Carbon-Based Catalysts from H3PO4 Activation of Olive Stones for Sustainable Solketal and γ-Valerolactone Production

The use of activated carbon-based catalysts for the production of solketal and γ-valerolactone (GVL), two products of interest for biorefinery processes, was investigated. Activated carbons (ACs) were prepared by chemical activation of olive stones, an agricultural byproduct, using H3PO4 to olive stone mass impregnation ratios (IRs) of 1:1 and 3:1, and under nitrogen or air atmosphere. The ACs showed SBET values of 1130–1515 m2/g, owing to the presence of micropores (0.45–0.60 cm3/g). The use of an IR of 3:1 delivered a wider pore size distribution, with mesopore volume increasing up to 1.36 cm3/g. XPS confirmed the presence of phosphorus groups with surface concentrations of 2.2–3.2 wt% strongly bonded the AC surface through C-O-P bonds. The ACs were tested as acid catalysts for the acetalization of glycerol in a stirred batch reactor at temperatures of 30–50 °C, glycerol concentrations of 1.5 to 3.4 mol/L, and 1–3 wt% catalytic loading. The catalytic activity was clearly correlated with the quantity of C-O-P acid groups determined by TPD, which increased when ACs were prepared under air atmosphere. The AC prepared with IR 3:1 under air achieved full selectivity to solketal, with activation energy of 49 kJ/mol and conversion of up to 70%, matching the equilibrium conversion value under the optimum reaction conditions. A bifunctional catalyst was prepared over this AC by deposition of 5 wt% zirconium and tested in stirred batch reactor for the hydrogenation of levulinic acid (LA) using isopropyl alcohol (IPA) as solvent and H2 donor, with LA:IPA ratios from 1:1 to 1:7 and temperatures between 160–200 °C. The catalyst reached full LA conversion and a GVL yield higher than 80% after only 12 h at 200 °C. A test conducted in the presence of water revealed that it was an inhibitor of the reaction. The identification of isopropyl levulinate as an intermediate suggests that the most likely reaction pathway was dehydration, followed by hydrogenation and cyclization, to obtain GVL. Kinetic modelling of the results showed a value of 42 kJ/mol for the hydrogenation step. The reusability of the catalyst was tested for five consecutive reaction cycles, maintaining most of the activity and selectivity towards GVL.