Copper chloride Wacker process

Another attractive commercial route to MEK is via direct oxidation of / -butenes (34—39) in a reaction analogous to the Wacker-Hoechst process for acetaldehyde production via ethylene oxidation. In the Wacker-Hoechst process the oxidation of olefins is conducted in an aqueous solution containing palladium and copper chlorides. However, unlike acetaldehyde production, / -butene oxidation has not proved commercially successflil because chlorinated butanones and butyraldehyde by-products form which both reduce yields and compHcate product purification, and also because titanium-lined equipment is required to withstand chloride corrosion. 

The Wacker process uses an aqueous solution of palladium(II) chloride, copper(II) chloride catalyst system. 

With the growing prominence of the petrochemicals industry this technology was, in turn, replaced by direct air oxidation of naphtha or butane. Both these processes have low selectivities but the naphtha route is still used since it is a valuable source of the co-products, formic and propanoic acid. The Wacker process, which uses ethylene as a feedstock for palladium/copper chloride catalysed synthesis of acetaldehyde, for which it is still widely used (Box 9.1), competed with the direct oxidation routes for a number of years. This process, however, produced undesirable amounts of chlorinated and oxychlorinated by-products, which required separation and disposal. 

Hoechst-Uhde (2) A variation of the Wacker process, which makes vinyl acetate from ethylene and acetic acid. The catalyst is an aqueous solution of palladium and copper chlorides. 

Wacker (1) A general process for oxidizing aliphatic hydrocarbons to aldehydes or ketones by the use of oxygen, catalyzed by an aqueous solution of mixed palladium and copper chlorides. Ethylene is thus oxidized to acetaldehyde. If the reaction is conducted in acetic acid, the product is vinyl acetate. The process can be operated with the catalyst in solution, or with the catalyst deposited on a support such as activated caibon. There has been a considerable amount of fundamental research on the reaction mechanism, which is believed to proceed by alternate oxidation and reduction of the palladium ... 

The more expedient, direct catalytic oxidation route to acetone was developed in Germany in the 1960s. If you had been in charge of building the acetone business from scratch, you d probably not have built any IPA-to-acetone plants if you had known about the Wacker process. It s a catalytic oxidation of propylene at 200—250°F and 125—200 psi over palladium chloride with a cupric (copper) chloride promoter. The yields are 91-94%. The hardware for the Wacker process is probably less than for the combined IPA/acetone plants. But once the latter plants were built, the economies of the Wacker process were not sufficient to shut them down and start all over. So the new technology never took hold in the United States. 

The previous examples involve reduction (hydrogenation) of organic molecules, but transition metal complexes can also catalyze oxidation. For example, the Wacker process, which has been widely used to convert ethylene to acetaldehyde, depends on catalysis by palladium(II) in the presence of copper(II) in aqueous HC1. The role of the copper chloride is to provide a means of using air to reoxidize the palladium to palladium(II). Once again, Zeise-type coordination of the ethylene to the metal center is believed to be involved ... 

The oxidation of olefins to aldehydes using a palladium chloride-copper(II) chloride catalyst, the Wacker Process, is a well-established industrial reaction. The mechanism of this reaction has not been established in detail, but it most probably involves a cr-7r rearrangement... 

Wacker Process The Wacker process is primarily used to produce acetaldehyde from the oxidation of ethylene by palladium(II)Copper(II) chloride solution. 

To overcome the problems encountered in the homogeneous Wacker oxidation of higher alkenes several attempts have been undertaken to develop a gas-phase version of the process. The first heterogeneous catalysts were prepared by the deposition of palladium chloride and copper chloride on support materials, such as zeolite Y [2,3] or active carbon [4]. However, these catalysts all suffered from rapid deactivation. Other authors applied other redox components such as vanadium pentoxide [5,6] or p-benzoquinone [7]. The best results have been achieved with catalysts based on palladium salts deposited on a monolayer of vanadium oxide spread out over a high surface area support material, such as y-alumina [8]. Van der Heide showed that with catalysts consisting of H2PdCU deposited on a monolayer vanadium oxide supported on y-alumina, ethene as well as 1-butene and styrene... 

The invention of the Wacker process was a triumph of common sense. It had been known since 1894 that ethylene is oxidized to acetaldehyde by palladium chloride in a stoichiometric reaction (Figure 27). However, it was not until 1956 that this reaction was combined with the known reoxidation reactions of palladium by copper and, in turn of copper by oxygen. The total process developed by Wacker and Hoechst between 1957 and 1959 can be depicted as an exothermic catalytic direct oxidation to yield acetaldehyde. 

Copper chloride complexes can be used as catalysts in a number of organic reactions. Examples include the Wacker process, which is the oxidization of ethylene to acetaldehyde by oxygen and aqueous Cu and Pd precatalysts (or, alternatively using iron catalysts) plus the synthesis of acrylonitrile from acetylene and hydrogen cyanide using CuCl. Cuprous chloride has also been used as a desulfiuizmg and... 

Oxidations. Various primary and secondary alcohols are oxidized to give aldehydes and ketones by PdfOAcl -O -pyridine in the presence of 3A molecular sieves. Modified Wacker processes which obviate copper and chloride employ the Pd(OAcl -02 system and a water-soluble 1, 10-phenanthroline ligand or polypyrrole as redox-active ligand.- ... 

Direct oxidation of n-butenes by the Wacker/Hoechst process, in the presence of palladium and copper chlorides, around 110°C, at 13.10 Pa absolute, with a yield of 85 to 88 molar per cent (see Section 103.3). 

Lead tetraacetate initiates a similar type of oxidation with terminal alkenes, in the presence of acid, to give an aldehyde hy selective oxidation of the terminal carhon. l Ajj example is the conversion of styrene to phenylacetaldehyde in 98% yield. Palladium chloride (PdCl2) reacts with terminal alkenes, in the presence of oxygen and copper salts, to give a methyl ketone (this reaction is called the Wacker process and is discussed in sec. 12.6.A). It is more useful than the LTA oxidation. Oxidation of terminal alkenes with LTA leads to the aldehyde, whereas oxidation with PdCl2 leads to the methyl ketone. The PdCl2 oxidation is illustrated hy conversion of 402 to 403 in 77% yield, in Ikegami s synthesis of coriolin. ... 

The conversion of ethanol to acetaldehyde can be effected by dehydrogenation over copper at 250-300°C or by (partially) oxidative dehydrogenation over silver at 450-500°C. However, this route was largely superseded by the Wacker process for the direct oxidation of ethylene in aqueous solutions of Pd/Cu chlorides. Rhone-Poulenc and BP have also patented potential processes for the homologation of methanol to acetaldehyde ... 

Scheme 9.133. A representation of the palladium(II) chloride-catalyzed oxidation of ethene (ethylene, CH2=CH2) to ethanal (acetaldehyde, CH3CHO), the Wacker process. Generally, a copper(II) catalyst (not shown) is also employed to effect the reoxidation of the palladium. Interestingly, it is probable that a 1,2-hydride shift occurs as the palladium is lost (rather than elimination to the corresponding enol and then rearrangement to the aldehyde) since nse of H20 (denterinm oxide) in place of its proton analogue (water, HaO) yields aldehyde in which there is no denterinm ( ) incorporation.

The process of choice for acetaldehyde production is ethylene oxidation according to the so-called Wacker-Hoechst process [route (c) in Topic 5.3.2]. The reaction proceeds by homogeneous catalysis in an aqueous solution of HQ in the presence of palladium and copper chloride complexes. The oxidation of ethylene occurs in a stoichiometric reaction of PdQ2 with ethylene and water that affords acetaldehyde, metallic palladium (oxidation state 0), and HQ [step (a) in Scheme 5.3.5). The elemental Pd is reoxidized in the process by Cu(II) chloride that converts in this step into Cu(I) chloride [step (b) in Scheme 5.3.5). The Cu(II) chloride is regenerated by oxidation with air to finally close the catalytic cycle [step (c) in Scheme 5.3.5). 

Wacker process 1. A catalytic process used to oxidize aliphatic hydrocarbons such as ethylene to ethanol, aldehydes, and ketones using oxygen. The process uses an aqueous solution of mixed palladium and copper chlorides either in solution or on a support of activated carbon through which the ethylene is bubbled. The process was invented in 1957 and is named after the chemical company. 2. A process used for the production of sodium salicylate through the reaction of sodium phenate and carbon dioxide. 

The palladium(II)-catalyzed olefin carbonylation reaction was first reported more than 30 years ago in studies by Stille and co-workers and James et al. The reaction of carbon monoxide with cis- and tra 5-but-2-ene in methanol in the presence of palladium(II)-chloride and copper(II)-chloride yielded threo- and eryt/zro-3-methoxy-2-methyl-butanoate, respectively. The transformation that was based on the well-known Wacker process for oxidation of ethylene into acetaldehyde in water " is now broadly defined as the Pd(II)-catalyzed oxycarbonylation of the unsaturated carbon-carbon bonds. This domino reaction includes oxypalladation of alkenes, migratory insertion of carbon monoxide, and alkoxylation. Since the development of this process, several transformations mediated by palladium(II) compounds have been described. The direct oxidative bisfunctionalization of alkenes represents a powerful transformation in the field of chemical synthesis. Palladium(II)-promoted carbonylation of alkenes in the presence of water/alcohol may lead to alkyl carboxylic acids (hydrocarboxylation), diesters [bis(aIkoxycarbonyla-tion)], (3-alkoxy carboxylic acids (alkoxy-carboxylation), or (3-alkoxy esters (alkoxy-carbonylation or alkoxy-alkoxy-carbonylation). Particularly attractive features of these multitransformation processes include the following ... 

The metal-catalysed autoxidation of alkenes to produce ketones (Wacker reaction) is promoted by the presence of quaternary ammonium salts [14]. For example, using copper(II) chloride and palladium(II) chloride in benzene in the presence of cetyltrimethylammonium bromide, 1-decene is converted into 2-decanone (73%), 1,7-octadiene into 2,7-octadione (77%) and vinylcyclohexane into cyclo-hexylethanone (22%). Benzyltriethylammonium chloride and tetra-n-butylammo-nium hydrogen sulphate are ineffective catalysts. It has been suggested that the process is not micellar, although the catalysts have the characteristics of those which produce micelles. The Wacker reaction is also catalysed by rhodium and ruthenium salts in the presence of a quaternary ammonium salt. Generally, however, the yields are lower than those obtained using the palladium catalyst and, frequently, several oxidation products are obtained from each reaction [15]. 

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