Catalyst, Copper

Colourless liquid with a strong peppermintlike odour b.p. 155" C. Manufactured by passing cyclohexanol vapour over a heated copper catalyst. Volatile in steam. Oxidized to adipic acid. Used in the manufacture of caprolactam. Nylon, adipic acid, nitrocellulose lacquers, celluloid, artificial leather and printing inks. 

Nitrogen trifluoride and trichloride can both be prepared as pure substances by the action of excess halogen on ammonia, a copper catalyst being necessary for the formation of nitrogen trifluoride. 

However, hydrogen chloride gas, obtained as a by-product in chlorination reactions, is commercially converted to chlorine by passing the hydrogen chloride mixed with air over a copper catalyst at a temperature of 600-670K when the following reaction occurs ... 

Arylation or alkenylation of soft carbon nucleophiles such as malonate is carried out by using a copper catalyst, but it is not a smooth reaction. The reaction of malononitrile, cyanoacetate, and phenylsulfonylacetonitrile with aryl iodide is possible by using a Pd catalyst to give the coupling products. 

Plot of pMp° - p) against p/p° (r is expressed in cm (stp)). (1) Unpromoted Fe catalyst (2) AljOj-promoted Fe catalyst (3) AI2O3-KjO-promoted Fe catalyst (4) fused copper catalyst (5) chromium oxide gel (6) silica gel. (Courtesy Brunauer, Emmett and Teller.)... 

In a related process, 1,4-dichlorobutene was produced by direct vapor-phase chlorination of butadiene at 160—250°C. The 1,4-dichlorobutenes reacted with aqueous sodium cyanide in the presence of copper catalysts to produce the isomeric 1,4-dicyanobutenes yields were as high as 95% (58). The by-product NaCl could be recovered for reconversion to Na and CI2 via electrolysis. Adiponitrile was produced by the hydrogenation of the dicyanobutenes over a palladium catalyst in either the vapor phase or the Hquid phase (59,60). The yield in either case was 95% or better. This process is no longer practiced by DuPont in favor of the more economically attractive process described below. 

Ma.nufa.cture. Butyrolactone is manufactured by dehydrogenation of butanediol. The butyrolactone plant and process in Germany, as described after World War II (179), approximates the processes presendy used. The dehydrogenation was carried out with preheated butanediol vapor in a hydrogen carrier over a supported copper catalyst at 230—250°C. The yield of butyrolactone after purification by distillation was about 90%. 

Even ia 1960 a catalytic route was considered the answer to the pollution problem and the by-product sulfate, but nearly ten years elapsed before a process was developed that could be used commercially. Some of the eadier attempts iacluded hydrolysis of acrylonitrile on a sulfonic acid ion-exchange resia (69). Manganese dioxide showed some catalytic activity (70), and copper ions present ia two different valence states were described as catalyticaHy active (71), but copper metal by itself was not active. A variety of catalysts, such as Umshibara or I Jllmann copper and nickel, were used for the hydrolysis of aromatic nitriles, but aUphatic nitriles did not react usiag these catalysts (72). Beginning ia 1971 a series of patents were issued to The Dow Chemical Company (73) describiag the use of copper metal catalysis. Full-scale production was achieved the same year. A solution of acrylonitrile ia water was passed over a fixed bed of copper catalyst at 85°C, which produced a solution of acrylamide ia water with very high conversions and selectivities to acrylamide. 

Mitsui Toatsu Chemical, Inc. disclosed a similar process usiag Raney copper (74) shortiy after the discovery at Dow, and BASF came out with a variation of the copper catalyst ia 1974 (75). Siace 1971 several hundred patents have shown modifications and improvements to this technology, both homogeneous and heterogeneous, and reviews of these processes have been pubHshed (76). Nalco Chemical Company has patented a process based essentially on Raney copper catalyst (77) ia both slurry and fixed-bed reactors and produces acrylamide monomer mainly for internal uses. Other producers ia Europe, besides Dow and American Cyanamid, iaclude AUied CoUoids and Stockhausen, who are beheved to use processes similar to the Raney copper technology of Mitsui Toatsu, and all have captive uses. Acrylamide is also produced ia large quantities ia Japan. Mitsui Toatsu and Mitsubishi are the largest producers, and both are beheved to use Raney copper catalysts ia a fixed bed reactor and to sell iato the merchant market. 

Silver Catalyst Process. In early formaldehyde plants methanol was oxidized over a copper catalyst, but this has been almost completely replaced with silver (75). The silver-catalyzed reactions occur at essentially atmospheric pressure and 600 to 650°C (76) and can be represented by two simultaneous reactions ... 

Oxalic acid produced from syngas can be esteiified (eq. 20) and reduced with hydrogen to form ethylene glycol with recovery of the esterification alcohol (eq. 21). Hydrogenation requires a copper catalyst giving 100% conversion with selectivities to ethylene glycol of 95% (15). 

Benzophenone Process. Benzophenone, (CgH5 )2C=0, reacts with ammonia to form diphenylmethanimine, (CgHg )2C=NH. In the presence of copper catalysts, this is oxidized with oxygen to benzophenone azine, (CgHg )2C=N—N=C(CgHg The formation of the imine and its... 

Reactions. The most important commercial reaction of cyclohexane is its oxidation (ia Hquid phase) with air ia the presence of soluble cobalt catalyst or boric acid to produce cyclohexanol and cyclohexanone (see Hydrocarbon oxidation Cyclohexanoland cyclohexanone). Cyclohexanol is dehydrogenated with 2iac or copper catalysts to cyclohexanone which is used to manufacture caprolactam (qv). 

Biacetyl is produced by the dehydrogenation of 2,3-butanediol with a copper catalyst (290,291). Prior to the availabiUty of 2,3-butanediol, biacetyl was prepared by the nitrosation of methyl ethyl ketone and the hydrolysis of the resultant oxime. Other commercial routes include passing vinylacetylene into a solution of mercuric sulfate in sulfuric acid and decomposing the insoluble product with dilute hydrochloric acid (292), by the reaction of acetal with formaldehyde (293), by the acid-cataly2ed condensation of 1-hydroxyacetone with formaldehyde (294), and by fermentation of lactic acid bacterium (295—297). Acetoin [513-86-0] (3-hydroxy-2-butanone) is also coproduced in lactic acid fermentation. 

Significant quantities of the diphenoquinone are also produced if the ortho substituents are methoxy groups (36). Phenols with less than two ortho substituents produce branched and colored products from the reactions that occur at the open ortho sites. It is possible to minimize such side reactions in the case of o-cresol oxidation by using a bulky ligand on the copper catalyst to block the open ortho position (38). 

An improved version of the amine hydrolysis process involves catalytic hydrogenation of 1,3,5-triaitrobenzene or 2,4,6-triaitrobenzoic acid in acetone solvent (138). Acid hydrolysis of 2,4,6-triaminobenzoic acid has been improved by addition of copper catalyst and gives phlorogluciaol in 80% yield (139). 

The Guerbet reaction can be used to obtain higher alcohols 2-propyl-1-heptanol [10042-59-8] from 1-pentanol condensation and 6-methyl-4-nonanol from 2-pentanol (80—83). Condensations with alkah phenolates as the base, instead of copper catalyst, produce lower amounts of carboxyhc acids and requke lower reaction temperatures (82,83). The crossed Guerbet reaction of 1-pentanol with methanol in the presence of sodium methoxide catalyst afforded 2-heptanol in selectivities of about 75% (84). 

Dkect synthesis is the preparative method that ultimately accounts for most of the commercial siUcon hydride production. This is the synthesis of halosilanes by the dkect reaction of a halogen or haUde with siUcon metal, siUcon dioxide, siUcon carbide, or metal sihcide without an intervening chemical step or reagent. Trichlorosilane is produced by the reaction of hydrogen chloride and siUcon, ferrosiUcon, or calcium sihcide with or without a copper catalyst (82,83). Standard purity is produced in a static bed at 400—900°C. 

Nerol, geraniol, and linalool, known as the rose alcohols, are found widely in nature. Nerol and geraniol have mild, sweet odors reminiscent of rose flowers. They are manufactured by the hydrochlorination of mycene at the conjugated double bonds when a copper catalyst is used (88,89). 

In this case the ylide was not isolated but allowed to react with ben2ophenone to give, after hydrolysis with hydrochloric acid, 1,1-diphenylethylene, diphenylacetaldehyde, and triphenylarsine (160). An excellent method for preparing arsonium ylides involves the reaction between a stable dia2o compound and triphenylarsine in the presence of a copper catalyst such as bis(acetylacetonato)copper(II) (161). Rather than a dia2o compound, an iodonium yhde can be used again a copper catalyst is necessary for an optimum yield of product. An example of the use of a dia2o compound is shown in the formulation of triphenyl arsonium 2,3,4-triphenylcyclopentadienyLide [29629-32-17, C H As ... 

Dutch State Mines (Stamicarbon). Vapor-phase, catalytic hydrogenation of phenol to cyclohexanone over palladium on alumina, Hcensed by Stamicarbon, the engineering subsidiary of DSM, gives a 95% yield at high conversion plus an additional 3% by dehydrogenation of coproduct cyclohexanol over a copper catalyst. Cyclohexane oxidation, an alternative route to cyclohexanone, is used in the United States and in Asia by DSM. A cyclohexane vapor-cloud explosion occurred in 1975 at a co-owned DSM plant in Flixborough, UK (12) the plant was rebuilt but later closed. In addition to the conventional Raschig process for hydroxylamine, DSM has developed a hydroxylamine phosphate—oxime (HPO) process for cyclohexanone oxime no by-product ammonium sulfate is produced. Catalytic ammonia oxidation is followed by absorption of NO in a buffered aqueous phosphoric acid... 

Work on the process for the production of these acids has continued in recent years. One patent discloses the use of 2eohte catalysts (34) for the synthesis of neopentanoic acid from isobutylene. The use of a copper catalyst in a strong acid, such as sulfuric acid, operating at lower pressures, has also been claimed (35). 

Although copper catalysts were known to be highly active for this reaction for many years, it was not until the late 1960s that gas purification processes for synthesis gas were introduced that would allow the commercial use of these catalysts, which require very low sulfur, chlorine, and phosphoms feed impurity levels to maintain catalyst activity. 

Dehydrochlorination of 1,1,2-trichloroethane at 500°C in the presence of a copper catalyst gives a different product, ie, cis- and /n7 j -l,2-dichloroethylene. Addition of small amounts of a chlorinating agent, such as chlorine, promotes radical dehydrochlorination in the gas phase through a disproportionation mechanism that results in loss of hydrogen chloride and formation of a double bond. The dehydrochlorination of 1,2-dichloroethane in the presence of chlorine, as shown in equations 19 and 20, is a typical example. 

The Dow Chemical Company in the mid-1920s developed two processes which consumed large quantities of chlorobenzene. In one process, chlorobenzene was hydrolyzed with ammonium hydroxide in the presence of a copper catalyst to produce aniline [62-53-3J. This process was used for more than 30 years. The other process hydrolyzed chlorobenzene with sodium hydroxide under high temperature and pressure conditions (4,5) to product phenol [108-95-2]. The LG. Earbenwerke in Germany independentiy developed an equivalent process and plants were built in several European countries after World War II. The ICI plant in England operated until its dosing in 1965. 

In the 1930s, the Raschig Co. in Germany developed a different chlorobenzene-phenol process in which steam with a calcium phosphate catalyst was used to hydrolyze chlorobenzene to produce phenol (qv) and HCl (6). The recovered HCl reacts with air and benzene over a copper catalyst (Deacon Catalyst) to produce chlorobenzene and water (7,8). In the United States, a similar process was developed by the BakeHte Division of Union Carbide Corp., which operated for many years. The Durez Co. Hcensed the Raschig process and built a plant in the United States which was later taken over by the Hooker Chemical Corp. who made significant process improvements. 

Many anthraquinone reactive and acid dyes are derived from bromamine acid. The bromine atom is replaced with appropriate amines in the presence of copper catalyst in water or water—alcohol mixtures in the presence of acid binding agents such as alkaU metal carbonate, bicarbonate, hydroxide, or acetate (Ullmaim condensation reaction). 

Yields depend on the reactivity of the amines and the choice of reaction conditions, including the choice of copper catalyst. Generally, the reactivity increases with increasing amine basicity. Thus, i7n7-toluidine (pTf = 5.1) reacts four times faster than aniline (pif = 4.7) (27). StericaHy hindered amines such as 3,5-di-amino-2,4,6-trimethylbenzenesulfonic acid react very slowly. 

The main by-products of the Ullmaim condensation are l-aniinoanthraquinone-2-sulfonic acid and l-amino-4-hydroxyanthraquinone-2-sulfonic acid. The choice of copper catalyst affects the selectivity of these by-products. Generally, metal copper powder or copper(I) salt catalyst has a greater reactivity than copper(Il) salts. However, they are likely to yield the reduced product (l-aniinoanthraquinone-2-sulfonic acid). The reaction mechanism has not been estabUshed. It is very difficult to clarify which oxidation state of copper functions as catalyst, since this reaction involves fast redox equiUbria where anthraquinone derivatives and copper compounds are concerned. Some evidence indicates that the catalyst is probably a copper(I) compound (28,29). 

Cl Reactive Blue 19 (9) is prepared by the reaction of bromamine acid (8) with y -aminophenyl-P-hydroxyethylsulfone [5246-57-1] (76) ia water ia the presence of an acid-hinding agent such as sodium bicarbonate and a copper catalyst (Ullmann condensation reaction) and subsequent esterification to form the sulfuric ester. 

There are two ways to produce acetaldehyde from ethanol oxidation and dehydrogenation. Oxidation of ethanol to acetaldehyde is carried out ia the vapor phase over a silver or copper catalyst (305). Conversion is slightly over 80% per pass at reaction temperatures of 450—500°C with air as an oxidant. Chloroplatinic acid selectively cataly2es the Uquid-phase oxidation of ethanol to acetaldehyde giving yields exceeding 95%. The reaction takes place ia the absence of free oxygen at 80°C and at atmospheric pressure (306). The kinetics of the vapor and Uquid-phase oxidation of ethanol have been described ia the Uterature (307,308). 

The reaction kinetics for the dehydrogenation of ethanol are also weU documented (309—312). The vapor-phase dehydrogenation of ethanol ia the presence of a chromium-activated copper catalyst at 280—340°C produces acetaldehyde ia a yield of 89% and a conversion of 75% per pass (313). Other catalysts used iaclude neodymium oxide and samarium hydroxide (314). 

Cyclization of the diazo compound (108) with a copper catalyst affords the clavulanic acid derivatives (110) and (111), possibly via rearrangement of the sulfur ylide (109) (80H(14)1999). Similar reactions have been reported in the recent literature (80H(14)1967, 81H(16)1305, 80TL31). 

From ethyl laurate by reduction with hydrogen under pressure with copper catalyst. Ger. pat. 552,888 [C. A. 26, 5573 (1932)]-... 

The copper catalyst may be prepared by the method of Brewster and Groening. ... 

This reaction is carried out in tall fluidized beds of high L/dt ratio. Pressures up to 200 kPa are used at temperatures around 300°C. The copper catalyst is deposited onto the surface of the silicon metal particles. The product is a vapor-phase material and the particulate silicon is gradually consumed. As the particle diameter decreases the minimum fluidization velocity decreases also. While the linear velocity decreases, the mass velocity of the fluid increases with conversion. Therefore, the leftover small particles with the copper catalyst and some debris leave the reactor at the top exit. 

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