Intensifying Cyclopentanone Synthesis from Furfural Using Supported Copper Catalysts

This work addresses catalytic strategies to intensify the synthesis of cyclopentanone, a bio-based platform chemical and a potential SAF precursor, via Cu-catalyzed furfural hydrogenation in aqueous media. When performed in a single step, using either uniform or staged catalytic bed configuration, high temperature and hydrogen pressures (180 °C and 38 bar) are necessary for maximum CPO yields (37 and 49 %, respectively). Parallel furanic ring hydrogenation of furfural and polymerisation of intermediates, namely furfuryl alcohol (FFA), limit CPO yields. Employing a two step configuration with optimal catalyst bed can curb this limitation. First, the furanic ring hydrogenation can be suppressed by using milder conditions (i. e., 150 °C and 7 bar, and 14 seconds of residence time). Second, FFA hydrogenation using tandem catalysis, i. e., a mix of β-zeolite and Cu/ZrO₂, at 180 °C, 38 bar and 0.6, allows sufficient time for CPO formation and minimises polymerisation of FFA, thereby resulting in 60 % CPO yield. Therefore, this work recommends a split strategy to produce CPO from furfural. Such modularity may aid in addressing flexible market needs.