Catalysis phenol

Benzene does not react with bromine except with Lewis acid catalysis. Phenols react in a very different manner no Lewis acid is needed, the reaction occurs very rapidly, and the product contains three atoms of bromine in specific positions. All that needs to be done is to add bromine dropwise to a solution of phenol in ethanol. Initially, the yellow colour of the bromine disappears but, if, when the colour just remains, water is added, a white precipitate of 2,4,6-tribromo phenol is formed. 

The differences between acid-catalyzed and base-catalyzed process are (1) in the rate of aldehyde attack on the phenol, (2) in the subsequent condensation of the phenolic alcohols, and (3) to some extent in the nature of the eondensation reaction. With acid catalysis, phenolic alcohol formation is relatively slow. Therefore, this is the step that determines the rate of the total reaction. The condensation of phenolie alcohols and phenols forming eompoimds of the dihydroxydiphenylmethane type is, instead, rapid. The latter are therefore predominant intermediates in novolak resins. 

In a general reaction known as the cyclohexadienone phenol rearrangement cyclohexa dienones are converted to phenols under conditions of acid catalysis An example is... 

Useful thermosetting resins are obtained by interaction of furfural with phenol. The reaction occurs under both acidic and basic catalysis. Other large uses of furfural together with phenol are in the manufacture of resin-bonded grinding wheels and coated abrasives (5). 

I ovolac Synthesis and Properties. Novolac resins used in DNQ-based photoresists are the most complex, the best-studied, the most highly engineered, and the most widely used polymers in microlithography. Novolacs are condensation products of phenoHc monomers (typically cresols or other alkylated phenols) and formaldehyde, formed under acid catalysis. Figure 13 shows the polymerization chemistry and polymer stmcture formed in the step growth polymerization (31) of novolac resins. 

Catalysis is usually accompHshed through the use of tertiary amines such as triethylenediamine. Other catalysts such as 2,4,6-/m(/V,/V-dimethylaminomethyl)phenol are used in the presence of high levels of cmde MDI to promote trimerization of the isocyanate and thus form isocyanurate ring stmctures. These groups are more thermally stable than the urethane stmcture and hence are desirable for improved flammabiUty resistance (236). Some urethane content is desirable for improved physical properties such as abrasion resistance. 

The most widely used process for the production of phenol is the cumene process developed and Hcensed in the United States by AHiedSignal (formerly AHied Chemical Corp.). Benzene is alkylated with propylene to produce cumene (isopropylbenzene), which is oxidized by air over a catalyst to produce cumene hydroperoxide (CHP). With acid catalysis, CHP undergoes controUed decomposition to produce phenol and acetone a-methylstyrene and acetophenone are the by-products (12) (see Cumene Phenol). Other commercial processes for making phenol include the Raschig process, using chlorobenzene as the starting material, and the toluene process, via a benzoic acid intermediate. In the United States, 35-40% of the phenol produced is used for phenoHc resins. 

Substituted Phenols. Phenol itself is used in the largest volume, but substituted phenols are used for specialty resins (Table 2). Substituted phenols are typically alkylated phenols made from phenol and a corresponding a-olefin with acid catalysts (13). Acidic catalysis is frequendy in the form of an ion-exchange resin (lER) and the reaction proceeds preferentially in the para position. For example, in the production of /-butylphenol using isobutylene, the product is >95% para-substituted. The incorporation of alkyl phenols into the resin reduces reactivity, hardness, cross-link density, and color formation, but increases solubiHty in nonpolar solvents, dexibiHty, and compatibiHty with natural oils. 

Alkaline Catalysts, Resoles. Resole-type phenoHc resins are produced with a molar ratio of formaldehyde to phenol of 1.2 1 to 3.0 1. For substituted phenols, the ratio is usually 1.2 1 to 1.8 1. Common alkaline catalysts are NaOH, Ca(OH)2, and Ba(OH)2. Whereas novolak resins and strong acid catalysis result in a limited number of stmctures and properties, resoles cover a much wider spectmm. Resoles may be soHds or Hquids, water-soluble or -insoluble, alkaline or neutral, slowly curing or highly reactive. In the first step, the phenolate anion is formed by delocali2ation of the negative charge to the ortho and para positions. 

The reaction is completed after 6—8 h at 95°C volatiles, water, and some free phenol are removed by vacuum stripping up to 140—170°C. For resins requiring phenol in only trace amounts, such as epoxy hardeners, steam distillation or steam stripping may be used. Both water and free phenol affect the cure and final resin properties, which are monitored in routine quaHty control testing by gc. OxaHc acid (1—2 parts per 100 parts phenol) does not require neutralization because it decomposes to CO, CO2, and water furthermore, it produces milder reactions and low color. Sulfuric and sulfonic acids are strong catalysts and require neutralization with lime 0.1 parts of sulfuric acid per 100 parts of phenol are used. A continuous process for novolak resin production has been described (31,32). An alternative process for making novolaks without acid catalysis has also been reported (33), which uses a... 

Alkylphenols containing 3—12-carbon alkyl groups are produced from the corresponding alkenes under acid catalysis. Alkylphenols containing the methyl group were traditionally extracted from coal tar. Today they are produced by the alkylation of phenol with methanol. 

In 1957 a procedure was described that selectively alkylated phenol in the ortho position (7). This approach, using aluminum catalysis, made a variety of 2,6-dialkylphenols accessible. The mechanism proposed for this ortho alkylation is outlined as follows ... 

The alkylation of phenol with an alkene using either acid or aluminum catalysis probably accounts for 95% of the commercially produced alkylphenols with alkyl groups of three carbons or larger. The alkenes are commercially available and environmentally kind. They do not produce by-products as do alkylations which use alcohols or alkyl haUdes. Together with an acid catalyst and the appropriate amount of phenol, mono-, di-, and trialkylphenols can be produced. 

Reactions with Aldehydes and Ketones. An important use for alkylphenols is ia phenol—formaldehyde resias. These resias are classified as resoles or aovolaks (see Phenolic resins). Resoles are produced whea oae or more moles of formaldehyde react with oae mole of pheaol uader basic catalysis. These resias are thermosets. Novolaks are thermoplastic resias formed whea an excess of phenol reacts with formaldehyde under acidic conditions. The acid protonates formaldehyde to generate the alkylating electrophile (17). 

Gumylphenol. -Cumylphenol (PGP) or 4-(1-methyl-l-phenylethyl)phenol is produced by the alkylation of phenol with a-methylstyrene under acid catalysis. a-Methylstyrene is a by-product from the production of phenol via the cumene oxidation process. The principal by-products from the production of 4-cumylphenol result from the dimerization and intramolecular alkylation of a-methylstyrene to yield substituted indanes. 4-Cumylphenol [599-64-4] is purified by either fractional distillation or crystallization from a suitable solvent. Purification by crystallization results in the easy separation of the substituted indanes from the product and yields a soHd material which is packaged in plastic or paper bags (20 kg net weight). Purification of 4-cumylphenol by fractional distillation yields a product which is almost totally free of any dicumylphenol. The molten product resulting from purification by distillation can be flaked to yield a soHd form however, the soHd form of 4-cumylphenol sinters severely over time. PGP is best stored and transported as a molten material. 

Methylphenol. This phenol, commonly known as o-cresol, is produced synthetically by the gas phase alkylation of phenol with methanol using modified alumina catalysis or it may be recovered from naturally occurring petroleum streams and coal tars. Most is produced synthetically. Reaction of phenol with methanol using modified zeoHte catalysts is a concerted dehydration of the methanol and alkylation of the aromatic ring. 2-Methylphenol [95-48-7] is available in 55-gal dmms (208-L) and in bulk quantities in tank wagons and railcars. 

Methylphenol is converted to 6-/ f2 -butyl-2-methylphenol [2219-82-1] by alkylation with isobutylene under aluminum catalysis. A number of phenoHc anti-oxidants used to stabilize mbber and plastics against thermal oxidative degradation are based on this compound. The condensation of 6-/ f2 -butyl-2-methylphenol with formaldehyde yields 4,4 -methylenebis(2-methyl-6-/ f2 butylphenol) [96-65-17, reaction with sulfur dichloride yields 4,4 -thiobis(2-methyl-6-/ f2 butylphenol) [96-66-2] and reaction with methyl acrylate under base catalysis yields the corresponding hydrocinnamate. Transesterification of the hydrocinnamate with triethylene glycol yields triethylene glycol-bis[3-(3-/ f2 -butyl-5-methyl-4-hydroxyphenyl)propionate] [36443-68-2] (39). 2-Methylphenol is also a component of cresyHc acids, blends of phenol, cresols, and xylenols. CresyHc acids are used as solvents in a number of coating appHcations (see Table 3). 

Diall lated Phenols. 2,4-Di-tert-amjlphenol (2,4-DTAP) or 2,4-bis(l,l-dimethylpropyl)phenol is produced by the alkylation of phenol with isoamylene under acid catalysis in a mole ratio of 2 1 (isoamylene to phenol). The cmde alkylation product contains 4-/ f2 -amylphenol,... 

A large number of hindered phenoHc antioxidants are based on the Michael addition of 2,6-di-/ f2 -butylphenol and methyl acrylate under basic catalysis to yield the hydrocinnamate which is a basic building block used in the production of octadecyl 3-(3,5-di-/ f2 butyl-4-hydroxyphenyl)propionate, [2082-79-3], tetrakis(methylene-3(3,5-di-/ f2 butyl-4-hydroxylphenyl)propionate)methane [6683-19-8], and many others (63,64). These hindered phenolic antioxidants are the most widely used primary stabilizers in the world and are used in polyolefins, synthetic and natural mbber, styrenics, vinyl polymers, and engineering resins. 2,6-Di-/ f2 -butylphenol is converted to a methylene isocyanate which is trimerized to a triazine derivative... 

Di-sec-butylphenol (DSBPJ is produced by the alkylation of phenol with 1-butene or 2-butene under acidic or aluminum catalysis. The production of di-j -butylphenol under acid catalysis gives a 2 to 1 mixture of 2,4-di-j -butylphenol and 2,6-di-j -butylphenol [2,4-bis(l-methylpropyl)phenol and... 

Phenols. Phenols are unreactive toward chloroformates at room temperature and at elevated temperatures the yields of carbonates are relatively poor (< 10%) in the absence of catalysis. Many catalysts have been claimed in the patent Hterature that lead to high yields of carbonates from phenol and chloroformates. The use of catalyst is even more essential in the reaction of phenols and aryl chloroformates. Among the catalysts claimed are amphoteric metals or thek haUdes (16), magnesium haUdes (17), magnesium or manganese (18), secondary or tertiary amines such as imidazole (19), pyridine, quinoline, picoline (20—22), heterocycHc basic compounds (23) and carbonamides, thiocarbonamides, phosphoroamides, and sulfonamides (24). 

Alkyl tertiary alkyl ethers can be prepared by the addition of an alcohol or phenol to a tertiary olefin under acid catalysis (Reycler reaction) sulfuric acid, phosphoric acid, hydrochloric acid, and boron trifluoride have all been used as catalysts ... 

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