Butadiene oxidative carbonylations

The adipic acid process we have developed involves butadiene oxidative carbonylation in the presence of methanol, a l, l-dimethoxycyclohexane dehydration agent, and a palladium(ll)/ copper(ll) redox catalyst system (Equation 1.). The reaction sequence includes an oxycarbonylation, hydrogenation and hydrolysis step(17-19). The net result is utilization of butadiene, the elements of synthesis gas, l, -dimethoxycyclohexane and air to give adipic acid, cyclohexanone and methanol. 

Hydroxycarbonylation and alkoxycarbonylation of alkenes catalyzed by metal catalyst have been studied for the synthesis of acids, esters, and related derivatives. Palladium systems in particular have been popular and their use in hydroxycarbonylation and alkoxycarbonylation reactions has been reviewed.625,626 The catalysts were mainly designed for the carbonylation of alkenes in the presence of alcohols in order to prepare carboxylic esters, but they also work well for synthesizing carboxylic acids or anhydrides.137 627 They have also been used as catalysts in many other carbonyl-based processes that are of interest to industry. The hydroxycarbonylation of butadiene, the dicarboxylation of alkenes, the carbonylation of alkenes, the carbonylation of benzyl- and aryl-halide compounds, and oxidative carbonylations have been reviewed.6 8 The Pd-catalyzed hydroxycarbonylation of alkenes has attracted considerable interest in recent years as a way of obtaining carboxylic acids. In general, in acidic media, palladium salts in the presence of mono- or bidentate phosphines afford a mixture of linear and branched acids (see Scheme 9). 

A patent claiming the following oxidative carbonylation of butadiene to give unsaturated mono- and diesters has been published (116) ... 

Conjugated dienes can also undergo Pd-catalyzed oxidative carbonylations. Thus, 1,3-butadiene has been converted into a mixture of 1,4-addition products, according to Eq. 15 [12]. 

After ARCO patents issued, Stille and coworkers published on butadiene oxycarbonylation(14-16). Palladium was utilized as the oxidative carbonylation catalyst and copper(II) chloride was employed as a stoichiometric reoxidation agent for palladium. Although the desired hex-3 -enedioate is the exclusive product, commercial technology which uses stoichiometric copper is not practical. Once the copper(Il) is consumed, the monoatomic palladium spent catalyst agglomerates affording polymeric palladium which is not easily reoxidized to an active form. 

In the absence of Aldol condensation, the only heavies forming reactions involve a butadiene Diels-Alder reaction to form 4-vinylcyclohexene and subsequent oxidative carbonylation. 

Typically, little butadiene is dimerized to 4-vinylcyclohexene under actual reaction conditionsOO,31). The butadiene used in the process, however, can contain up to. 5 weight % Diels-Alder product, and at this level oxidative carbonylation can become a significant heavies forming reaction (Equation 9.). The major product from this reaction comes from l, -dicarbonylation of the 4-vinylcyclohexene exocyclic double bond. 

A commercially attractive palladium catalyzed oxidative carbonylation route to adipic and sebacic acid has been developed which uses butadiene and the elements of synthesis gas as the raw... 

Manganese(III) can oxidize carbonyl compounds and nitroalkanes to carboxy-methyl and nitromethyl radicals [186]. With Mn(III) as mediator, a tandem reaction consisting of an intermolecular radical addition followed by an intramolecular electrophilic aromatic substitution can be accomplished [186, 187). Further Mn(III)-mediated anodic additions of 1,3-dicarbonyl and l-keto-3-nitroalkyl compounds to alkenes and alkynes are reported in [110, 111, 188). Sorbic acid precursors have been obtained in larger scale and high current efficiency by a Mn(III)-mediated oxidation of acetic acid acetic anhydride in the presence of butadiene [189]. Also the nitromethylation of benzene can be performed in 78% yield with Mn(III) as electrocatalyst [190]. A N03 radical, generated by oxidation of a nitrate anion, can induce the 1,4-addition of aldehydes to activated olefins. NOj abstracts a hydrogen from the aldehyde to form an acyl radical, which undergoes addition to the olefin to afford a 1,4-diketone in 34-58% yield [191]. 

Palladium catalysts are widely used in liquid phase aerobic oxidations, and numerous examples have been employed for large-scale chemical production (Scheme 8.1). Several industrially important examples are the focus ofdedicated chapters in this book Wacker and Wacker-type oxidation of alkenes into aldehydes, ketones, and acetals (Scheme 8.1a Chapters 9 and 11), 1,4-diacetoxylation of 1,3-butadiene (Scheme 8.1b Chapter 10), and oxidative esterification of methacrolein to methyl methacrylate (Scheme 8.1c Chapter 13). In this introductory chapter, we survey a number of other Pd-catalyzed oxidation reactions that have industrial significance, including acetoxylation of ethylene to vinyl acetate (Scheme 8. Id), oxidative carbonylation of alcohols to dialkyl oxalates and carbonates (Scheme 8.1e), and oxidative coupling of dimethyl phthalate to 3,3, 4,4 -tetramethyl biphenylcarboxy-late (Scheme 8.1f). 

Butadiene also is a suitable substrate for oxidative carbonylation. Patent literature describes the use of CO in conjunction with Pd-C, CUCI2, and 02. Another patent uses a quinone as reoxidant system and a compound of Mn or V as cocatalyst. An 89% selectivity of diethyl 3-hexenedioate and diethyl 2-hexenedioate is obtained. (Scheme 11) Molecular sieves have been claimed to improve oxidative carbonylation of butadiene in the presence of PdCl2, CUCI2, and oxygen. ... 

Most rubbers used in adhesives are not resistant to oxidation. Because the degree of unsaturation present in the polymer backbone of natural rubber, styrene-butadiene rubber, nitrile rubber and polychloroprene rubber, they can easily react with oxygen. Butyl rubber, however, possesses small degree of unsaturation and is quite resistant to oxidation. The effects of oxidation in rubber base adhesives after some years of service life can be assessed using FTIR spectroscopy. The ratio of the intensities of the absorption bands at 1740 cm" (carbonyl group) and at 2900 cm" (carbon-hydrogen bonds) significantly increases when the elastomer has been oxidized [50]. 

Due to the retractive forces in stretched mbber, the aldehyde and zwitterion fragments are separated at the molecular-relaxation rate. Therefore, the ozonides and peroxides form at sites remote from the initial cleavage, and underlying mbber chains are exposed to ozone. These unstable ozonides and polymeric peroxides cleave to a variety of oxygenated products, such as acids, esters, ketones, and aldehydes, and also expose new mbber chains to the effects of ozone. The net result is that when mbber chains are cleaved, they retract in the direction of the stress and expose underlying unsaturation. Continuation of this process results in the formation of the characteristic ozone cracks. It should be noted that in the case of butadiene mbbers a small amount of cross-linking occurs during ozonation. This is considered to be due to the reaction between the biradical of the carbonyl oxide and the double bonds of the butadiene mbber [47]. 

Nickel(O) complexes are extremely effective for the dimerization and oligomerization of conjugated dienes [8,9]. Two molecules of 1,3-butadiene readily undergo oxidative cyclization with a Ni(0) metal to form bis-allylnickel species. Palladium(O) complexes also form bis-allylpalladium species of structural similarity (Scheme 2). The bis-allylpalladium complexes show amphiphilic reactivity and serve as an allyl cation equivalent in the presence of appropriate nucleophiles, and also serve as an allyl anion equivalent in the presence of appropriate electrophiles. Characteristically, the bis-allylnickel species is known to date only as a nucleophile toward carbonyl compounds (Eq. 1) [10,11],... 

Suitable carbonyl compounds can thus be olefmated photochemicully with (diazobenzyl)diphenylphosphine oxide (7), the oxygen function being substituted by a diphenylmethylene group 18,20). Hence irradiation of 7 for a sufficient length of time in the presence of the corresponding unsaturated ketones affords the hepta-fulvene 27 23), the trans-1,3-butadiene 28 22 and the cross-conjugated hexatriene 2922> by direct olefination with the intermediate 9. 

More recently, using the cyclometallated iridium C,(7-benzoate derived from allyl acetate, 4-methoxy-3-nitrobenzoic acid and BIPHEP, catalytic carbonyl crotylation employing 1,3-butadiene from the aldehyde, or alcohol oxidation was achieved under transfer hydrogenation conditions [274]. Carbonyl addition occurs with roughly equal facility from the alcohol or aldehyde oxidation level. However, products are obtained as diastereomeric mixtures. Stereoselective variants of these processes are under development. It should be noted that under the conditions of ruthenium-catalyzed transfer hydrogenation, conjugated dienes, including butadiene, couple to alcohols or aldehydes to provide either products of carbonyl crotylation or p,y-enones (Scheme 16) [275, 276]. 

Carbinolamines, 87 Carbodiimides, 205-222 reaction with alcohols, 170 Carbon monoxide, as reducing agent, 336 a-Carbonyl azo compounds, 324, 326 Caro s add (permonosulfuric add), 408 oxidation with, 409 preparation of, 409 Chloramine T, 377 Chloroacetylenes 120-122 4-Chloro-l, 2-butadiene, 33 Chlorocyclohexenyl acetylene, 121 1 -Chloro-2-JV,N-diphenylaminoacetylene, 128-129... 

Synthetically especially valuable is the oxidation of carbonyl compounds and nitroalkanes by manganese(III) salts to form carboxymethyl and nitromethyl radicals, respectively. These radicals can be trapped by olefins like 1,3-butadiene or aromatic compounds to yield synthetically interesting products. In this case it is very advantageous to generate and regenerate the oxidizing species in situ by indirect electrolysis. This was the basis for the development of a process for the synthesis of sorbic acid viay-vinyl-y-butyrolactone Equations (31)—(35) summarize the im-... 

This last example makes it clear that we shall normally have to make the cyclohexenes we need for oxidative cleavage and one of the best routes to such compounds is the Diels-Alder reaction (Chapter 17). A generalised example would be ozonolysis of the alkene 21, the adduct of butadiene and the enone 20. The product 22 has a 1,6-relationship between the two carboxylic acids. Since Diels-Alder adducts have a carbonyl group outside the ring (the ketone in 21) the cleavage products 22 also have 1,5- and 1-4-diCO relationships and would be a matter for personal judgement which of these should be disconnected instead if you choose that alternative strategy. 

Heterogcnized complexes have been used to catalyze a great number of reactions, such as hydrogenation [18], hydroformylation [19], ethylene oligomerization [20], hydrosilylation [21, 22], polymerization [23], telo-merization [24], oxidation [25], oligomerization of monoalkenc [26], methanol carbonylation [27], butadiene oligomerization [28], synthesis gas chemistry [29], and isomerization [30],... 

This benzene oxide may look very dubious and unstable, but benzene oxides can be made in the laboratory by ordinary chemical reactions (though not usually by the direct oxidation of benzene). We can instead start with a Diels-Alder reaction between butadiene and an alkyne. Epoxidation with a nucleophilic reagent (HO-O- from H2O2 and NaOH) occurs chemoselectively on the more electrophilic double bond—the one that is conjugated to the electron-withdrawing carbonyl group. 

The active species in the methoxycarbonylation is presumably CoH(CO)4 (in equilibrium with Co2(CO)g and Co(CO)4 ) which adds Co-H 1,4- to the diene this is followed by carbonylation of the Co-C bond, methanolysis of the RCO-Co bond by MeOH or OMe , and regeneration of the hydride. The methoxycarbonylation route to adipic acid is an alternative both to the du Pont (Ni(II)/Lewis acid (BPhs)) catalyzed double hydrocyanation of butadiene (Section 5.4.4) and to the process based on the oxidation of cyclohexane (Section 2.2). 

An oxidative addition with concomitant carbonylation also occurs when (butadiene)Fe(CO)j is protonated under CO by HBF4 or CF3COOH [( -crotyl)Fe(CO)4] is formed . Phase-transfer catalysis can be used to prepare metal carbonyl anions. For example it has been applied to the preparation of [NR4][Ni(CO)3CN] from NiCNj and CO in a 4-methyl-2-pentanone mixture, tetrabu-tylammonium hydrogen sulfate being the phase-transfer catalyst . ... 

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