Chloride catalysts

The problem with the fiowsheet shown in Fig. 10.5 is that the ferric chloride catalyst is carried from the reactor with the product. This is separated by washing. If a reactor design can be found that prevents the ferric chloride leaving the reactor, the effluent problems created by the washing and neutralization are avoided. Because the ferric chloride is nonvolatile, one way to do this would be to allow the heat of reaction to raise the reaction mixture to the boiling point and remove the product as a vapor, leaving the ferric chloride in the reactor. Unfortunately, if the reaction mixture is allowed to boil, there are two problems ... 

Example 86 A 0.10 mole amount of the starting 3-(4-hydroxyphenyl) propylene, 0.25 mole of methyl nitrite, 0.5 liter of methyl alcohol, and 0.006 mole of a palladium chloride catalyst were charged into a reaction vessel. Then, the reaction was carried out at a temperature of 20.degree. C. for 1.5hours."... 

In the presence of a pyridine-cuprous chloride catalyst, the following polymerization occurs ... 

Acetic anhydride adds to acetaldehyde in the presence of dilute acid to form ethyUdene diacetate [542-10-9], boron fluoride also catalyzes the reaction (78). Ethyfldene diacetate decomposes to the anhydride and aldehyde at temperatures of 220—268°C and initial pressures of 14.6—21.3 kPa (110—160 mm Hg) (79), or upon heating to 150°C in the presence of a zinc chloride catalyst (80). Acetone (qv) [67-64-1] has been prepared in 90% yield by heating an aqueous solution of acetaldehyde to 410°C in the presence of a catalyst (81). Active methylene groups condense acetaldehyde. The reaction of isobutfyene/715-11-7] and aqueous solutions of acetaldehyde in the presence of 1—2% sulfuric acid yields alkyl-y -dioxanes 2,4,4,6-tetramethyl-y -dioxane [5182-37-6] is produced in yields up to 90% (82). 

With a palladium chloride catalyst, butenediol is carbonylated by carbon monoxide, giving 3-hexenedioic acid [4436-74-2] C HgO (94). 

With palladium chloride catalyst, carbon monoxide, and an alcohol the labile hydroxyl is alkylated during carbonylation (199). 

At one time, the only commercial route to 2-chloro-1,3-butadiene (chloroprene), the monomer for neoprene, was from acetylene (see Elastomers, synthetic). In the United States, Du Pont operated two plants in which acetylene was dimeri2ed to vinylacetylene with a cuprous chloride catalyst and the vinyl-acetylene reacted with hydrogen chloride to give 2-chloro-1,3-butadiene. This process was replaced in 1970 with a butadiene-based process in which butadiene is chlorinated and dehydrochlorinated to yield the desired product (see Chlorocarbonsandchlorohydrocarbons). 

Twelve-membered rings have been obtained using coordination catalysts. The transJmns,ds-cyc. ododec2Lti ien.e has been prepared with a tetrabutyl titanate—diethylalurninum chloride catalyst (48,49) and with a chromium-based system (50). The trans,trans,trans-isom.e-i. has been prepared with a nickel system. 

Triaryl phosphates are produced by reaction of phosphoms oxychloride with phenoHc compounds at 100—200°C with magnesium or aluminum chloride catalyst. Past use of cresols and xylenols from coal tar or petroleum is replaced for lower toxicity and cost by synthetic phenoHcs, primarily isopropyl phenol, /-butyl phenol, and phenol itself A range of viscosities is achieved by selection and proportioning of the phenols and their isomers used for the starting material. 

Isopropylnaphthalenes can be prepared readily by the catalytic alkylation of naphthalene with propjiene. 2-lsopropylnaphthalene [2027-17-0] is an important intermediate used in the manufacture of 2-naphthol (see Naphthalenederivatives). The alkylation of naphthalene with propjiene, preferably in an inert solvent at 40—100°C with an aluminum chloride, hydrogen fluoride, or boron trifluoride—phosphoric acid catalyst, gives 90—95% wt % 2-isopropylnaphthalene however, a considerable amount of polyalkylate also is produced. Preferably, the propylation of naphthalene is carried out in the vapor phase in a continuous manner, over a phosphoric acid on kieselguhr catalyst under pressure at ca 220—250°C. The alkylate, which is low in di- and polyisopropylnaphthalenes, then is isomerized by recycling over the same catalyst at 240°C or by using aluminum chloride catalyst at 80°C. After distillation, a product containing >90 wt % 2-isopropylnaphthalene is obtained (47). 

Nonregenerable aluminum chloride catalyst is employed with various carriers ia a fixed-bed or Hquid contactor. Platinum or other metal catalyst processes that utilize fixed-bed operation can be either regenerable or nonregenerable. The reaction conditions vary widely, between 40—480°C and 1035— 6900 kPa (150—1000 psi), depending on the particular process and feedstock. 

Benzene Chlorination. In this process, benzene is chlorinated at 38—60°C in the presence of ferric chloride catalyst. The chlorobenzene is hydrolyzed with caustic soda at 400°C and 2.56 kPa (260 atm) to form sodium phenate. The impure sodium phenate reacts with hydrochloric acid to release the phenol from the sodium salt. The yield of phenol is about 82 mol % to that of the theoretical value based on benzene. Plants employing this technology have been shut down for environmental and economic reasons. 

Benzene Oxychlorin tion. In the benzene oxychlorination process, also known as the Raschig Hooker process, benzene is oxychlorinated with hydrogen chloride, air, and with the presence of iron and copper chloride catalyst to form chlorobenzene. The reaction occurs at 200—260°C and atmospheric pressure. The chlorobenzene is hydrolyzed at 480°C in the presence of a suitable catalyst to produce phenol and chloride. The yield of phenol is - 90 mol% of theoretical. These plants have been shut down for environmental and economic reasons. 

Currently, almost all cumene is produced commercially by two processes ( /) a fixed-bed, kieselguhr-supported phosphoric acid catalyst system developed by UOP and (2) a homogeneous AlCl and hydrogen chloride catalyst system developed by Monsanto. 

AlCl and Hydrogen Chloride Catalyst. Historically, AIQ processes have been used more extensively for the production of ethylbenzene than for the production of cumene. In 1976, Monsanto developed an improved cumene process that uses an AIQ. catalyst, and by the mid-1980s, the technology had been successfully commercialized. The overall yields of cumene for this process can be as high as 99 wt % based on benzene and 98 wt % based on propylene (60). 

The order of reactivity with acid is HI > HBi > HCl. Reaction with hydrochloric acid [7647-01-0] to form isopropyl chloride [75-29-6] is faciUtated by a zinc chloride catalyst. 

Aluminum Chloride-Based All lation. The eadier alkylation processes were variations of the Eriedel-Craft reaction on an aluminum chloride catalyst complex in a Hquid-phase reactor (27), including those developed by Dow Chemical, BASE, Monsanto, and Union Carbide in cooperation with Badger. The Union Carbide-Badger process was the one most widely used during the 1960s and 1970s, with 20 plants built worldwide. 

Resin-based repeUents may be used alone or in combination with durable-press resins. They are widely used as extenders for fluorochemical repeUents. When used alone, several of the resin-based finishes require an acid catalyst and curing at temperatures above 150°C for maximum repeUency and durabUity. When coappUed with durable-press finishes, which themselves require a magnesium chloride catalyst, the catalyst and curing conditions for the durable-press finish provide the necessary conditions for the repeUent. 

Oxidative Garbonylation. Carbon monoxide is rapidly oxidized to carbon dioxide however, under proper conditions, carbon monoxide and oxygen react with organic molecules to form carboxyUc acids or esters. With olefins, unsaturated carboxyUc acids are produced, whereas alcohols yield esters of carbonic or oxalic acid. The formation of acryUc and methacrylic acid is carried out in the Hquid phase at 10 MPa (100 atm) and 110°C using palladium chloride or rhenium chloride catalysts (eq. 19) (64,65). 

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. 

Oxychlorination. This is an important process for the production of 1,2-dichloroethane which is mainly produced as an intermediate for the production of vinyl chloride. The reaction consists of combining hydrogen chloride, ethylene, and oxygen (air) in the presence of a cupric chloride catalyst to produce 1,2-dichloroethane (eq. 24). The hydrogen chloride produced from thermal dehydrochlorination of 1,2-dichloroethane to produce vinyl chloride (eq. 25) is usually recycled back to the oxychlorination reactor. The oxychlorination process has been reviewed (31). 

Significant quantities of ethyl chloride are also produced as a by-product of the catalytic hydrochlorination over a copper chloride catalyst, of ethylene and hydrogen chloride to produce 1,2-dichloroethane, which is used as feedstock in the manufacture of vinyl choride (see Vinyl polymers). This ethyl chloride can be recovered for sale or it can be concentrated and catalyticaHy cracked back to ethylene and hydrogen chloride (25). As the market for ethyl chloride declines, recovery as an intermediate by-product of vinyl chloride manufacture may become a predominant method of manufacture of ethyl chloride. 

Dichloroethane is produced commercially from hydrogen chloride and vinyl chloride at 20—55°C ia the presence of an aluminum, ferric, or 2iac chloride catalyst (8,9). Selectivity is nearly stoichiometric to 1,1-dichloroethane. Small amounts of 1,1,3-tfichlorobutane may be produced. Unreacted vinyl chloride and HCl exit the top of the reactor, and can be recycled or sent to vent recovery systems. The reactor product contains the Lewis acid catalyst and must be separated before distillation. Spent catalyst may be removed from the reaction mixture by contacting with a hydrocarbon or paraffin oil, which precipitates the metal chloride catalyst iato the oil (10). Other iaert Hquids such as sdoxanes and perfluorohydrocarbons have also been used (11). 

Oxychl orin ation of ethylene has become the second important process for 1,2-dichloroethane. The process is usually incorporated into an integrated vinyl chloride plant in which hydrogen chloride, recovered from the dehydrochlorination or cracking of 1,2-dichloroethane to vinyl chloride, is recycled to an oxychl orin a tion unit. The hydrogen chloride by-product is used as the chlorine source in the chlorination of ethylene in the presence of oxygen and copper chloride catalyst ... 

Hydrolysis. 1,1,1-Trichloroethane heated with water at 75—160°C under pressure and in the presence of sulfuric acid or a metal chloride catalyst decomposes to acetyl chloride, acetic acid, or acetic anhydride (54). However, hydrolysis under normal use conditions proceeds slowly. The hydrolysis is 100—1000 times faster with trichloroethane dissolved in the water phase than vice versa. Refluxing 1,1,1-trichloroethane with ferric and gallium chloride... 

Hexachloroethane is formed in minor amounts in many industrial chlorination processes designed to produce lower chlorinated hydrocarbons, usually via a sequential chlorination step. Chlorination of tetrachloroethylene, in the presence of ferric chloride, at 100—140°C is one convenient method of preparing hexachloroethane (142). Oxychlorination of tetrachloroethylene, using a copper chloride catalyst (143) has also been used. Photochemical chlorination of tetrachloroethylene under pressure and below 60°C has been studied (144) and patented as a method of producing hexachloroethane (145), as has recovery of hexachloroethane from a mixture of other perchlorinated hydrocarbon derivatives via crystalH2ation in carbon tetrachloride. Chlorination of hexachlorobutadiene has also been used to produce hexachloroethane (146). 

Dichloroethylene can be produced by direct chlorination of acetylene at 40°C. It is often produced as a by-product ia the chlorination of chloriaated compounds (2) and recycled as an iatermediate for the synthesis of more useful chloriaated ethylenes (3). 1,2-Dichloroethylene can be formed by contiauous oxychloriaation of ethylene by use of a cupric chloride—potassium chloride catalyst, as the first step ia the manufacture of vinyl chloride [75-01-4] (4). 

Cumene as a pure chemical intermediate is produced in modified Friedel-Crafts reaction processes that use acidic catalysts to alkylate benzene with propylene (see Alkylation Friedel-CRAFTSreactions). The majority of cumene is manufactured with a soHd phosphoric acid catalyst (7). The remainder is made with aluminum chloride catalyst (8). 

Halobutyl Cures. Halogenated butyls cure faster in sulfur-accelerator systems than butyl bromobutyl is generally faster than chlorobutyl. Zinc oxide-based cure systems result in C—C bonds formed by alkylation through dehydrohalogenation of the halobutyl to form a zinc chloride catalyst (94,95). Cure rate is increased by stearic acid, but there is a competitive reaction of substitution at the halogen site. Because of this, stearic acid can reduce the overall state of cure (number of cross-links). Water is a strong retarder because it forms complexes with the reactive intermediates. Amine cure may be represented as follows ... 

The unique advantage of the nickel system is that it can produce either stmctures of i7j -I,4-polybutadiene, /n j -I,4-polybutadiene, or a mixture of both depending on the reducing agent and the co-catalyst used. For example, chloride catalyst yields i7j -I,4-polybutadiene, whereas bromide or iodide yields /n j -I,4-polybutadiene. The counterion also has an effect on the polymer microstmcture. A 50/50 cis- 4l/n j -I,4-polybutadiene has been prepared using a carboxyhc counterion (95—105). 

Catalysis is done by an acidic solution of the stabilized reaction product of stannous chloride and palladium chloride. Catalyst absorption is typically 1—5 p-g Pd per square centimeter. Other precious metals can be used, but they are not as cost-effective. The exact chemical identity of this catalyst has been a matter of considerable scientific interest (19—21,23). It seems to be a stabilized coUoid, co-deposited on the plastic with excess tin. The industry trends have been to use higher activity catalysts at lower concentrations and higher temperatures. Typical usage is 40—150 ppm of palladium at 60°C maximum, and a 30—60-fold or more excess of stannous chloride. Catalyst variations occasionally used include alkaline and non-noble metal catalysts. 

Halogenation—Hydrohalogenation. The most important iatermediate is ethylene dichloride [107-06-2] (EDC) which is produced from ethylene either by direct chlorination or by oxychloriaation. Direct chlorination is carried out ia the Hquid or vapor phase over catalysts of iron, alumiaum, copper, or antimony chlorides, and at conditions of 60°C. Oxychloriaation is carried out ia a fixed or fluidized bed at 220°C with a suitable soHd chloride catalyst. 

Trichloro- and tetrachloroethylene are important organic solvents. These are produced by further chlorination of 1,2-dichloroethylene ia the gas phase with simultaneous dehydrochloriaation ia the preseace of a suitable chloride catalyst (see Chlorocarbonsandchlorohydrocarbons). 

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