Cobalt acetates acetic acid

Cobaltous acetate acetic acid ozone Carboxylic acids from isocycles... 

Two important commercial diacids are adipic acid (hexanedioic acid) and tere-phthalic acid (benzene-1,4-dicarboxylic acid). Adipic acid is used in making nylon 66, and terephthalic acid is used to make polyesters. The industrial synthesis of adipic acid uses benzene as the starting material. Benzene is hydrogenated to cyclohexane, whose oxidation (using a cobalt/acetic acid catalyst) gives adipic acid. Terephthalic acid is produced by the direct oxidation of para-xylene in acetic acid using a cobalt-molybdenum catalyst. 

There is no further, destructive, oxidation as can be observed in cobalt-acetic acid systems, and the remaining unreacted ethylbenzene may be recycled. The reaction can be extended to a range of substituted ethylbenzenes. It may also be possible selectively to oxidise the side chain of other alkylaromatics, although toluenes are largely resistant to oxidation except under forcing conditions. 

Oxidation. Acetaldehyde is readily oxidised with oxygen or air to acetic acid, acetic anhydride, and peracetic acid (see Acetic acid and derivatives). The principal product depends on the reaction conditions. Acetic acid [64-19-7] may be produced commercially by the Hquid-phase oxidation of acetaldehyde at 65°C using cobalt or manganese acetate dissolved in acetic acid as a catalyst (34). Liquid-phase oxidation in the presence of mixed acetates of copper and cobalt yields acetic anhydride [108-24-7] (35). Peroxyacetic acid or a perester is beheved to be the precursor in both syntheses. There are two commercial processes for the production of peracetic acid [79-21 -0]. Low temperature oxidation of acetaldehyde in the presence of metal salts, ultraviolet irradiation, or osone yields acetaldehyde monoperacetate, which can be decomposed to peracetic acid and acetaldehyde (36). Peracetic acid can also be formed directiy by Hquid-phase oxidation at 5—50°C with a cobalt salt catalyst (37) (see Peroxides and peroxy compounds). Nitric acid oxidation of acetaldehyde yields glyoxal [107-22-2] (38,39). Oxidations of /)-xylene to terephthaHc acid [100-21-0] and of ethanol to acetic acid are activated by acetaldehyde (40,41). 

Butane-Naphtha Catalytic Liquid-Phase Oxidation. Direct Hquid-phase oxidation ofbutane and/or naphtha [8030-30-6] was once the most favored worldwide route to acetic acid because of the low cost of these hydrocarbons. Butane [106-97-8] in the presence of metallic ions, eg, cobalt, chromium, or manganese, undergoes simple air oxidation in acetic acid solvent (48). The peroxidic intermediates are decomposed by high temperature, by mechanical agitation, and by action of the metallic catalysts, to form acetic acid and a comparatively small suite of other compounds (49). Ethyl acetate and butanone are produced, and the process can be altered to provide larger quantities of these valuable materials. Ethanol is thought to be an important intermediate (50) acetone forms through a minor pathway from isobutane present in the hydrocarbon feed. Formic acid, propionic acid, and minor quantities of butyric acid are also formed. 

The Acetaldehyde Oxidation Process. Liquid-phase catalytic oxidation of acetaldehyde (qv) can be directed by appropriate catalysts, such as transition metal salts of cobalt or manganese, to produce anhydride (26). Either ethyl acetate or acetic acid may be used as reaction solvent. The reaction proceeds according to the sequence... 

Copper acetate, ferrous acetate, silver acetate [563-63-3] basic aluminum acetate, nickel acetate [373-02-4] cobalt acetate, and other acetate salts have been reported to furnish anhydride when heated. In principle, these acetates could be obtained from low concentration acetic acid. CompHcations of soHds processing and the scarcity of knowledge about these thermolyses make industrial development of this process expensive. In the eady 1930s, Soviet investigators discovered the reaction of dinitrogen tetroxide [10544-72-6] and sodium acetate [127-09-3] to form anhydride ... 

This reaction is rapidly replacing the former ethylene-based acetaldehyde oxidation route to acetic acid. The Monsanto process employs rhodium and methyl iodide, but soluble cobalt and iridium catalysts also have been found to be effective in the presence of iodide promoters. 

Butane LPO conducted in the presence of very high concentrations of cobalt catalyst has been reported to have special character (2,205,217—219). It occurs under mild conditions with reportedly high efficiency to acetic acid. It is postulated to involve the direct attack of Co(III) on the substrate. Various additives, including methyl ethyl ketone, -xylene, or water, are claimed to be useful. 

A one-step LPO of cyclohexane directly to adipic acid (qv) has received a lot of attention (233—238) but has not been implemented on a large scale. The various versions of this process use a high concentration cobalt catalyst in acetic acid solvent and a promoter (acetaldehyde, methyl ethyl ketone, water). 

Various ways of overcoming the PTA oxidation problem have been incorporated into commercial processes. The predominant solution is the use of high concentrations of manganese and cobalt ions (2,248—254), optionally with various cocatalysts (204,255,256), in the presence of an organic or inorganic bromide promoter in acetic acid solvent. Operational temperatures are rather high (ca 200°C). A lesser but significant alternative involves isolation of intermediate PTA, conversion to methyl/)-toluate, and recycle to the reactor. The ester is oxidized to monomethyl terephthalate, which is subsequentiy converted to DMT and purified by distillation (248,257—264). 

Acetic acid is produced by direct carbonylation of methanol in the presence of a homogeneous rhodium or cobalt catalyst. 

Because of its volatility, the cobalt catalyst codistills with the product aldehyde necessitating a separate catalyst separation step known as decobalting. This is typically done by contacting the product stream with an aqueous carboxyhc acid, eg, acetic acid, subsequently separating the aqueous cobalt carboxylate, and returning the cobalt to the process as active catalyst precursor (2). Alternatively, the aldehyde product stream may be decobalted by contacting it with aqueous caustic soda which converts the catalyst into the water-soluble Co(CO). This stream is decanted from the product, acidified, and recycled as active HCo(CO)4. 

Solvent Extraction Reagents. Solvent extraction is a solution purification process that is used extensively in the metallurgical and chemical industries. Both inorganic (34,35) and organic (36) solutes are recovered. The large commercial uses of phosphine derivatives in this area involve the separation of cobalt [7440-48-4] from nickel [7440-02-0] and the recovery of acetic acid [61-19-7] and uranium [7440-61-1]. 

Technical-Grade Terephthalic Acid. All technical-grade terephthahc acid is produced by catalytic, hquid-phase air oxidation of xylene. Several processes have been developed, but they all use acetic acid as a solvent and a multivalent heavy metal or metals as catalysts. Cobalt is always used. In the most popular process, cobalt and manganese are the multivalent heavy-metal catalysts and bromine is the renewable source for free radicals (51,52). 

Acetaldehyde can be used as an oxidation-promoter in place of bromine. The absence of bromine means that titanium metallurgy is not required. Eastman Chemical Co. has used such a process, with cobalt as the only catalyst metal. In that process, acetaldehyde is converted to acetic acid at the rate of 0.55—1.1 kg/kg of terephthahc acid produced. The acetic acid is recycled as the solvent and can be isolated as a by-product. Reaction temperatures can be low, 120—140°C, and residence times tend to be high, with values of two hours or more (55). Recovery of dry terephthahc acid follows steps similar to those in the Amoco process. Eastman has abandoned this process in favor of a bromine promoter (56). Another oxidation promoter which has been used is paraldehyde (57), employed by Toray Industries. This leads to the coproduction of acetic acid. 2-Butanone has been used by Mobil Chemical Co. (58). 

Eigure 3 is a flow diagram which gives an example of the commercial practice of the Dynamit Nobel process (73). -Xylene, air, and catalyst are fed continuously to the oxidation reactor where they are joined with recycle methyl -toluate. Typically, the catalyst is a cobalt salt, but cobalt and manganese are also used in combination. Titanium or other expensive metallurgy is not required because bromine and acetic acid are not used. The oxidation reactor is maintained at 140—180°C and 500—800 kPa (5—8 atm). The heat of reaction is removed by vaporization of water and excess -xylene these are condensed, water is separated, and -xylene is returned continuously (72,74). Cooling coils can also be used (70). 

Eastman Chemical Co. uses only cobalt and bromine, and lower temperature oxidations are held at 175—230°C (83). Solution of 4-formylbenzoic acid is obtained by using hydroclones to replace the mother hquor from the first oxidation with fresh acetic acid. A residence time of up to 2 h is used in order to allow for sufficient digestion to take place and to reduce the 4-formylbenzoic acid content to 40—270 ppm (83). Recovery of dry terephthahc acid is as described above. 

Chevron Chemical Co. began commercial production of isophthahc acid in 1956. The sulfur-based oxidation of / -xylene in aqueous ammonia at about 320°C and 7,000—14,000 kPa produced the amide. This amide was then hydrolyzed with sulfuric acid to produce isophthahc acid at about 98% purity. Arco Chemical Co. began production in 1970 using air oxidation in acetic acid catalyzed by a cobalt salt and promoted by acetaldehyde at 100—150°C and 1400—2800 kPa (14—28 atm). The cmde isophthahc acid was dissolved and recrystallized to yield a product exceeding 99% purity. The Arco technology was not competitive and the plant was shut down in 1974. 

Of the three benzenetricarboxyhc acids, only trimellitic acid as the anhydride is commercially produced in large volume, by Hquid-phase air oxidation of either pseudocumene or dimethyl benzaldehyde. The pseudocumene oxidation is another variant of the cobalt—manganese—bromine catalyst in acetic acid solvent as described in the terephthaUc acid section. The acid is available as a laboratory chemical (99). The lUPAC name of trimellitic anhydride is 5-isobenzofurancarboxyhc acid (l,3-dihydro-l,3-dioxo). 

Manufacture. The only current U.S. manufacturer of trimesic acid is Amoco Chemical Co. It is produced by oxidation of mesitylene (1,3,5-trimethylbenzene) via the Hquid-phase oxidation in acetic acid using the cobalt— manganese—bromine catalyst system (138). This is a variant of the system used to produce terephthaUc and isophthaUc acids as well as trimellitic anhydride. American Bio-Synthetics Corp. did produce it by batch oxidation of mesitylene with potassium permanganate. 

The use of the Hquid-phase process in acetic acid with the cobalt— manganese—bromine system as explained in the tetephthaUc acid section is also possible (149). This process has been used by Amoco Chemical to produce pyromellitic acid, and facUities remain in place to do so again in the future. As with all hquid-phase oxidations of this type, yields ate high. A separate dehydration step would be needed to yield the dianhydtide. 

Although an inherently more efficient process, the direct chemical oxidation of 3-methylpyridine does not have the same commercial significance as the oxidation of 2-methyl-5-ethylpyridine. Liquid-phase oxidation procedures are typically used (5). A Japanese patent describes a procedure that uses no solvent and avoids the use of acetic acid (6). In this procedure, 3-methylpyridine is combined with cobalt acetate, manganese acetate and aqueous hydrobromic acid in an autoclave. The mixture is pressurized to 101.3 kPa (100 atm) with air and allowed to react at 210°C. At a 32% conversion of the picoline, 19% of the acid was obtained. Electrochemical methods have also been described (7). 

The original catalysts for this process were iodide-promoted cobalt catalysts, but high temperatures and high pressures (493 K and 48 MPa) were required to achieve yields of up to 60% (34,35). In contrast, the iodide-promoted, homogeneous rhodium catalyst operates at 448—468 K and pressures of 3 MPa. These conditions dramatically lower the specifications for pressure vessels. Yields of 99% acetic acid based on methanol are readily attained (see Acetic acid Catalysis). 

With Alcohols, Ethers, and Esters. Carbon monoxide reacts with alcohols, ethers, and esters to give carboxyHc acids. The reaction yielding carboxyHc acids is general for alkyl (53) and aryl alcohols (54). It is cataly2ed by rhodium or cobalt in the presence of iodide and provides the basis for a commercial process to acetic acid. 

Acetic acid (qv) can be produced synthetically (methanol carbonylation, acetaldehyde oxidation, butane/naphtha oxidation) or from natural sources (5). Oxygen is added to propylene to make acrolein, which is further oxidized to acryHc acid (see Acrylic acid and derivatives). An alternative method adds carbon monoxide and/or water to acetylene (6). Benzoic acid (qv) is made by oxidizing toluene in the presence of a cobalt catalyst (7). 

Physical and Chemical Properties. The (F)- and (Z)-isomers of cinnamaldehyde are both known. (F)-Cinnamaldehyde [14371-10-9] is generally produced commercially and its properties are given in Table 2. Cinnamaldehyde undergoes reactions that are typical of an a,P-unsaturated aromatic aldehyde. Slow oxidation to cinnamic acid is observed upon exposure to air. This process can be accelerated in the presence of transition-metal catalysts such as cobalt acetate (28). Under more vigorous conditions with either nitric or chromic acid, cleavage at the double bond occurs to afford benzoic acid. Epoxidation of cinnamaldehyde via a conjugate addition mechanism is observed upon treatment with a salt of /-butyl hydroperoxide (29). 

Homogeneous Oxidation Catalysts. Cobalt(II) carboxylates, such as the oleate, acetate, and naphthenate, are used in the Hquid-phase oxidations of -xylene to terephthaUc acid, cyclohexane to adipic acid, acetaldehyde (qv) to acetic acid, and cumene (qv) to cumene hydroperoxide. These reactions each involve a free-radical mechanism that for the cyclohexane oxidation can be written as... 

A Belgian patent (178) claims improved ethanol selectivity of over 62%, starting with methanol and synthesis gas and using a cobalt catalyst with a hahde promoter and a tertiary phosphine. At 195°C, and initial carbon monoxide pressure of 7.1 MPa (70 atm) and hydrogen pressure of 7.1 MPa, methanol conversions of 30% were indicated, but the selectivity for acetic acid and methyl acetate, usehil by-products from this reaction, was only 7%. Ruthenium and osmium catalysts (179,180) have also been employed for this reaction. The addition of a bicycHc trialkyl phosphine is claimed to increase methanol conversion from 24% to 89% (181). 

Oxidation catalysts are either metals that chemisorb oxygen readily, such as platinum or silver, or transition metal oxides that are able to give and take oxygen by reason of their having several possible oxidation states. Ethylene oxide is formed with silver, ammonia is oxidized with platinum, and silver or copper in the form of metal screens catalyze the oxidation of methanol to formaldehyde. Cobalt catalysis is used in the following oxidations butane to acetic acid and to butyl-hydroperoxide, cyclohexane to cyclohexylperoxide, acetaldehyde to acetic acid and toluene to benzoic acid. PdCh-CuCb is used for many liquid-phase oxidations and V9O5 combinations for many vapor-phase oxidations. 

The TCBOC group is stable to the alkaline hydrolysis of methyl esters and to the acidic hydrolysis of r-butyl esters. It is rapidly cleaved by the supemucleophile lithium cobalt(I)phthalocyanine, by zinc in acetic acid, and by cobalt phthalocy-anine (0.1 eq., NaBH4, EtOH, 77-90% yield). 

Cobaltous acetate (4H2O) [6147-53-1] M 249.1, pKj 9.85 (for Co " "). Crystd several times as the tetrahydrate from 50% aqueous acetic acid. Converted to the anhydrous salt by drying at 80°/1mm for 60h. 

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