Cocatalysts, industrial

Although catalytic hydration of ethylene oxide to maximize ethylene glycol production has been studied by a number of companies with numerous materials patented as catalysts, there has been no reported industrial manufacture of ethylene glycol via catalytic ethylene oxide hydrolysis. Studied catalysts include sulfonic acids, carboxyUc acids and salts, cation-exchange resins, acidic zeoHtes, haUdes, anion-exchange resins, metals, metal oxides, and metal salts (21—26). Carbon dioxide as a cocatalyst with many of the same materials has also received extensive study. 

Tertiary stibines have been widely employed as ligands in a variety of transition metal complexes (99), and they appear to have numerous uses in synthetic organic chemistry (66), eg, for the olefination of carbonyl compounds (100). They have also been used for the formation of semiconductors by the metal—organic chemical vapor deposition process (101), as catalysts or cocatalysts for a number of polymerization reactions (102), as ingredients of light-sensitive substances (103), and for many other industrial purposes. 

Tertiary bismuthines appear to have a number of uses in synthetic organic chemistry (32), eg, they promote the formation of 1,1,2-trisubstituted cyclopropanes by the iateraction of electron-deficient olefins and dialkyl dibromomalonates (100). They have also been employed for the preparation of thin films (qv) of superconducting bismuth strontium calcium copper oxide (101), as cocatalysts for the polymerization of alkynes (102), as inhibitors of the flammabihty of epoxy resins (103), and for a number of other industrial purposes. 

Polymerization of alkenes and the isomerization of alkanes and alkenes occur in the presence of a cocatalyst such as H2O, whereas the cracking of hydrocarbons is best performed with HF as cocatalyst. These latter reactions are of major commercial importance in the petrochemicals industry. 

Transition metal catalysis plays a key role in the polyolefin industry. The discovery by Ziegler and Natta of the coordination polymerization of ethylene, propylene, and other non-polar a-olefins using titanium-based catalysts, revolutionized the industry. These catalysts, along with titanium- and zirconium-based metallocene systems and aluminum cocatalysts, are still the workhorse in the manufacture of commodity polyolefin materials such as polyethylene and polypropylene [3-6],... 

The Wacker process (Eq. 1) was developed nearly 50 years ago [1-3] and represents one of the most successful examples of homogeneous catalysis in industry [4-9]. This palladium-catalyzed method for the oxidation of ethylene to acetaldehyde in aqueous solution employs a copper cocatalyst to facilitate aerobic oxidation of Pd° (Scheme 1). Despite the success of this process, certain features of the reaction have Umited the development of related aerobic oxidation reactions. Many organic molecules are only sparingly sol-... 

One of the most efficient methods for oxidation of primary alcohols to either aldehydes or carboxylic acids is the one, commonly known as the Anelli oxidation. This reaction is carried out in a two-phase (CH2Cl2/aq.buffer) system utilizing TEMPO/NaBr as a catalyst and NaOCl as the terminal oxidant The new system described here is an extension of the Anelli oxidation, but surprisingly, does not require the use of any organic solvents and replaces the KBr co-catalyst with the more benign, Na2B40y (Borax). The use of the new cocatalyst reduces the volume of the buffer solution and eliminates completely the need of a reaction solvent. The new system was successfully applied in the industrial synthesis of the 3,3-Dimethylbutanal, which is a key intermediate in the preparation of the new artificial sweetener Neotame. 

When an alkene is used in the alkylation of arenes, metal halides with hydrogen halide or water as cocatalyst, protic acids, and acidic oxides can be used as catalysts. Both linear and cyclic alkenes are used in alkylations. Alkylation with alkenes is usually preferred in industry because the processes are simpler and olefins are readily and cheaply available in pure form from petroleum refining processes. 

Addition of hydrogen to terminate the chains is the most important and widely used industrial process to control molecular weight. Chain transfer with organometallic compounds (cocatalysts), which is basically an alkyl exchange, can take place with titanium-based and chromium-based systems ... 

Predominantly cis-1,4-polybutadiene is produced by coordination polymerization with mixed catalysts.187,487,488 Three catalyst systems based on titanium, cobalt, or nickel are used in industrial practice. Iodine is an inevitable component in titanium-alkylaluminum sytems to get high cis content. Numerous different technologies are used 490,491 A unique process was developed by Snamprogetti employing a (Tr-allyl)uranium halide catalyst with a Lewis acid cocatalyst.492-494 This catalyst system produces poly butadiene with 1,4-ris content up to 99%. 

The selectivity in the formation of 1,4-diacetoxy-2-butene (1,4-DAB) is considerably enhanced when tellurium compounds are used as cocatalysts. Thus a heterogeneous catalyst, prepared by impregnation of Pd(N03)2 and Te02 dissolved in HN03 over active charcoal (Pd/Te = 10), can be used for the oxidation of butadiene (by 02 in AcOH at 90 °C) to 63% trans-l,4-DAB, 25% cis-1,4-DAB and 12% 3,4-diacetoxy-l-butene. Conventional soluble catalysts such as Pd(OAc)2/Li(OAc) are much less selective in the formation of 1,4-DAB 429 The gas-phase 1,4-diacetoxylation of butadiene in the presence of Pd-Te catalysts is currently being industrially developed by Mitsubishi and BASF 430... 

The Wacker Oxidation is an industrial process, which allows the synthesis of ethanal from ethene by palladium-catalyzed oxidation with oxygen. Copper serves as redox cocatalyst. 

For instance, in the field of elastomers, alkyllithium catalyst systems are used commercially for producing butadiene homopolymers and copolymers and, to a somewhat lesser extent, polyisoprene. Another class of important, industrial polymerization systems consists of those catalyzed by alkylaluminum compounds and various compounds of transition metals used as cocatalysts. The symposium papers reported several variations of these polymerization systems in which cocatalysts are titanium halides for isoprene or propylene and cobalt salts for butadiene. The stereospecificity and mechanism of polymerization with these monomers were compared using the above cocatalysts as well as vanadium trichloride. Also included is the application of Ziegler-Natta catalysts to the rather novel polymerization of 1,3-pentadiene to polymeric cis-1,4 stereoisomers which have potential interest as elastomers. 

Methylaluminoxane (MAO), sometimes referred to as polymethylaluminoxane (PMAO), currently gamers the most industrial interest of aU the alkylaluminoxanes owing to its activity as a cocatalyst for metallocene-catalyzed alkene polymerization (see Oligomerization Polymerization by... 

Other apphcations of sodium bromide include use in the photographic industry both to make light-sensitive silver bromide [7785-23-1] emulsions and to lower the solubility of silver bromides during the developing process use as a wood (qv) preservative in conjunction with hydrogen peroxide (14) as a cocatalyst along with cobalt acetate [917-69-1] for the partial oxidation of alkyl side chains on polystyrene polymers (15) and as a sedative, hypnotic, and anticonvulsant. The FDA has, however, indicated that sodium bromide is ineffective as an over-the-counter sleeping aid for which it has been utilized (16). 

Catalyst Cocatalyst Polymerization Process Polymerization Parameters Industrial Requirements... 

Aluminum alkyls are still used industrially for prereduction of transition metal compounds. However, far more is used in the role of cocatalyst, described in the next section. 

In this case, the aluminum alkyl is functioning as a cocatalyst, sometimes also called an "activator." Titanium alkyls, believed to be active centers for polymerization, are created through transfer of an alkyl from aluminum to titanium, known as "alkylation." Molar ratios of cocatalyst to transition metal (Al/Ti) are typically 30 for commercial polyethylene processes using Ziegler-Natta catalysts (lower ratios are used for polypropylene). The vast majority of aluminum alkyls sold into the polyethylene industry today is for use as cocatalysts. With TEAL, the most widely used cocatalyst, alkylation proceeds as in eq 4.8 ... 

Organoboron compounds constitute a broad and rich area of organometallic chemistry and a detailed discussion is inappropriate for an introductory text on polyethylene. However, several organoboron compounds are crucial for selected polyethylene catalyst technologies. For example, arylboranes are used as cocatalysts for single site catalyst systems and will be discussed in Chapter 6 (see section 6.3.2). The purpose of this section is to introduce the trialkylborane that is a component of 3 generation Phillips catalyst systems (Chapter 5) employed in industrial processes in for linear polyethylene. 

For most industrial polyethylene processes (slurry and gas phase), thermal stability of the cocatalyst is not a factor since most operate in the temperature range 80-110 °C. However, solution processes operate at high enough temperatures where thermal decomposition of the cocatalyst could become a factor. Fortunately, residence times are typically short in solution processes. 

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