Acetaldehyde, ethylene oxide synthesis

Not so for synthesis in the chemical industry where a compound must be prepared not only on a large scale but at low cost There is a pronounced bias toward reactants and reagents that are both abundant and inexpensive The oxidizing agent of choice for example in the chemical industry is O2 and extensive research has been devoted to develop mg catalysts for preparing various compounds by air oxidation of readily available starting materials To illustrate air and ethylene are the reactants for the industrial preparation of both acetaldehyde and ethylene oxide Which of the two products is ob tamed depends on the catalyst employed... 

Ethene is used as a starting material for the synthesis of many industrial compounds, including ethanol, ethylene oxide, ethanal (acetaldehyde), and polyethylene (PE). 

Oxygen has major uses in the chemical industry too. It is used to oxidize methane, ethylene, and other hydrocarbons. Oxidation of methane produces synthesis gas. Ethylene oxidation yields products such as ethylene oxide, acetaldehyde, and acetic acid. Oxygen also is used in making many commercial inorganic compounds including various metal oxides, oxoacids, and 0x0-salts. 

Acrolein and condensable by-products, mainly acrylic acid plus some acetic acid and acetaldehyde, are separated from nitrogen and carbon oxides in a water absorber. However in most industrial plants the product is not isolated for sale, but instead the acrolein-rich effluent is transferred to a second-stage reactor for oxidation to acrylic acid. In fact the volume of acrylic acid production ca. 4.2 Mt/a worldwide) is an order of magnitude larger than that of commercial acrolein. The propylene oxidation has supplanted earlier acrylic acid processes based on other feedstocks, such as the Reppe synthesis from acetylene, the ketene process from acetic acid and formaldehyde, or the hydrolysis of acrylonitrile or of ethylene cyanohydrin (from ethylene oxide). In addition to the (preferred) stepwise process, via acrolein (Equation 30), a... 

The synthesis of acetaldehyde by oxidation of ethylene, generally known as the Wacker process, was a major landmark in the application of homogeneous catalysis to industrial organic chemistry. It was also a major step in the displacement of acetylene (made from calcium carbide) as the feedstock for the manufacture of organic chemicals. Acetylene-based acetaldehyde was a major intermediate for production of acetic acid and butyraldehyde. However the cost was high because a large energy input is required to produce acetylene. The acetylene process still survives in a few East European countries and in Switzerland, where low cost acetylene is available. 

Acrylonitrile and methacrylonitrile can be obtained from petro-chemical olefins [2] by the noncatalytic reactions of HCN with acetaldehyde, acetone (cyanohydrin is the intermediate in these processes) or oxiranes (Z-cyanoetltanol being the intermediate in the acrylonitrile synthesis from ethylene oxide). 

Since 1960, the Hquid-phase oxidation of ethylene has been the process of choice for the manufacture of acetaldehyde. There is, however, stiU some commercial production by the partial oxidation of ethyl alcohol and hydration of acetylene. The economics of the various processes are strongly dependent on the prices of the feedstocks. Acetaldehyde is also formed as a coproduct in the high temperature oxidation of butane. A more recently developed rhodium catalyzed process produces acetaldehyde from synthesis gas as a coproduct with ethyl alcohol and acetic acid (83—94). 

With the growing prominence of the petrochemicals industry this technology was, in turn, replaced by direct air oxidation of naphtha or butane. Both these processes have low selectivities but the naphtha route is still used since it is a valuable source of the co-products, formic and propanoic acid. The Wacker process, which uses ethylene as a feedstock for palladium/copper chloride catalysed synthesis of acetaldehyde, for which it is still widely used (Box 9.1), competed with the direct oxidation routes for a number of years. This process, however, produced undesirable amounts of chlorinated and oxychlorinated by-products, which required separation and disposal. 

This process, developed in Germany, was one of the first to foretell the importance of alkenes following World War II. About 4 million pounds of aldehydes are produced yearly by this method. Acetaldehyde is easily oxidized to acetic acid and the overall conversion of ethylene to the acid represents a principal route to its synthesis, ft has been said that the invention of the Wacker process was a triumph of common sense. 82... 

The recent dramatic increase in the price of petroleum feedstocks has made the search for high selectivities more urgent. Several new processes based on carbon monoxide sources are currently competing with older oxidation processes.103,104 The more straightforward synthesis of acetic acid from methanol carbonylation (Monsanto process) has made the Wacker process obsolete for the manufacture of acetaldehyde, which used to be one of the main acetic acid precursors. Several new methods for the synthesis of ethylene glycol have also recently emerged and will compete with the epoxidation of ethylene, which is not sufficiently selective. The direct synthesis of ethylene... 

Acetic acid is also an industrial chemical. It serves as a solvent, a starting material for synthesis, and a catalyst for a wide variety of reactions. Some industrial acetic acid is produced from ethylene, using a catalytic oxidation to form acetaldehyde, followed by another catalytic oxidation to acetic acid. 

Acetic Acid. Acetic acid production in the United States has increased by large numbers in the last half century, since the monomer has many uses such as to make polymers for chewing gum, to use as a comonomer in industrial and trade coatings and paint, and so on. In the 1930s, a three-step synthesis process from ethylene through acid hydrolysis to ethanol followed by catalytic dehydrogenation of acetaldehyde and then a direct liquid-phase oxidation to acetic acid and acetic anhydride as co-products was used to produce acetic acid... 

Process Economics Program Report SRI International. Menlo Park, CA, Isocyanates IE, Propylene Oxide 2E, Vinyl Chloride 5D, Terephthalic Acid and Dimethyl Terephthalate 9E, Phenol 22C, Xylene Separation 25C, BTX, Aromatics 30A, o-Xylene 34 A, m-Xylene 25 A, p-Xylene 93-3-4, Ethylbenzene/Styrene 33C, Phthalic Anhydride 34B, Glycerine and Intermediates 58, Aniline and Derivatives 76C, Bisphenol A and Phosgene 81, C1 Chlorinated Hydrocarbons 126, Chlorinated Solvent 48, Chlorofluorocarbon Alternatives 201, Reforming for BTX 129, Aromatics Processes 182 A, Propylene Oxide Derivatives 198, Acetaldehyde 24 A2, 91-1-3, Acetic Acid 37 B, Acetylene 16A, Adipic Acid 3 B, Ammonia 44 A, Caprolactam 7 C, Carbon Disulfide 171 A, Cumene 92-3-4, 22 B, 219, MDA 1 D, Ethanol 53 A, 85-2-4, Ethylene Dichloride/Vinyl Chloride 5 C, Formaldehyde 23 A, Hexamethylenediamine (HMDA) 31 B, Hydrogen Cyanide 76-3-4, Maleic Anhydride 46 C, Methane (Natural Gas) 191, Synthesis Gas 146, 148, 191 A, Methanol 148, 43 B, 93-2-2, Methyl Methacrylate 11 D, Nylon 6-41 B, Nylon 6,6-54 B, Ethylene/Propylene 29 A, Urea 56 A, Vinyl Acetate 15 A. 

Ever since the initial discovery of the Wacker process [1], i.e. the Pd/Cu-catalyzed oxidation of ethylene to acetaldehyde (1) in water, methods for the palladium (II) - mediated oxidative functionalization of alkenes have found widespread application in the synthesis of complex molecules [2J. 

Copper chloride complexes can be used as catalysts in a number of organic reactions. Examples include the Wacker process, which is the oxidization of ethylene to acetaldehyde by oxygen and aqueous Cu and Pd precatalysts (or, alternatively using iron catalysts) plus the synthesis of acrylonitrile from acetylene and hydrogen cyanide using CuCl. Cuprous chloride has also been used as a desulfiuizmg and... 

Additions to nonactivated olefins and dienes are important reactions in organic synthesis [1]. Although cycloadditions may be used for additions to double bonds, the most common way to achieve such reactions is to activate the olefins with an electrophilic reagent. Electrophilic activation of the olefin or diene followed by a nucleophilic attack at one of the sp carbon atoms leads to a 1,2- or 1,4-addition. More recently, transition metals have been employed for the electrophilic activation of the double bond [2]. In particular, palladium(II) salts are known to activate carbon-carbon double bonds toward nucleophilic attack [3] and this is the basis for the Wacker process for industrial oxidation of ethylene to acetaldehyde [41. In this process, the key step is the nucleophilic attack by water on a (jt-ethylene)palladium complex. 

The low-pressure acetic acid process was developed by Monsanto in the late 1960s and proved successful with commercialization of a plant producing 140 X 10 metric tons per year in 1970 at the Texas City (TX, USA) site [21]. The development of this technology occurred after the commercial implementation by BASF of the cobalt-catalyzed high-pressure methanol carbonylation process [22]. Both carbonylation processes were developed to utilize carbon monoxide and methanol as alternative raw materials, derived from synthesis gas, to compete with the ethylene-based acetaldehyde oxidation and saturated hydrocarbon oxidation processes (cf. Sections 2.4.1 and 2.8.1.1). Once the Monsanto process was commercialized, the cobalt-catalyzed process became noncom-... 

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