Gas-expanded liquids for sustainable catalysis and novel materials: Recent advances

Employing a multiscale systems-based research approach, chemists and chemical engineers at the Center for Environmentally Beneficial Catalysis (CEBC) are collaboratively addressing major grand challenges facing the sustainable manufacture of fuels and chemicals from both traditional and renewable feedstocks. By judiciously combining the principles of green chemistry and green reactor engineering, augmented by valuable insights from industrial partners, CEBC researchers are developing alternative technology concepts that minimize the environmental footprint of chemical manufacturing processes including the reduction of carbon emissions. Such collaborations have resulted in several remarkable discoveries as follows: CO₂-expanded liquids (CXLs) as reaction media for selective and inherently safe O₂ oxidations including that for terephthalic acid production from p-xylene with potentially reduced solvent burning (i.e., reduced carbon footprint); propylene oxide production with environmentally benign solvents and oxidant, exploiting the compressibility of propylene at ambient temperatures for process intensification; a novel pressure-intensified ethylene oxide process virtually eliminating CO₂ formation as a byproduct; highly selective hydroformylation of higher olefins employing CXLs and soluble polymer-supported homogeneous Rh-based catalysts that are easily retained in solution while the product is isolated by membrane filtration; and creation of nanoparticles of transition metal complexes with unique functional properties such as reversible oxygen binding and room-temperature nitric oxide disproportionation. Quantitative economic and environmental impact analyses have been employed to benchmark CEBC's novel technology concepts against conventional processes and to guide research and development. Examples of such advances in green processing are discussed in this review.