Cellulose anhydride

Recent Developments. A considerable amount of cellulose acetate is manufactured by the batch process, as described previously. In order to reduce production costs, efforts have been made to develop a continuous process that includes continuous activation, acetylation, hydrolysis, and precipitation. In this process, the reaction mixture, ie, cellulose, anhydride, catalyst, and solvent, pass continuously through a number of successive reaction zones, each of which is agitated (92,93). In a similar process, the reaction mass is passed through tubular zones in which the mixture is forced through screens of successively small openings to homogenize the mixture effectively (94). Other similar methods for continuous acetylation of cellulose have been described (95,96). 

Cellulose esters of the 2-.. 3-. and 4-carbon acids are readily prepared by the cellulose-anhydride reaction the acetate ester and the mixed acetate butyrate and acetate propionate esters arc manufactured and used in large amounts. Esters of higher acids require different synthesis techniques and tend to be prohibitively expensive except as specialty products. Some arc in commercial production, however. Cellulose acclalc phlhalatc, for example, is manufactured for use as an enteric coating on pills. 

Perchloric acid Acetic acid, acetic anhydride, alcohols, antimony compounds, azo pigments, bismuth and its alloys, methanol, carbonaceous materials, carbon tetrachloride, cellulose, dehydrating agents, diethyl ether, glycols and glycolethers, HCl, HI, hypophosphites, ketones, nitric acid, pyridine, steel, sulfoxides, sulfuric acid... 

The cellulose molecule contains three hydroxyl groups which can react and leave the chain backbone intact. These alcohol groups can be esterified with acetic anhydride to form cellulose acetate. This polymer is spun into the fiber acetate rayon. Similarly, the alcohol groups in cellulose react with CS2 in the presence of strong base to produce cellulose xanthates. When extruded into fibers, this material is called viscose rayon, and when extruded into sheets, cellophane. In both the acetate and xanthate formation, some chain degradation also occurs, so the resulting polymer chains are shorter than those in the starting cellulose. 

Figure 3 shows the production of acetaldehyde in the years 1969 through 1987 as well as an estimate of 1989—1995 production. The year 1969 was a peak year for acetaldehyde with a reported production of 748,000 t. Acetaldehyde production is linked with the demand for acetic acid, acetic anhydride, cellulose acetate, vinyl acetate resins, acetate esters, pentaerythritol, synthetic pyridine derivatives, terephthaHc acid, and peracetic acid. In 1976 acetic acid production represented 60% of the acetaldehyde demand. That demand has diminished as a result of the rising cost of ethylene as feedstock and methanol carbonylation as the preferred route to acetic acid (qv). 

Most of the acetic acid is produced in the United States, Germany, Great Britain, Japan, France, Canada, and Mexico. Total annual production in these countries is close to four million tons. Uses include the manufacture of vinyl acetate [108-05-4] and acetic anhydride [108-24-7]. Vinyl acetate is used to make latex emulsion resins for paints, adhesives, paper coatings, and textile finishing agents. Acetic anhydride is used in making cellulose acetate fibers, cigarette filter tow, and ceUulosic plastics. 

About half of the wodd production comes from methanol carbonylation and about one-third from acetaldehyde oxidation. Another tenth of the wodd capacity can be attributed to butane—naphtha Hquid-phase oxidation. Appreciable quantities of acetic acid are recovered from reactions involving peracetic acid. Precise statistics on acetic acid production are compHcated by recycling of acid from cellulose acetate and poly(vinyl alcohol) production. Acetic acid that is by-product from peracetic acid [79-21-0] is normally designated as virgin acid, yet acid from hydrolysis of cellulose acetate or poly(vinyl acetate) is designated recycle acid. Indeterrninate quantities of acetic acid are coproduced with acetic anhydride from coal-based carbon monoxide and unknown amounts are bartered or exchanged between corporations as a device to lessen transport costs. 

By-product acetic acid is obtained chiefly from partial hydrolysis of cellulose acetate [9004-35-7]. Lesser amounts are obtained through the reaction of acetic anhydride and cellulose. Acetylation of saHcyHc acid [69-72-7] produces one mole of acetic acid per mole of product and the oxidation of allyl alcohol using peracetic acid to yield glycerol furnishes by-product acid, but the net yield is low. 

Nitration of cellulose may result in the addition of from one to three nitrate groups per glucose anhydride unit. The following compounds and their nitrogen content have been postulated ... 

Eastman Goal Chemicals. In 1983 Eastman Chemical Co. became the first chemical producer in the United States to return to coal as a raw material for large-scale manufacture of industrial chemicals (35). In that year, Eastman started manufacturing acetic anhydride from coal. Acetic anhydride is a key intermediate for production of coatings, ceUulosic plastics, and cellulose acetate fibers. Acetic anhydride from other sources also is used in the manufacture of pharmaceuticals, starches and sweeteners, and flavors and fragrances. 

Cellulose triacetate is obtained by the esterification of cellulose (qv) with acetic anhydride (see Cellulose esters). Commercial triacetate is not quite the precise chemical entity depicted as (1) because acetylation does not quite reach the maximum 3.0 acetyl groups per glucose unit. Secondary cellulose acetate is obtained by hydrolysis of the triacetate to an average degree of substitution (DS) of 2.4 acetyl groups per glucose unit. There is no satisfactory commercial means to acetylate direcdy to the 2.4 acetyl level and obtain a secondary acetate that has the desired solubiUty needed for fiber preparation. 

Most cellulose acetate is manufactured by a solution process, ie, the cellulose acetate dissolves as it is produced. The cellulose is acetylated with acetic anhydride acetic acid is the solvent and sulfuric acid the catalyst. The latter can be present at 10—15 wt % based on cellulose (high catalyst process) or at ca 7 wt % (low catalyst process). In the second most common process, the solvent process, methylene chloride replaces the acetic acid as solvent, and perchloric acid is frequentiy the catalyst. There is also a seldom used heterogeneous process that employs an organic solvent as the medium, and the cellulose acetate produced never dissolves. More detailed information on these processes can be found in Reference 28. 

When the acetylation is completed, microscopic examination of the solution should reveal no undissolved residues. The reaction is terrninated by adding water to destroy the excess anhydride and provide a water concentration of 5—10% for hydrolysis. A 10—25% cellulose acetate concentration is typical. 

In many appHcations succinic acid and anhydride are esterified with polyhydric compounds, ie, polyols (57—59), cellulose (60), or starch (61—64). 

Cellulose acetate [9004-35-7], prepared by reaction of cellulose with acetic anhydride, acetic acid, and sulfuric acid, is spun into acetate rayon fibers by dissolving it in acetone and spinning the solution into a column of warm air that evaporates the acetone. Cellulose acetate is also shaped into a variety of plastic products, and its solutions are used as coating dopes. Cellulose acetate butyrate [9004-36-8], made from cellulose, acetic anhydride, and butyric anhydride in the presence of sulfuric acid, is a shock-resistant plastic. 

Cellulose esters are commonly derived from natural cellulose by reaction with organic acids, anhydrides, or acid chlorides. Cellulose esters of almost any organic acid can be prepared, but because of practical limitations esters of acids containing more than four carbon atoms have not achieved commercial significance. 

Cellulose acetate [9004-35-7] is the most important organic ester because of its broad appHcation in fibers and plastics it is prepared in multi-ton quantities with degrees of substitution (DS) ranging from that of hydrolyzed, water-soluble monoacetates to those of fully substituted triacetate (Table 1). Soluble cellulose acetate was first prepared in 1865 by heating cotton and acetic anhydride at 180°C (1). Using sulfuric acid as a catalyst permitted preparation at lower temperatures (2), and later, partial hydrolysis of the triacetate gave an acetone-soluble cellulose acetate (3). The solubiUty of partially hydrolyzed (secondary) cellulose acetate in less expensive and less toxic solvents such as acetone aided substantially in its subsequent commercial development. 

Cellulose esters of aromatic acids, aUphatic acids containing more than four carbon atoms and aUphatic diacids are difficult and expensive to prepare because of the poor reactivity of the corresponding anhydrides with cellulose Httle commercial interest has been shown in these esters. Of notable exception, however, is the recent interest in the mixed esters of cellulose succinates, prepared by the sodium acetate catalyzed reaction of cellulose with succinic anhydride. The additional expense incurred in manufacturing succinate esters is compensated by the improved film properties observed in waterborne coatings (5). 

Mixed cellulose esters containing the dicarboxylate moiety, eg, cellulose acetate phthalate, have commercially useful properties such as alkaline solubihty and excellent film-forming characteristics. These esters can be prepared by the reaction of hydrolyzed cellulose acetate with a dicarboxyhc anhydride in a pyridine or, preferably, an acetic acid solvent with sodium acetate catalyst. Cellulose acetate phthalate [9004-38-0] for pharmaceutical and photographic uses is produced commercially via the acetic acid—sodium acetate method. 

Cellulose valerates have been synthesized by conventional methods using valeric anhydride and sulfuric acid catalyst (25,26). Alternatively, the cellulose is activated by soaking in water, which is then displaced by methylene chloride or valeric acid the temperature is maintained at <38° C to minimize degradation. 

Production of cellulose esters from aromatic acids has not been commercialized because of unfavorable economics. These esters are usually prepared from highly reactive regenerated cellulose, and their physical properties do not differ markedly from cellulose esters prepared from the more readily available aHphatic acids. Benzoate esters have been prepared from regenerated cellulose with benzoyl chloride in pyridine—nitrobenzene (27) or benzene (28). These benzoate esters are soluble in common organic solvents such as acetone or chloroform. Benzoate esters, as well as the nitrochloro-, and methoxy-substituted benzoates, have been prepared from cellulose with the appropriate aromatic acid and chloroacetic anhydride as the impelling agent and magnesium perchlorate as the catalyst (29). 

Cellulose chloroacetates (30) and aminoacetates (30,31), acetate sorbates (32), and acetate maleates (33) have been prepared but are not commercially important. These esters are made from hydrolyzed cellulose acetate with the appropriate anhydride or acid chloride in pyridine. 

Mixed esters containing the dicarboxylate moiety, eg, cellulose acetate phthalate, are usually prepared from the partially hydroly2ed lower aUphatic acid ester of cellulose in acetic acid solvent by using the corresponding dicarboxyhc acid anhydride and a basic catalyst such as sodium acetate (41,42). Cellulose acetate succinate and cellulose acetate butyrate succinate are manufactured by similar methods as described in reference 43. 

Other mixed esters, eg, cellulose acetate valerate [55962-79-3] cellulose propionate valerate [67351-41-17, and cellulose butyrate valerate [53568-56-2] have been prepared by the conventional anhydride sulfuric acid methods (25). Cellulose acetate isobutyrate [67351-38-6] (44) and cellulose propionate isobutyrate [67351-40-0] (45) have been prepared with a 2inc chloride catalyst. Large amounts of catalyst and anhydride are required to provide a soluble product, and special methods of delayed anhydride addition are necessary to produce mixed esters containing the acetate moiety. Mixtures of sulfuric acid and perchloric acid are claimed to be effective catalysts for the preparation of cellulose acetate propionate in dichi oromethane solution at relatively low temperatures (46) however, such acid mixtures are considered too corrosive for large-scale productions. 

Cellulose dissolved in suitable solvents, however, can be acetylated in a totally homogeneous manner, and several such methods have been suggested. Treatment in dimethyl sulfoxide (DMSO) with paraformaldehyde gives a soluble methylol derivative that reacts with glacial acetic acid, acetic anhydride, or acetyl chloride to form the acetate (63). The maximum degree of substitution obtained by this method is 2.0 some oxidation also occurs. Similarly, cellulose can be acetylated in solution with dimethylacetamide—paraformaldehyde and dimethylformamide-paraformaldehyde with a potassium acetate catalyst (64) to provide an almost quantitative yield of hydroxymethylceUulose acetate. 

Several derivatives of cellulose, including cellulose acetate, can be prepared in solution in dimethylacetamide—lithium chloride (65). Reportedly, this combination does not react with the hydroxy groups, thus leaving them free for esterification or etherification reactions. In another homogeneous-solution method, cellulose is treated with dinitrogen tetroxide in DMF to form the soluble cellulose nitrite ester this is then ester-interchanged with acetic anhydride (66). With pyridine as the catalyst, this method yields cellulose acetate with DS < 2.0. 

In the fibrous acetylation process, part or all of the acetic acid solvent is replaced with an inert dilutent, such as toluene, benzene, or hexane, to maintain the fibrous stmcture of cellulose throughout the reaction. Perchloric acid is often the catalyst of choice because of its high activity and because it does not react with cellulose to form acid esters. Fibrous acetylation also occurs upon treatment with acetic anhydride vapors after impregnation with a suitable catalyst such as zinc chloride (67). 

---