Potassium Exchanged FAU Zeolites for Improved Lactic to Acrylic Selectivity and Deactivation Rate for Decarbonization of the Acrylic Acid Industry

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 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 utilize potassium (K+) exchanged FAU zeolites as the catalyst base to significantly improve the technical 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. Catalyst synthesis and testing will be used to examine K+-FAU, as we hypothesize that K+ interaction with engineered amines relative to Na+ shifts the competing catalytic cycles away from decarbonylation (undesired side reaction) toward the desired dehydration of lactate to acrylate products. Commercial Applications – our high yield lactic-to-acrylic technology helps: 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.