1. Introduction
Biodiesel has emerged as a key renewable fuel within the global energy transition. However, its large-scale production generates crude glycerol as a major byproduct (10 wt.%), which represents a significant challenge for the economic and environmental sustainability of the biodiesel industry. In this context, the catalytic valorization of glycerol into high-value-added products has become a central topic within waste-derived feedstock upgrading strategies.
Among the different glycerol transformation pathways, glycerol carbonate (GC) stands out as a particularly attractive target molecule due to its excellent physicochemical properties, such as low toxicity, low flammability, high biodegradability, low vapor pressure, and high hydration capacity, which are fully aligned with green chemistry principles [
1,
2,
3]. GC has found applications as a solvent and intermediate in polymers, resins, surfactants, adhesives, paints, and lithium-ion batteries, with new applications continuously emerging.
Traditionally, GC has been produced via reactions involving phosgene, urea, or carbonylation with CO
2 or CO. However, these routes suffer from severe drawbacks, including toxicity, corrosiveness, the need for continuous byproduct removal, or harsh operating conditions such as high pressures and temperatures [
4,
5,
6]. In contrast, the transesterification of glycerol with dimethyl carbonate (DMC) represents a more sustainable and efficient alternative, as it can be conducted under relatively mild conditions and avoids the use of hazardous reagents. This reaction requires basic catalysts, although homogeneous systems, despite their high activity, present significant limitations related to separation, corrosion, and catalyst recovery. As a result, heterogeneous catalysts have attracted increasing attention due to their reusability, operational simplicity, and potential for surface property tuning [
7].
Among the heterogeneous catalysts reported for this transesterification reaction, CaO [
8], KNO
3/CaO [
9], and Li/ZnO [
10] could be mentioned. Nevertheless, many of these catalysts still face important challenges, such as carbonation, excessive reactant ratios, solvent use, high reaction temperatures, or demanding calcination treatments. These limitations highlight the need for the rational design of catalytic surfaces capable of combining high activity, selectivity, and stability under mild and sustainable conditions.
In this regard, mixed metal oxides (MMOs) derived from layered double hydroxides (LDHs) have gained increasing relevance as tunable heterogeneous catalysts for glycerol carbonate synthesis [
11]. The catalytic performance of MMOs is strongly governed by their surface properties, particularly the nature, strength, and distribution of basic and acidic sites, which directly influence the reaction mechanism [
12,
13].
LDH-derived MMOs offer remarkable versatility, as their acid–base surface characteristics can be finely adjusted by modifying the type and proportion of metal cations incorporated into the structure. Moreover, LDHs can be synthesized through simple, reproducible, and environmentally friendly co-precipitation methods, followed by controlled thermal decomposition to generate highly dispersed mixed oxides with high surface areas and structural stability [
14,
15,
16,
17,
18]. LDHs are anionic nanoclays, which can be found in nature or synthesized in the laboratory. The structure of Mg-Al LDH mimics the mineral brucite structure, consisting of stacked sheets of octahedral magnesium hydroxides, where the magnesium ions are coordinated to six hydroxyl groups. The partial replacement of Mg
2+ by Al
3+ generates positive charges in the brucite-like layers, which are compensated by interlayer carbonate anions. LDHs can be generally described by the formula
, where
and
represent divalent and trivalent ions, respectively. Anions and a specific number of water molecules, symbolized by
A and
m, respectively occupy the space between the sheets. The value of
x can vary between 0.17 and 0.33. Mg
2+ ions can be replaced by other divalent metal ions with a similar ionic radius [
15].
Several magnesium-based heterogeneous mixed metal oxide catalysts, such as MgCr
2O
4 [
19], MgO/La
2O
3 [
20], Mg/Zr/Sr [
21], MgO/Al
2O
3 [
22], Mg/Al/Zr [
23], and LiNO
3/Mg
4AlO
5.5 [
24], were applied in GC synthesis. These catalysts achieved glycerol conversions of 70–99% in a reaction temperature range of 75–100 °C, although they required calcination temperatures above 500 °C. The authors reported a correlation between catalytic activity and surface basicity, but did not report data on the acidity of the MMOs. Wang et al. also reported Mg-Al-Zr catalysts, although their maximum performance required a reduced pressure of 10 kPa and a temperature of 140 °C [
5]. These authors reported surface acidity results associated with catalytic activity. On the other hand, glycidol is a byproduct generated by decarboxylation of GC in the presence of strong bases [
25], high reaction temperatures [
26], or defects produced by oxygen vacancies in CeO
2 that favor CO
2 adsorption [
27]. These observations underscore the importance of designing catalytic surfaces with a balanced distribution of basic and acid sites to maximize GC yield while suppressing side reactions.
Accordingly, this work proposes the rational design of quaternary Ni-Zn-Mg-Al mixed metal oxide catalysts derived from LDH precursors, aiming to tune surface acid–base properties through controlled Ni and Zn incorporation. To the best of our knowledge, Ni-Zn-Mg-Al MMOs have not been previously reported for glycerol carbonate synthesis. The influence of Zn loading on the structural, textural, and surface properties of the catalysts was systematically investigated and correlated with their catalytic performance. Additionally, ternary Ni-Mg-Al and Zn-Mg-Al systems, along with the unmodified Mg-Al matrix, were synthesized for comparative purposes. Through comprehensive characterization, this study establishes clear structure–surface–activity relationships, contributing to the design of efficient catalytic surfaces for sustainable glycerol valorization.
2. Materials and Methods
2.1. Catalysts Synthesis
LDH precursors were prepared using the co-precipitation method. The molar ratio between divalent and trivalent metals (M/Al, where M represents the whole amount of divalent metals: Mg, Ni, and Zn) was a constant value of 3. Three solutions named A, B, and C were prepared. Solution A contained the metal ions to be incorporated, according to the LDH to be synthetized. The metal sources were Mg(NO
3)
2·6H
2O (Biopack, Buenos Aires, Argentina, analytical grade), Al(NO
3)
3·9H
2O (Biopack, analytical grade), Ni(NO
3)
2·6H
2O (Tetrahedron, Buenos Aires, Argentina, analytical grade), and Zn(NO
3)
2·6H
2O (Sigma-Aldrich, St. Louis, MO, USA, 98.0%). The solutes are dissolved in distilled water with a total cation concentration of 0.95 M. Solution B contained 0.12 M of Na
2CO
3 (Cicarelli, Buenos Aires, Argentina, analytical grade) as a source of carbonate anions with [CO
32−] = 0.5 [M
3+]. Solution C contained 2.00 M NaOH (Biopack, analytical grade). The three solutions were added simultaneously to 30 mL of distilled water at a dropping rate of 60 mL h
−1. The pH was kept constant (10.0 ± 0.2) with the NaOH solution. Co-precipitation was carried out at room temperature. The obtained gel was kept under stirring for 4 h and then aged for 18 h. The gel was separated by filtration and washed with distilled water until reaching a pH of 7. Finally, the solid was dried in an oven at 90 °C. All samples were calcined in an air atmosphere at 450 °C for 9 h (heating rate = 3 °C min
−1). The Ni load was kept to constant value of 15% from the total amount of M, while different Zn loads were used to evaluate their effect on the properties of LDHs and their calcination products. For this purpose, 0, 15, 20, and 25 atomic percentages of Zn replaced the Mg one. The transition metal-free material was designated as LDH-MgAl and MMO-MgAl, regarding the precursor and calcined solid, respectively. The other solid materials obtained have the nomenclatures LDH-Ni
xZn
y and MMO-Ni
xZn
y, where
x and
y indicate the percentage of Mg replacement by Ni and Zn, respectively. Consequently, the materials contain Mg, Al, and one or two transition metals, called ternary or quaternary solids, respectively. The compositions are presented in
Table 1 as theoretical atomic percentage (at. %) for each metal to incorporate. The respective column indicates the metal atomic percentage results considering the four metals’ contents in the material’s structure as 100%. The letter M, used in
Table 1, represents the sum of the atomic percentages of Ni, Zn, and Mg.
2.2. Characterization Techniques
Material elemental analysis was performed using microwave plasma atomic emission spectrometry (MP-AES), using Agilent 4200 equipment (Agilent, Santa Clara, CA, USA). The samples were previously exposed to acid digestion according to the U.S. EPA Method 3052A.
The powder solids were characterized by X-ray diffraction (XRD) to study the crystal structure and phases present using an X’Pert Pro-PANalytical diffractometer (PANalytical, Almelo, The Netherlands) equipped with CuKα radiation (λ = 1.54 Å). The diffractograms were measured in a 2θ range between 4° and 70° with a step size of 0.03 and 4.5 s/step. Crystalline phases were identified using PANalytical X’pert High Score software (version 3.1), with reference to the International Center for Diffraction Data/Joint Committee on Powder Diffraction Standards (ICDD/JCPDS) database. Crystallite size (D) was estimated using the Debye–Scherrer equation, D = K λ/β cosθ, where K is the Scherrer constant (0.94), λ is the wavelength of the X-ray radiation (λ = 1.54 Å), θ is the scattering angle of the principal reflection, and β is the reflection width at half maximum (FWHM).
Calcined materials’ morphology was analyzed using high-resolution scanning electron microscopy on a Σigma-ZEISS instrument (Carl Zeiss, Oberkochen, Germany). This instrument also included an energy-dispersive X-ray analyzer (EDS, Oxford AZTec, Oxford Instruments, Abingdon, United Kingdom). EDS analysis was used to add elemental composition information to the electron microscopy images. The samples were metallized with Au/Pd of a 70/30 weight ratio.
The surface basicity of the oxides was studied by temperature-programmed desorption (CO2-TPD) with CO2 as the probe molecule, using Chemisorb 2720 equipment (Micromeritics, Norcross, GA, USA). The samples (0.04 g) were pretreated under N2 flow (20 mL min−1) at 150 °C for 30 min. They were subsequently saturated with CO2 (50 mL min−1) at 80 °C for 1 h and purged with He (20 mL min−1) at 100 °C for 45 min. Desorption profiles were recorded from 80 to 950 °C (10 °C min−1) under He (50 mL min−1), and the CO2 removal was monitored with a thermal conductivity detector (TCD). The surface acidity of the oxides was determined by temperature-programmed desorption of NH3 (NH3-TPD) performed on an AutoChem III instrument (Micromeritics, USA). Approximately 0.04 g of the sample was pretreated in a stream of He at 450 °C for 30 min. The sample was then saturated with a flow of NH3 (50 mL min−1) at 100 °C for 15 min, and the excess was removed with a flow of He (50 mL min−1) at 100 °C for 30 min. Finally, desorption was performed from 60 to 550 °C (10 °C min−1), and NH3 desorption was monitored by mass spectrometry. The signals obtained by CO2-TPD and NH3-TPD were deconvoluted using Gaussian functions via Origin software (version 9.5).
The coordination and aggregation of the metallic species present in the samples were recorded using UV-vis diffuse reflectance spectroscopy (UV-vis DR). For this analysis, a JASCO-V650 spectrophotometer (JASCO Corporation, Tokyo, Japan) equipped with an integrating sphere for diffuse reflectance was used. Measurements were made in a wavelength range between 200 and 900 nm. The obtained data were transformed using the Kubelka–Munk equation. The reference material was BaSO4.
2.3. Catalytic Experiments
Scheme 1 shows the catalytic transesterification reactions between glycerol (Gly) (Cicarelli, 99.5%) and dimethyl carbonate (DMC) (Sigma-Aldrich, >99%). The reaction was performed in a 20 mL glass batch reactor with magnetic stirring, which was immersed in a thermostated bath and fitted with a condensation system. The reaction parameters used corresponded to previous experiments with similar catalysts. A total of 24 mmol of dimethyl carbonate, 12 mmol of glycerol, and 7.5% by weight of catalyst (based on the mass of Gly) were placed in the reactor for 270 min at 85 °C, without solvents. When the reaction time was over, the catalyst was separated from the reaction medium by centrifugation and filtration. The recovered solid was washed several times with methanol before drying at 120 °C overnight. Then, the dried material was calcined at 450 °C for 9 h for reuse and stability studies. The reaction medium was analyzed by gas chromatography on an Agilent Technologies 7820A chromatograph equipped with a capillary column (HP-20M, 25 m × 0.20 mm × 0.20 μm) and a flame ionization detector (FID). Quantitative analysis of the reaction mixture was performed using response factors and cyclohexanol (Merck, Darmstadt, Germany, reagent grade) as an internal standard. Product identification was performed by gas chromatography using pure standards of methanol (solvent), glycerol, glycerol carbonate, and glycidol. The absence of additional peaks in the chromatograms indicates that the formation of other carbonate derivatives or oligomeric byproducts is negligible under the investigated reaction conditions (
Figure S1). Standard deviations were calculated from three repeated injections of each reaction sample into the gas chromatograph. This procedure allowed for the estimation of the variability associated with the instrumental analysis and ensured the precision of product quantification.
4. Conclusions
Ni-Zn-Mg-Al quaternary mixed metal oxides were successfully synthesized via a co-precipitation route using layered double hydroxides as precursors and evaluated as heterogeneous catalysts for the transesterification of glycerol with dimethyl carbonate to produce glycerol carbonate. For comparison, Mg-Al, Ni-Mg-Al, and Zn-Mg-Al mixed oxides were also synthesized and tested.
The results demonstrate that the simultaneous incorporation of Ni and Zn into the Mg-Al oxide matrix contributes to enhanced catalytic performance. Quaternary Ni-Zn-Mg-Al catalysts exhibited higher glycerol conversions and glycerol carbonate yields than the corresponding ternary systems, mainly due to their increased surface basicity in both strength and density, combined with a suitable population of moderate and strong acid sites. Among them, the MMO-Ni15Zn20 catalyst achieved the highest glycerol carbonate yield (89.6%) under mild and solvent-free reaction conditions.
Structure–activity relationship analysis revealed that catalytic efficiency is governed by the combined effects of surface acid–base properties, textural parameters, and morphology. In particular, the larger pore volumes of the quaternary oxides favored reactant accessibility to active sites, contributing to improved performance.
Reuse experiments performed with MMO-Ni15Zn20 evidenced a progressive decrease in glycerol conversion upon consecutive cycles, indicating limited catalyst stability under the applied regeneration protocol. This deactivation was associated with a reduction in strong basic sites, surface agglomeration, and changes in metal surface distribution, while no phase transformation was detected. Notably, complete selectivity toward glycerol carbonate was preserved throughout reuse, highlighting the intrinsic selectivity of the catalytic surface despite activity loss.
Overall, this study emphasizes the importance of rational surface design, suggesting that the catalytic performance is associated with compositional effects arising from Ni-Zn incorporation and the resulting acid–base balance in mixed metal oxides. While further optimization of catalyst stability and regeneration strategies is required, the results provide valuable insights for the rational design of mixed metal oxide catalysts aimed at the efficient conversion of waste-derived glycerol.