Non-Oxidative Regeneration Processes for Na-FAU based catalysts for Decarbonization of the Acrylic Acid Industry through Biomanufacturing

C56-10d-273742 The problem we are addressing is petroleum-derived acrylic acid and acrylate derivatives (together, acrylics) that are produced via a petroleum refining value chain releasing over 16 million kg CO2 each year globally. Among the many industrial sectors in need of decarbonization, the National Academies of Science recently identified a low-cost transition to a lower carbon chemical base by 2030 as a key need. Our proposed solution to decarbonize the acrylic chemicals industry is a lactic-to-acrylic biomanufacturing technology to produce sustainable and eco-friendly bio-based acrylics at cost parity with petrochemicals. By leveraging the domestic commercial production of lactic acid from fermentation of bio-derived sugar sources such as corn, over 35% CO2 intensity reduction for acrylic production can be achieved. In this proposal, we will devise catalyst regeneration methods to significantly improve the technical/economic viability of our process by increasing the longevity of the catalyst while maintaining a constant >90% yield of acrylic product. Our catalyst innovation combines a solid acid (Na+-FAU zeolite) with an engineered amine additive to control the lactic-to-acrylic reaction. Our working hypothesis is that high product yield arises from the competition between amine basicity and steric limitations. However, we have yet to be able to regenerate the catalyst without burning off the amine. We hypothesize that non- oxidative methods of catalyst regeneration such as steam stripping will allow carbonaceous material removal, thus restoring process yields without having to reload a new batch of catalyst. Our high yield lactic-to-acrylic technology helps to: grow the industrial chemicals portion of corn utilization; provides societal impact and high paying jobs across rural America; economic competitiveness in global markets; and supports national defense priorities.