenylenediamine.
The obtained organic acid polymer is more excellent in the color, weight average molecular weight, melting point, and weight reduction rate upon heating than biomass resource-derived organic acid polymers obtained by conventional methods. In particular, in cases where a polymer is used for a fiber, film or molded product, the polymer preferably has an APHA value of not more than 15 in terms of the color. A biomass resource-derived organic acid polymer that is excellent in color and has an APHA value of not more than 15 can thus be obtained.
Our methods are is described below by way of Examples, but this disclosure is not limited to the Examples below.
HI003, which is an L-lactic acid fermentation yeast strain described in Reference Example 1 of WO2009/099044, was used as a microorganism for production of L-lactic acid.
Using the HI003 strain of Reference Example 1 and a raw sugar medium (70 g/L Yutosei (manufactured by MUSO Co., Ltd.), 1.5 g/L ammonium sulfate), a batch fermentation test was carried out under the following culture conditions by the method described below. The medium was autoclaved (121° C., 15 minutes) before use.
Reaction vessel capacity (volume of the lactic acid fermentation medium): 30 (L); temperature control: 32 (° C.); aeration rate in the reaction vessel: 0.1 (L/min.); reaction vessel stirring rate: 200 (rpm); pH control: adjustment to pH 6.5 with 1 N calcium hydroxide.
The HI003 strain was cultured in 5 ml of the raw sugar medium in a test tube overnight with shaking (pre-preculture). The obtained pre-preculture liquid was inoculated to 100 ml of a fresh portion of the raw sugar medium, and cultured in a 500-ml Sakaguchi flask for 24 hours with shaking (preculture). The temperature control and the pH control were carried out, and fermentation culture was performed.
The concentration and the optical purity of the lactic acid obtained by the batch fermentation in Reference Example 2 were evaluated under the following measurement conditions by HPLC.
Column: Shim-Pack SPR-H (manufactured by Shimadzu Corporation)
Mobile phase: 5 mM p-Toluenesulfonic acid (flow rate, 0.8 mL/min.)
Reaction solution: 5 mM p-Toluenesulfonic acid, 20 mM bis-Tris, 0.1 mM EDTA 2Na (flow rate, 0.8 mL/min.)
Detection method: Electric conductivity
The L-lactic acid and D-lactic acid concentrations were measured under the following conditions:
Column: TSK-gel Enantio L1 (manufactured by Tosoh Corporation)
Mobile phase: 1 mM Aqueous copper sulfate solution
Flow rate: 1.0 ml/min.
Detection method: UV 254 nm
Subsequently, the optical purity was calculated according to the following equation:
Optical purity (% e.e.)=100×(L−D) or (D−L)/(L+D)
In the equation, L represents the concentration of L-lactic acid, and D represents the concentration of D-lactic acid. An optical purity of 100% (100% ee) herein means that no peak for the enantiomer could be detected in the HPLC for measuring the optical purity described later.
As a result of the batch fermentation for 50 hours, the concentration of lactic acid accumulated was 45 to 49 g/L, and the optical purity was 100% for L-lactic acid.
Yeast cells were removed from 30 L of the L-lactic acid culture liquid prepared in Reference Example 2 using a centrifuge, and 95% sulfuric acid (manufactured by Sigma Aldrich) was added to the obtained supernatant to pH 2.5, followed by stirring the resulting mixture for 2 hours. The produced calcium sulfate was removed by suction filtration, and the obtained filtrate was passed through a column packed with a strong anion-exchange resin (“DIAION SA10A”, manufactured by Mitsubishi Chemical Corporation) in the downflow direction. The resultant was then passed through a column packed with a strong cation-exchange resin (“DIAION SK1B” manufactured by Mitsubishi Chemical Corporation) in the downflow direction. Subsequently, the resultant was filtered through a nanofiltration membrane (4-inch spiral element “SU-610”, manufactured by Toray Industries, Inc.), to obtain 28 L of a raw aqueous lactic acid solution. Subsequently, the solution was concentrated to 47 wt % using a thin-film evaporator (manufactured by Tokyo Rikakikai Co., Ltd.), to provide a test solution. The color intensity of the test solution was analyzed according to JIS K 0071-1 using a colorimeter (manufactured by Nippon Denshoku Industries Co., Ltd.) in terms of the APHA unit color number. As a result, the AHPA value of the test solution was found to be 150. This test solution was subjected to distillation at 130° C. under a reduced pressure of 133 Pa. The APHA value and the optical purity of the lactic acid obtained by the distillation are shown in Table 1.
In a glass Schlenk flask, 500 mL of the test solution obtained in Reference Example 3 was placed. Each of various oxidizing agents (Examples 1 to 16, 5% aqueous sodium hypochlorite solution; Examples 17 to 36, 30% hydrogen peroxide solution; Examples 37 to 52, sodium chlorite; Examples 53 to 68, tert-butylhydroperoxide; all reagents were manufactured by Wako Pure Chemical Industries, Ltd.) was added to the test solution, and the resulting mixture was stirred at 25° C. (without heating), 60° C., 100° C. or 180° C. for 2 hours. The types and the concentrations of the oxidizing agents added, and the heating conditions; and the results of measurement, according to the measurement methods described in the above Reference Examples, of the APHA values and the optical purities of the lactic acids after oxidizing agent treatment, and the APHA values and the optical purities of the lactic acids obtained after distillation at 130° C. under a reduced pressure of 133 Pa; are shown in Tables 1 and 2. In cases where the oxidizing agent was in the form of an aqueous solution, the concentration of the oxidizing agent added to the test solution was measured in terms of the pure content excluding water. The concentration of the oxidizing agent added was calculated according to Equation 1.
Concentration of oxidizing agent added (%)=(weight of oxidizing agent excluding water/weight of lactic acid excluding water)×100 (1)
Thereafter, lactic acids whose APHA was not more than 10 after the distillation were subjected to a polylactic acid polymerization test as described below.
In a reaction vessel equipped with a stirrer, 150 g of lactic acid was heated at 800 Pa at 160° C. for 3.5 hours, to obtain oligomers. Subsequently, 0.12 g of tin(II) acetate (manufactured by Kanto Chemical Co., Inc.) and 0.33 g of methanesulfonic acid (manufactured by Wako Pure Chemical Industries, Ltd.) were added to the oligomers, and the resulting mixture was heated at 500 Pa at 180° C. for 7 hours, to obtain a prepolymer. Subsequently, the prepolymer was heated in an oven at 120° C. for 2 hours to allow crystallization. The obtained prepolymer was pulverized using a hammer crusher, and sieved to obtain a powder with an average particle size of 0.1 mm. In the solid phase polymerization step, 50 g of the prepolymer was placed in an oven connected to an oil rotary pump, and heat treatment was performed under reduced pressure. In this treatment, the pressure was 50 Pa, the heating temperatures were: 140° C. for 10 hours, 150° C. for 10 hours, and 160° C. for 20 hours. The obtained polylactic acid was subjected to analysis of the weight average molecular weight by GPC, analysis of the melting point by DSC, analysis of the weight reduction rate upon heating by TG, and measurement of the degree of coloration. The results are shown in Tables 3 and 4.
The weight average molecular weight (Mw) of the polylactic acid is the value of the weight average molecular weight measured by gel permeation chromatography (GPC) in terms of a standard polymethyl methacrylate. In the GPC measurement, HLC 8320GPC (manufactured by Tosoh Corporation) was used as the GPC system, and two linearly connected TSK-GEL Super HM-M columns (manufactured by Tosoh Corporation) were used. Detection was carried out with a differential refractometer. In terms of the measurement conditions, the flow rate was 0.35 mL/min.; hexafluoroisopropanol was used as the solvent; and 0.02 mL of a sample solution at a concentration of 1 mg/mL was injected.
The melting point of the polylactic acid was measured using a differential scanning calorimeter DSC7020 (manufactured by SII Nanotechnology Inc.). The measurement was carried out with 10 mg of the sample under nitrogen atmosphere at a rate of temperature increase of 20° C./min.
Analysis of Weight Reduction Rate upon Heating of Polylactic Acid
The weight reduction rate upon heating of the polylactic acid was measured using a thermogravimetry/differential thermal analyzer TG/DTA7200 (manufactured by SII Nanotechnology Inc.). The measurement was carried out with 10 mg the sample under nitrogen atmosphere at a constant temperature of 200° C. for a heating time of 30 minutes.
For measuring the degree of coloration of the polylactic acid produced by polymerization, 0.4 g of the polylactic acid was dissolved in 25 mL of chloroform and analyzed according to JIS K 0071-1 using a colorimeter (manufactured by Nippon Denshoku Industries Co., Ltd.) in terms of the APHA unit color number.
In a glass Schlenk flask, 500 mL of the test solution obtained in Reference Example 3 was placed. Without addition of an oxidizing agent, the solution was stirred at 60° C., 100° C. or 180° C. for 2 hours. The APHA value and the optical purity of the lactic acid after heating, and the APHA value and the optical purity of the lactic acid obtained after distillation at 130° C. under a reduced pressure of 133 Pa are shown in Table 5. Subsequently, 150 g of each lactic acid obtained by the distillation was subjected to a polymerization test in the same manner as in Examples 1 to 68. The results are shown in Table 6.
In a glass Schlenk flask, 500 mL of the test solution obtained in Reference Example 3 was placed. Each of various reducing agents was added to the test solution, and the resulting mixture was stirred at 25° C. for 2 hours. The types of the reducing agents added; and the APHA values and the optical purities of the lactic acids after reducing agent treatment, and the APHA values and the optical purities of the lactic acids obtained after distillation at 130° C. under a reduced pressure of 133 Pa; are shown in Table 5. Further, a polymerization test was carried out in the same manner as in Examples 1 to 68 for 150 g of each of the lactic acids obtained by distillation in Comparative Example 4, Comparative Example 8, Comparative Example 12 and Comparative Example 16. The results are shown in Table 6.
In a glass Schlenk flask, 200 mL of the test solution obtained in Reference Example 3 was placed. As described in JP 3880175 B, 5% palladium-alumina (manufactured by NE Chemcat Corporation) as a catalyst was added to the test solution, and the atmosphere in the reaction container was replaced with nitrogen. Subsequently, the atmosphere in the reaction container was replaced with 200 mL of hydrogen, and catalytic reduction treatment was performed at normal pressure with vigorous stirring. The reduction treatment was finished upon completion of consumption of the hydrogen, and the catalyst was then removed by filtration using a qualitative filter paper NO2 (ADVANTEC). Although the obtained solution had a reduced degree of coloration with an APHA of 138, the solution had a reduced optical purity of 98.8% e.e. By distillation of the filtrate in the same manner as in Examples 1 to 68, the APHA value became 25, and the optical purity became 99.0% e.e. A polymerization test was carried out in the same manner as in Examples 1 to 68 with 150 g of the lactic acid obtained by distillation. The results are shown in Table 6.
From the results of the above Examples and Comparative Examples, it became clear that addition of an oxidizing agent to a raw lactic acid solution containing a colored component allows removal of the colored impurity and improvement of properties of polylactic acid produced by polymerization, without decreasing the optical purity of the lactic acid.
In an anaerobic glove box, 1 mL of 30 mM sodium carbonate and 0.15 mL of 180 mM sulfuric acid were added to 100 mL of the medium for seed culture composed of 20 g/L glucose, 10 g/L polypeptone, 5 g/L yeast extract, 3 g/L dipotassium hydrogen phosphate, 1 g/L sodium chloride, 1 g/L ammonium sulfate, 0.2 g/L magnesium chloride hexahydrate and 0.2 g/L calcium chloride dihydrate that was heat-sterilized at 121° C. at 2 atm for 20 minutes, and 0.5 mL of the reducing solution composed of 0.25 g/L cysteine-HCl and 0.25 g/L sodium sulfide was further added to the resulting mixture. Anaerobiospirillum succiniciproducens ATCC53488 was inoculated to the prepared medium, and static culture was carried out at 39° C. overnight to prepare a preculture liquid.
Thereafter, CO2 gas was flown from a sparger at a rate of 10 mL/min. into 3 L of the fermentation medium composed of 50 g/L glucose, 10 g/L polypeptone, 5 g/L yeast extract, 1 g/L dipotassium hydrogen phosphate, 0.4 g/L ammonium chloride, 0.2 g/L calcium chloride dihydrate, 0.2 g/L magnesium chloride hexahydrate and 0.001 g/L iron sulfate heptahydrate that was heat-sterilized at 121° C. at 2 atm for 20 minutes, and 30 mL of 3M sodium carbonate was then added to the medium, followed by adjusting the pH of the resulting medium to 6.8 with a sulfuric acid solution. Thereafter, 1.5 mL of the reducing solution composed of 0.25 g/L cysteine-HCl and 0.25 g/L sodium sulfide was added to the resulting medium, and 50 mL of the preculture liquid described above was inoculated thereto, followed by performing main culture at a stirring rate of 200 rpm at 39° C. for 39 hours. During the culture, the pH of the culture liquid was adjusted to 6.4 using 5 M calcium hydroxide.
As a result of HPLC analysis of 100 L of the succinic acid culture liquid under the following measurement conditions, the amount of succinic acid accumulated was 1150 g.
Column: Shim-Pack SPR-H (manufactured by Shimadzu Corporation), 45° C.
Mobile phase: 5 mM p-Toluenesulfonic acid, 0.8 mL/min.
Reaction solution: 5 mM p-Toluenesulfonic acid, 20 mM bis-Tris, 0.1 mM EDTA-2Na (0.8 mL/min.)
Detector: Electric conductivity
A culture liquid containing calcium succinate was obtained by heat-sterilizing 100 L of the culture liquid prepared in Reference Example 4 at 120° C. for 20 minutes, centrifuging the resultant at 5000×G for 20 minutes and collecting the resulting supernatant. Ultrapure water and 95% sulfuric acid (manufactured by Sigma Aldrich) were added to the culture supernatant until the pH became 2.5, and the produced calcium sulfate was removed by suction filtration to obtain an aqueous succinic acid solution. This was further followed by purification with a strong cation-exchange resin and a strong anion-exchange resin in the same manner as in Reference Example 3. Ultrapure water was added to the purified solution to prepare 1 wt % aqueous succinic acid solution, which was used as a test solution. The color intensity of the test solution was analyzed according to JIS K 0071-1 using a colorimeter (manufactured by Nippon Denshoku industries Co., Ltd.) in terms of the APHA unit color number. As a result, the AHPA value of the test solution was 121. Using a rotary evaporator (manufactured by Tokyo Rikakikai Co., Ltd.), 10 L of the test solution was concentrated at 70° C. at 10 kPa, to obtain 1 L of 10 wt % aqueous succinic acid solution. Thereafter, the obtained solution was stirred at 4° C. for 12 hours, and precipitated succinic acid crystals were collected by solid-liquid separation by suction filtration. To 1600 g of ultrapure water, 205 g of the wet crystals (water content, 58%) of succinic acid obtained by crystallization were added, and the crystals were dissolved in the ultrapure water, to provide 5 wt % aqueous succinic acid solution. The APHA value of the solution was 29.
In a glass flask, 10 L of the test solution obtained in Reference Example 5 was placed. Each of various oxidizing agents was added to the test solution, and the resulting mixture was stirred at 25° C. (without heating), 60° C., 100° C. or 180° C. for 2 hours. The types and the concentrations of the oxidizing agents added, and the heating conditions; the APHA values after the oxidizing agent treatment; and the APHA values of 5 wt % aqueous succinic acid solutions obtained by concentration, crystallization and redissolution in the same manner as in Reference Example 4; are shown in Tables 7 and 8. In cases where the oxidizing agent was in the form of an aqueous solution, the concentration of the oxidizing agent added to the test solution was measured in terms of the pure content excluding water. The concentration of the oxidizing agent added was calculated according to the calculation equation shown in Equation 2.
Concentration of oxidizing agent added (%)=(weight of oxidizing agent excluding water/weight of succinic acid excluding water)×100 (2)
In a glass flask, 10 L of the test solution obtained in Reference Example 5 was placed. Without addition of an oxidizing agent, the solution was stirred at 60° C., 100° C. or 180° C. for 2 hours. The APHA values after the heat treatment, and the APHA values of 5 wt % aqueous succinic acid solutions obtained by concentration, crystallization and redissolution in the same manner as in Reference Example 4; are shown in Table 9.
In a glass flask, 10 L of the test solution obtained in Reference Example 5 was placed. Each of various reducing agents was added to the test solution, and the resulting mixture was stirred at 25° C. (without heating) for 2 hours. The types of the reducing agents added, the APHA values after the treatment with reducing agents, and the APHA values of 5 wt % aqueous succinic acid solutions obtained by concentration, crystallization and redissolution in the same manner as in Reference Example 4; are shown in Table 9.
Hydrogenation reaction of succinic acid was carried out according to Examples in JP 4380654 B, to synthesize 1,4-butanediol. More specifically, 254 g of methanol (manufactured by Wako Pure Chemical Industries, Ltd.) and 1.6 g of 95% sulfuric acid (manufactured by Sigma Aldrich) were mixed with 80 g each of the succinic acid crystals obtained in Reference Example 5, Example 72, Example 92, Example 108 and Example 124, and the reaction was allowed to proceed under reflux with stirring for 2 hours. After cooling the reaction solution, 2.9 g of sodium hydrogen carbonate was added thereto, and the resulting mixture was stirred at 60° C. for 30 minutes. The mixture was then subjected to distillation at normal pressure, and the distillation residue was filtered and subjected to distillation under reduced pressure, to obtain dimethyl succinate. To the dimethyl succinate, a CuO—ZnO catalyst was added, and the temperature was increased to 230° C. for 1 hour in a pressurized reaction vessel in the presence of hydrogen at 5 MPa with stirring. Thereafter, the reaction was allowed to proceed at 230° C. under a hydrogen pressure of 15 MPa for 9 hours, and degassing was carried out after cooling. The catalyst was removed from the reaction solution by filtration, and the filtrate was subjected to distillation under reduced pressure, to obtain 49 g of 1,4-butanediol.
With 45.0 g of each synthesized 1,4-butanediol, 94.0 g of terephthalic acid (manufactured by Wako Pure Chemical Industries, Ltd.) was mixed, and 0.07 g of tetra-n-butyl titanate (manufactured by Kanto Chemical Co., Inc.) and 0.06 g of monobutylhydroxytin oxide (manufactured by Tokyo Chemical Industry Co., Ltd.) were added to the resulting mixture as catalysts. The reaction was started in a reactor equipped with a rectifying column at 190° C. at 79.9 kPa, and the temperature was increased stepwise while 56.9 g of 1,4-butanediol was gradually added to the reaction mixture (final molar concentration: 1,4-butanediol/terephthalic acid=2/1), to obtain an esterified reaction product. To 100 g of this esterified product, 0.06 g of tetra-n-butyl titanate and 0.01 g of phosphoric acid (manufactured by Wako Pure Chemical Industries, Ltd.) as polycondensation catalysts were added, and polycondensation was carried out at 250° C. at 67 Pa. The molecular weight, melting point, weight reduction rate upon heating, and APHA of the produced polybutylene terephthalate were measured under the same conditions as those for the polylactic acids of Examples 1 to 68 (as the solvent for measurement of APHA, hexafluoroisopropyl alcohol was used). The results are shown in Table 10.
From the above results of Examples and Comparative Examples, it became clear that addition of an oxidizing agent to a raw aqueous succinic acid solution containing a colored component allows removal of the colored impurity and improvement of properties of polybutylene terephthalate produced by polymerization.
According to the methods described in the Examples 8 and 10 of WO2010/140602, SU042, which is a D-lactic acid fermentation yeast, was cultured, to obtain a D-lactic acid culture liquid.
Bacterial cells were removed from 30 L of the D-lactic acid culture liquid prepared in Reference Example 5 by filtration through a microfiltration membrane (“Microza”, manufactured by Asahi Kasei Corporation), and 95% sulfuric acid (manufactured by Sigma Aldrich) was added to the resulting filtrate until the pH became 2.5, followed by stirring the obtained mixture for 2 hours. The produced calcium sulfate was removed by suction filtration, and the obtained filtrate was passed through a column packed with a strong anion-exchange resin (“DIAION SA10A”, manufactured by Mitsubishi Chemical Corporation) in the downflow direction. The resultant was then passed through a column packed with a strong cation-exchange resin (“DIAION SK1B” manufactured by Mitsubishi Chemical Corporation) in the downflow direction. Subsequently, the resultant was filtered through a nanofiltration membrane (4-inch spiral element “SU-610”, manufactured by Toray Industries, Inc.), to obtain 28 L of a raw aqueous lactic acid solution. Subsequently, the solution was concentrated to 56 wt % using a thin-film evaporator (manufactured by Tokyo Rikakikai Co., Ltd.), to provide a raw lactic acid test solution. The AHPA value of the raw lactic acid test solution was 49. The raw lactic acid test solution was subjected to distillation at 130° C. under a reduced pressure of 133 Pa. The APHA value and the optical purity of the lactic acid obtained by the distillation are shown in Table 11.
In a reaction vessel equipped with a stirrer, 30 g of the obtained lactic acid was heated at 800 Pa at 160° C. for 3.5 hours, to obtain oligomers. Subsequently, 24 mg of tin(II) acetate (manufactured by Kanto Chemical Co., Inc.) and 66 mg of methanesulfonic acid (manufactured by Wako Pure Chemical Industries, Ltd.) were added to the oligomers, and the resulting mixture was heated at 500 Pa at 180° C. for 7 hours, to obtain a prepolymer. Subsequently, the prepolymer was heated in an oven at 120° C. for 2 hours to allow crystallization. The obtained prepolymer was pulverized using a hammer crusher, and sieved to obtain a powder with an average particle size of 0.1 mm. In the solid phase polymerization step, 10 g of the prepolymer was placed in an oven connected to an oil rotary pump, and heat treatment was performed under reduced pressure. In this treatment, the pressure was 50 Pa, the heating temperatures were: 140° C. for 10 hours, 150° C. for 10 hours, and 160° C. for 20 hours. The obtained polylactic acid was subjected to analysis of the weight average molecular weight by GPC, analysis of the melting point by DSC, analysis of the weight reduction rate upon heating by TG, and measurement of the degree of coloration under the same conditions as in Examples 1 to 68. The results are shown in Table 12.
In a glass Schlenk flask, 80 mL of the raw lactic acid test solution obtained in Reference Example 6 was weighed. To the test solution, 280 mL of 50 ppm ozone water (manufactured by Unno Giken Co., Ltd.) was added, and the resulting mixture was stirred at room temperature (25° C.) for 16 hours. The amount of ozone added at this time was 0.03% as calculated according to (Equation 1). Thereafter, while the test solution was heated from room temperature to 35° C., the test solution was concentrated under a reduced pressure of 20 hPa to a lactic acid concentration of 56%. The obtained concentrate was subjected to distillation at 130° C. under a reduced pressure of 133 Pa, to obtain D-lactic acid. The APHA value and the optical purity of the lactic acid after distillation are shown in Table 11. Subsequently, a polymerization test and analysis were carried out in the same manner as in Reference Example 6. The results are shown in Table 12.
In a glass Schlenk flask, 80 mL of the raw lactic acid test solution obtained in Reference Example 6 was weighed. To the test solution, 1.5 mL of 30% hydrogen peroxide solution (manufactured by Wako Pure Chemical Industries, Ltd.) was added, and the resulting mixture was stirred at 120° C. for 4 hours. The amount of hydrogen peroxide added at this time was 1% as calculated according to (Equation 1). The resulting product was subjected to distillation at 130° C. under a reduced pressure of 133 Pa. The APHA value and the optical purity of the lactic acid obtained by distillation are shown in Table 11. Subsequently, a polymerization test and analysis were carried out in the same manner as in Reference Example 6. The results are shown in Table 12.
In a glass Schlenk flask, 80 mL of the raw lactic acid test solution obtained in Reference Example 6 was weighed. To the test solution, 280 mL of 50 ppm hydrogen peroxide solution (prepared by diluting 47 μL of 30% hydrogen peroxide solution manufactured by Wako Pure Chemical Industries, Ltd. with 280 mL of distilled water) was added, and the resulting mixture was stirred at 120° C. for 4 hours. The amount of hydrogen peroxide added at this time was 0.03% as calculated according to (Equation 1). Subsequently, the test solution was once cooled to room temperature (25° C.). Thereafter, while the test solution was heated again to 35° C., the test solution was concentrated under a reduced pressure of 20 hPa to a lactic acid concentration of 56%. The resulting solution was then subjected to distillation at 130° C. under a reduced pressure of 133 Pa, to obtain D-lactic acid. The APHA value and the optical purity of the lactic acid obtained by the distillation are shown in Table 11. Subsequently, a polymerization test and analysis were carried out in the same manner as in Reference Example 6. The results are shown in Table 12.
From the results of the above Reference Examples and Examples, it became clear that addition of an oxidizing agent to an aqueous lactic acid solution containing a colored component allows removal of the colored impurity and improvement of properties of polylactic acid produced by polymerization, without decreasing the optical purity of the lactic acid.
Since colored impurities contained in an organic acid derived from a biomass resource are removed, the obtained organic acid can be suitably used as an industrial chemical product such as a polymer material.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2011-160643 | Jul 2011 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2012/068427 | 7/20/2012 | WO | 00 | 2/27/2014 |
