Zeolitic solid acid catalyzed alkylation

Alkaloid synthons, synthesis, 191 Alkylation, zeolitic solid acid catalyzed, kinetics, 105-114 Alternative feedstocks and starting materials... 

SIMPSON ETAL. Zeolitic Solid Acid-Catalyzed Alkylation of Isobutane 107... 

Both sulfuric acid and hydrofluoric acid catalyzed alkylations are low temperature processes. Table 3-13 gives the alkylation conditions for HF and H2SO4 processes. One drawback of using H2SO4 and HF in alkylation is the hazards associated with it. Many attempts have been tried to use solid catalysts such as zeolites, alumina and ion exchange resins. Also strong solid acids such as sulfated zirconia and SbFs/sulfonic acid resins were tried. Although they were active, nevertheless they lack stability. No process yet proved successful due to the fast deactivation of the catalyst. A new process which may have commercial possibility, uses... 

Since the discovery of alkylation, the elucidation of its mechanism has attracted great interest. The early findings are associated with Schmerling (17-19), who successfully applied a carbenium ion mechanism with a set of consecutive and simultaneous reaction steps to describe the observed reaction kinetics. Later, most of the mechanistic information about sulfuric acid-catalyzed processes was provided by Albright. Much less information is available about hydrofluoric acid as catalyst. In the following, a consolidated view of the alkylation mechanism is presented. Similarities and dissimilarities between zeolites as representatives of solid acid alkylation catalysts and HF and H2S04 as liquid catalysts are highlighted. Experimental results are compared with quantum-chemical calculations of the individual reaction steps in various media. 

A variety of solid acids besides zeolites have been tested as alkylation catalysts. Sulfated zirconia and related materials have drawn considerable attention because of what was initially thought to be their superacidic nature and their well-demonstrated ability to isomerize short linear alkanes at temperatures below 423 K. Corma et al. (188) compared sulfated zirconia and zeolite BEA at reaction temperatures of 273 and 323 K in isobutane/2-butene alkylation. While BEA catalyzed mainly dimerization at 273 K, the sulfated zirconia exhibited a high selectivity to TMPs. At 323 K, on the other hand, zeolite BEA produced more TMPs than sulfated zirconia, which under these conditions produced mainly cracked products with 65 wt% selectivity. The TMP/DMH ratio was always higher for the sulfated zirconia sample. These distinctive differences in the product distribution were attributed to the much stronger acid sites in sulfated zirconia than in zeolite BEA, but today one would question this suggestion because of evidence that the sulfated zirconia catalyst is not strongly acidic, being active for alkane isomerization because of a combination of acidic character and redox properties that help initiate hydrocarbon conversions (189). The time-on-stream behavior was more favorable for BEA, which deactivated at a lower rate than sulfated zirconia. Whether differences in the adsorption of the feed and product molecules influenced the performance was not discussed. 

The catalyst is reported to be a true solid acid without halogen ion addition. In the patent describing the process (239), a Pt/USY zeolite with an alumina binder is employed. It was claimed that the catalyst is rather insensitive to feed impurities and feedstock composition, so that feed pretreatment can be less stringent than in conventional liquid acid-catalyzed processes. The process is operated at temperatures of 323-363 K, so that the cooling requirements are less than those of lower temperature processes. The molar isobutane/alkene feed ratio is kept between 8 and 10. Alkene space velocities are not reported. Akzo claims that the alkylate quality is identical to or higher than that attained with the liquid acid-catalyzed processes. 

The conventional resinsulfonic acids such as sulfonated polystyrenes (Dowex-50, Amberlite IR-112, and Permutit Q) are of moderate acidity with limited thermal stability. Therefore, they can be used only to catalyze alkylation of relatively reactive aromatic compounds (like phenol) with alkenes, alcohols, and alkyl halides. Nafion-H, however, has been found to be a suitable superacid catalyst in the 110-190°C temperature range to alkylate benzene with ethylene (vide infra) 16 Furthermore, various solid acid catalysts (ZSM-5, zeolite /3, MCM-22) are applied in industrial ethylbenzene technologies in the vapor phase.177... 

The enhanced diffusivity of polynuclear compounds in sc C02 has been utilized to enhance catalyst lifetimes in both 1-butene/isoparaffin alkylations (Clark and Subramaniam, 1998 Gao et al., 1996). The former may be catalyzed using a number of solid acid catalysts (zeolites, sulfated zeolites, etc.), and the use of sc C02 as a solvent/diluent permits the alkylations to be carried out at relatively mild temperatures, leading to the increased production of valuable trimethylpentanes (which are used as high-octane gasoline blending components). The enhancement of product selectivity in the latter process is believed to result from rapid diffusion of ethylbenzene product away from the Y-type zeolite catalysts, thus preventing product isomerization to xylenes. 

Olefin alkylation, long carried out in solution with Bronsted acids, is now beginning to turn to the use of zeolites or other solid acid reagents under mild conditions. The main problem is removal of both the heat generated by the reaction and the carbon deposits. While the former problem can be solved by slurry reactor techniques, the latter requires a chemical treatment which is best carried out by metal-catalyzed hydrogenation at high temperature. 

Analogously to acid-catalyzed alkylations, which are now mostly carried out with zeolites or solid acids, base-catalyzed alkylations can also be conducted over solid catalysts. The usage is much smaller, however. 

Olah et al. reported the triflic acid-catalyzed isobutene-iso-butylene alkylation, modified with trifluoroacetic acid (TEA) or water. They found that the best alkylation conditions were at an acid strength of about Ho = —10.7, giving a calculated research octane number (RON) of 89.1 (TfOH/TFA) and 91.3 (TfOH/HzO). Triflic acid-modified zeolites can be used for the gas phase synthesis of methyl ferf-butyl ether (MTBE), and the mechanism of activity enhancement by triflic acid modification appears to be related to the formation of extra-lattice Al rather than the direct presence of triflic acid. A thermally stable solid catalyst prepared from amorphous silica gel and triflic acid has also been reported. The obtained material was found to be an active catalyst in the alkylation of isobutylene with w-butenes to yield high-octane gasoline components. A similar study has been carried out with triflic acid-functionalized mesoporous Zr-TMS catalysts. Triflic acid-catalyzed carbonylation, direct coupling reactions, and formylation of toluene have also been reported. Triflic acid also promotes transalkylation and adaman-tylation of arenes in ionic liquids. Triflic acid-mediated reactions of methylenecyclopropanes with nitriles have also been investigated to provide [3 + 2] cycloaddition products as well as Ritter products. Triflic acid also catalyzes cyclization of unsaturated alcohols to cyclic ethers. ... 

Elements such as B, Ga, P and Ge can substitute for Si and A1 in zeolitic frameworks. In naturally-occurring borosilicates B is usually present in trigonal coordination, but four-coordinated (tetrahedral) B is found in some minerals and in synthetic boro- and boroaluminosilicates. Boron can be incorporated into zeolitic frameworks during synthesis, provided that the concentration of aluminium species, favoured by the solid, is very low. (B,Si)-zeolites cannot be prepared from synthesis mixtures which are rich in aluminium. Protonic forms of borosilicate zeolites are less acidic than their aluminosilicate counterparts (1-4). but are active in catalyzing a variety of organic reactions, such as cracking, isomerization of xylene, dealkylation of arylbenzenes, alkylation and disproportionation of toluene and the conversion of methanol to hydrocarbons (5-11). It is now clear that the catalytic activity of borosilicates is actually due to traces of aluminium in the framework (6). However, controlled substitution of boron allows fine tuning of channel apertures and is useful for shape-selective sorption and catalysis. 

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