Acetic anhydride, production catalyst

This process is one of the three commercially practiced processes for the production of acetic anhydride. The other two are the oxidation of acetaldehyde [75-07-0] and the carbonylation of methyl acetate [79-20-9] in the presence of a rhodium catalyst (coal gasification technology, Halcon process) (77). The latter process was put into operation by Tennessee Eastman in 1983. In the United States the total acetic anhydride production has been reported to be in the order of 1000 metric tons. 

The methyl acetate carbonylation process was successfully started and operated in the early 1980s as part of a coal-to-syngas-to-acetic anhydride complex. This new process introduction resulted in a major improvement in acetic anhydride production economics. In this process, methyl acetate, itself the product of a one-step esterification of acetic acid and methanol, is reacted with carbon monoxide in the presence of a promoted rhodium-iodide catalyst. Figure 22.20 illustrates this process... 

Homogeneous catalysts. With a homogeneous catalyst, the reaction proceeds entirely in the vapor or liquid phase. The catalyst may modify the reaction mechanism by participation in the reaction but is regenerated in a subsequent step. The catalyst is then free to promote further reaction. An example of such a homogeneous catalytic reaction is the production of acetic anhydride. In the first stage of the process, acetic acid is pyrolyzed to ketene in the gas phase at TOO C ... 

In general, however, the diacetyl derivatives are unstable in the presence of water, undergoing hydrolysis to the mono-acetyl compound, so that when they (or a mixture of mono- and di-acetyl derivatives) are crystallised from an aqueous solvent, e.g., dilute alcohol, only the mono-acetyl derivative is obtained. A further disadvantage of the use of acetic anhydride in the absence of a solvent is that all the impm-ities in the amine are generally present in the reaction product. Heavily substituted amines, t.g., 2 4 6-tribromoaniline, react extremely slowly with acetic anhydride, but in the presence of a few drops of concentrated sulphuric acid as catalyst acetylation occurs rapidly, for example ... 

Oxidation. Acetaldehyde is readily oxidised with oxygen or air to acetic acid, acetic anhydride, and peracetic acid (see Acetic acid and derivatives). The principal product depends on the reaction conditions. Acetic acid [64-19-7] may be produced commercially by the Hquid-phase oxidation of acetaldehyde at 65°C using cobalt or manganese acetate dissolved in acetic acid as a catalyst (34). Liquid-phase oxidation in the presence of mixed acetates of copper and cobalt yields acetic anhydride [108-24-7] (35). Peroxyacetic acid or a perester is beheved to be the precursor in both syntheses. There are two commercial processes for the production of peracetic acid [79-21 -0]. Low temperature oxidation of acetaldehyde in the presence of metal salts, ultraviolet irradiation, or osone yields acetaldehyde monoperacetate, which can be decomposed to peracetic acid and acetaldehyde (36). Peracetic acid can also be formed directiy by Hquid-phase oxidation at 5—50°C with a cobalt salt catalyst (37) (see Peroxides and peroxy compounds). Nitric acid oxidation of acetaldehyde yields glyoxal [107-22-2] (38,39). Oxidations of /)-xylene to terephthaHc acid [100-21-0] and of ethanol to acetic acid are activated by acetaldehyde (40,41). 

The unit has virtually the same flow sheet (see Fig. 2) as that of methanol carbonylation to acetic acid (qv). Any water present in the methyl acetate feed is destroyed by recycle anhydride. Water impairs the catalyst. Carbonylation occurs in a sparged reactor, fitted with baffles to diminish entrainment of the catalyst-rich Hquid. Carbon monoxide is introduced at about 15—18 MPa from centrifugal, multistage compressors. Gaseous dimethyl ether from the reactor is recycled with the CO and occasional injections of methyl iodide and methyl acetate may be introduced. Near the end of the life of a catalyst charge, additional rhodium chloride, with or without a ligand, can be put into the system to increase anhydride production based on net noble metal introduced. The reaction is exothermic, thus no heat need be added and surplus heat can be recovered as low pressure steam. 

Acetic anhydride and acetic acid increase the solubiUty of the two phases in each other, and they are employed for the commercial N-nitration of hexamethylenetetramine [100-97-0] (11) to form cyclotrimethylenetrinitramine [121-82-4] (RDX), (CH2)3(NN02)3. Renewed consideration has been given to replacing H2SO4 with an improved soHd catalyst to reduce the environmental problems of disposal or reconcentration of the waste acid and to increase production of desired nitrated isomers. For example, a catalyst with suitable pore size might increase the production of 4-MNT and reduce that of 3-MNT when toluene is nitrated. 

Many other polymerization processes have been patented, but only some of them appear to be developed or under development ia 1996. One large-scale process uses an acid montmorrillonite clay and acetic anhydride (209) another process uses strong perfiuorosulfonic acid reski catalysts (170,210). The polymerization product ia these processes is a poly(tetramethylene ether) with acetate end groups, which have to be removed by alkaline hydrolysis (211) or hydrogenolysis (212). If necessary, the product is then neutralized, eg, with phosphoric acid (213), and the salts removed by filtration. Instead of montmorrillonite clay, other acidic catalysts can be used, such as EuUer s earth or zeoHtes (214—216). 

Nitrile Intermediates. Most quaternary ammonium compounds are produced from fatty nitriles (qv), which are ia turn made from a natural fat or oil-derived fatty acid and ammonia (qv) (Fig. 2) (see Fats AND FATTY oils) (225). The nitriles are then reduced to the amines. A variety of reduciag agents maybe used (226). Catalytic hydrogenation over a metal catalyst is the method most often used on a commercial scale (227). Formation of secondary and tertiary amine side-products can be hindered by the addition of acetic anhydride (228) or excess ammonia (229). In some cases secondary amines are the desired products. 

Reactions. Saligenin [90-01-7] undergoes the typical reactions of phenols and benzyl alcohol. When heated above 100°C, it transforms into a pale yellow resinous material. Amorphous condensation products are obtained when saligenin reacts with acetic anhydride, phosphoms pentachloride, or mineral acids. Upon boiling with dilute acids, saligenin is converted into a resinous body, saliretin, a condensed form of saligenin. Condensation reactions of saligenin with itself in the absence of any catalysts and in the presence of bases have also been studied. 

Uses ndReactions. The Prins reaction of 3-carene with formaldehyde in acetic acid gives mainly 2-carene-4-methanol acetate, which when saponified produces the 2-carene-4-methanol, both of which are commercial products of modest usage (60). 3-Carene (28) also reacts with acetic anhydride with a catalyst (ZnCl2) to give 4-acetyl-2-carene (29) (61), which is also a commercial product. Although 3-carene does not polymerize to produce terpene resins, copolymerization with phenol has been successfully commercialized by DRT in France (62). 

Manufacture of 2-acetylthiophenes involves direct reaction of thiophene or alkylthiophene with acetic anhydride or acetyl chloride. Preferred systems use acetic anhydride and have involved iodine or orthophosphoric acid as catalysts. The former catalyst leads to simpler workup, but has the disadvantage of leading to a higher level of 3-isomer in the product. Processes claiming very low levels of 3-isomer operate with catalysts that are proprietary, though levels of less than 0.5% are not easily attained. 

Solution Process. With the exception of fibrous triacetate, practically all cellulose acetate is manufactured by a solution process using sulfuric acid catalyst with acetic anhydride in an acetic acid solvent. An excellent description of this process is given (85). In the process (Fig. 8), cellulose (ca 400 kg) is treated with ca 1200 kg acetic anhydride in 1600 kg acetic acid solvent and 28—40 kg sulfuric acid (7—10% based on cellulose) as catalyst. During the exothermic reaction, the temperature is controlled at 40—45°C to minimize cellulose degradation. After the reaction solution becomes clear and fiber-free and the desired viscosity has been achieved, sufficient aqueous acetic acid (60—70% acid) is added to destroy the excess anhydride and provide 10—15% free water for hydrolysis. At this point, the sulfuric acid catalyst may be partially neutralized with calcium, magnesium, or sodium salts for better control of product molecular weight. 

However, this method is appHed only when esterification cannot be effected by the usual acid—alcohol reaction because of the higher cost of the anhydrides. The production of cellulose acetate (see Fibers, cellulose esters), phenyl acetate (used in acetaminophen production), and aspirin (acetylsahcyhc acid) (see Salicylic acid) are examples of the large-scale use of acetic anhydride. The speed of acylation is greatiy increased by the use of catalysts (68) such as sulfuric acid, perchloric acid, trifluoroacetic acid, phosphoms pentoxide, 2inc chloride, ferric chloride, sodium acetate, and tertiary amines, eg, 4-dimethylaminopyridine. 

In a typical process for manufacture on a commercial scale bleached wood pulp or cotton linters are pretreated for 12 hours with 40-50% sulphuric acid and then, after drying, with acetic acid. Esterification of the treated cellulose is then carried out using a mixture of butyric acid and acetic anhydride, with a trace of sulphuric acid as catalyst. Commercial products vary extensively in the acetate/ butyrate ratios employed. 

Boron trifluoride etherate in benzene converts A -20-acetoximinosteroids to the 17-ketones in somewhat lower yield, but the reaction of A -20-oximino steroids with this catalyst in the presence of acetic anhydride does not give the expected product two different compounds have been isolated and identified. ... 

Ion 21 can either lose a proton or combine with chloride ion. If it loses a proton, the product is an unsaturated ketone the mechanism is similar to the tetrahedral mechanism of Chapter 10, but with the charges reversed. If it combines with chloride, the product is a 3-halo ketone, which can be isolated, so that the result is addition to the double bond (see 15-45). On the other hand, the p-halo ketone may, under the conditions of the reaction, lose HCl to give the unsaturated ketone, this time by an addition-elimination mechanism. In the case of unsymmetrical alkenes, the attacking ion prefers the position at which there are more hydrogens, following Markovnikov s rule (p. 984). Anhydrides and carboxylic acids (the latter with a proton acid such as anhydrous HF, H2SO4, or polyphosphoric acid as a catalyst) are sometimes used instead of acyl halides. With some substrates and catalysts double-bond migrations are occasionally encountered so that, for example, when 1 -methylcyclohexene was acylated with acetic anhydride and zinc chloride, the major product was 6-acetyl-1-methylcyclohexene. ... 

This mixture is fed into bubble columns and contacted with chlorine gas at 3.5 bar and 115-145 °C [57]. A typical reaction mixture has a composition of 38.5% acetic acid, 11.5% acetic anhydride and 50% chlorine gas. The crude product is first purified by distillation. Thereafter, either crystallization or hydrogen reduction at a Pd catalyst is conducted to separate the monochlorinated from the dichlorinated product. 

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