Oxidation cumene

The cumene oxidation route is the lea ding commercial process of synthetic phenol production, accounting for more than 95% of phenol produced in the world. The remainder of synthetic phenol is produced by the toluene oxidation route via benzoic acid. Other processes including benzene via cyclohexane, benzene sulfonation, benzene chlorination, and benzene oxychl orin ation have also been used in the manufacture of phenol. A Hst of U.S. phenol production plants and their estimated capacities in 1994 are shown in Table 2, and worldwide plants and capacities are shown in Table 3. 

Gumylphenol. -Cumylphenol (PGP) or 4-(1-methyl-l-phenylethyl)phenol is produced by the alkylation of phenol with a-methylstyrene under acid catalysis. a-Methylstyrene is a by-product from the production of phenol via the cumene oxidation process. The principal by-products from the production of 4-cumylphenol result from the dimerization and intramolecular alkylation of a-methylstyrene to yield substituted indanes. 4-Cumylphenol [599-64-4] is purified by either fractional distillation or crystallization from a suitable solvent. Purification by crystallization results in the easy separation of the substituted indanes from the product and yields a soHd material which is packaged in plastic or paper bags (20 kg net weight). Purification of 4-cumylphenol by fractional distillation yields a product which is almost totally free of any dicumylphenol. The molten product resulting from purification by distillation can be flaked to yield a soHd form however, the soHd form of 4-cumylphenol sinters severely over time. PGP is best stored and transported as a molten material. 

Chemical. The use of isopropyl alcohol as a feedstock for the production of acetone is expected to remain stable, as the dominant process for acetone is cumene oxidation. Isopropyl alcohol is also consumed in the production of other chemicals such as methyl isobutyl ketone, methyl isobutyl carbinol [108-11-2] isopropjlamine, and isopropyl acetate. The use of diisopropyl ether as a fuel ether may become a significant oudet for isopropyl alcohol. 

More than 95% of the cumene produced is used as feedstock for the production of phenol (qv) and its coproduct acetone (qv). The cumene oxidation process for phenol synthesis has been growing in popularity since the 1960s and is prominent today. The first step of this process is the formation of cumene hydroperoxide [80-15-9]. The hydroperoxide is then selectively cleaved to phenol [108-95-2] and acetone [67-64-1/ in an acidic environment (21). 

The acetone supply is strongly influenced by the production of phenol, and so the small difference between total demand and the acetone suppHed by the cumene oxidation process is made up from other sources. The largest use for acetone is in solvents although increasing amounts ate used to make bisphenol A [80-05-7] and methyl methacrylate [80-62-6]. a-Methylstyrene [98-83-9] is produced in controlled quantities from the cleavage of cumene hydroperoxide, or it can be made directly by the dehydrogenation of cumene. About 2% of the cumene produced in 1987 went to a-methylstyrene manufacture for use in poly (a-methylstyrene) and as an ingredient that imparts heat-resistant quaUties to polystyrene plastics. 

Phenol is the starting material for numerous intermediates and finished products. About 90% of the worldwide production of phenol is by Hock process (cumene oxidation process) and the rest by toluene oxidation process. Both the commercial processes for phenol production are multi step processes and thereby inherently unclean [1]. Therefore, there is need for a cleaner production method for phenol, which is economically and environmentally viable. There is great interest amongst researchers to develop a new method for the synthesis of phenol in a one step process [2]. Activated carbon materials, which have large surface areas, have been used as adsorbents, catalysts and catalyst supports [3,4], Activated carbons also have favorable hydrophobicity/ hydrophilicity, which make them suitable for the benzene hydroxylation. Transition metals have been widely used as catalytically active materials for the oxidation/hydroxylation of various aromatic compounds. 

Oxidation of organic compounds by dioxygen is a phenomenon of exceptional importance in nature, technology, and life. The liquid-phase oxidation of hydrocarbons forms the basis of several efficient technological synthetic processes such as the production of phenol via cumene oxidation, cyclohexanone from cyclohexane, styrene oxide from ethylbenzene, etc. The intensive development of oxidative petrochemical processes was observed in 1950-1970. Free radicals participate in the oxidation of organic compounds. Oxidation occurs very often as a chain reaction. Hydroperoxides are formed as intermediates and accelerate oxidation. The chemistry of the liquid-phase oxidation of organic compounds is closely interwoven with free radical chemistry, chemistry of peroxides, kinetics of chain reactions, and polymer chemistry. 

The initiating action of ozone on hydrocarbon oxidation was demonstrated in the case of oxidation of paraffin wax [110] and isodecane [111]. The results of these experiments were described in a monograph [109]. The detailed kinetic study of cyclohexane and cumene oxidation by a mixture of dioxygen and ozone was performed by Komissarov [112]. Ozone is known to be a very active oxidizing agent [113 116]. Ozone reacts with C—H bonds of hydrocarbons and other organic compounds with free radical formation, which was proved by different experimental methods. 

Hock and Kropf [253] studied cumene oxidation catalyzed by Pb02. They proposed that Pb02 decomposed cumyl hydroperoxide (ROOH) into free radicals (R0 , R02 ). The free radicals started the chain oxidation of cumene in the liquid phase. Lead dioxide introduced into cumene was found to be reduced to lead oxide. The reduction product lead oxide was found to possess catalytic activity. The following tentative mechanism was proposed. 

The increase in the amount of catalyst introduced in oxidized cumene (353 K) increases the oxidation rate, decreases the amount of the formed hydroperoxide, and increases the yield of the products of hydroperoxide decomposition methylphenyl ethanol and acetophenone. Similar mechanism was proposed for catalysis by copper phthalocyanine in cumene oxidation [254],... 

Free radicals were found to be generated on the catalyst surface in hydrocarbon oxidation in the absence of hydroperoxide. The activation of absorbed dioxygen was supposed to be the source of radicals [255], The catalytic action of the silver surface on cumene oxidation was supposed to be the result of activation of sorbed dioxygen [265]. 

The effect of jumping of the maximal hydroperoxide concentration after the introduction of hydrogen peroxide is caused by the following processes. The cumyl hydroperoxide formed during the cumene oxidation is hydrolyzed slowly to produce phenol. The concentration of phenol increases in time and phenol retards the oxidation. The concentration of hydroperoxide achieves its maximum when the rate of cumene oxidation inhibited by phenol becomes equal to the rate of hydroperoxide decomposition. The lower the rate of oxidation the higher the phenol concentration. Hydrogen peroxide efficiently oxidizes phenol, which was shown in special experiments [8]. Therefore, the introduction of hydrogen peroxide accelerates cumene oxidation and increases the yield of hydroperoxide. 

The experiments on emulsion cumene oxidation with AIBN as initiator proved that oxidation proceeds via the chain mechanism inside hydrocarbon drops [17]. The presence of an aqueous phase and surfactants compounds does not change the rate constants of chain propagation and termination the ratio (fcp(2fct)-1/2 = const in homogeneous and emulsion oxidation (see Chapter 2). Experiments on emulsion cumene oxidation with cumyl hydroperoxide as the single initiator evidenced that the main reason for acceleration of emulsion oxidation versus homogeneous oxidation is the rapid decomposition of hydroperoxide on the surface of the hydrocarbon and water drops. Therefore, the increase in the aqueous phase and introduction of surfactants accelerate cumene oxidation. 

Phenol formed in the system due to acid-catalyzed decomposition of hydroperoxide retards the cumene oxidation. The aqueous phase withdraws phenol from the hydrocarbon phase. This is the reason why the emulsion oxidation of cumene helps to increase the yield of hydroperoxide. The addition of hydrogen peroxide into the system helps to increase the yield of hydroperoxide. 

Cumox [Cumene oxidation] A process for making acetone and phenol by oxidizing cumene, based on the Hock process. This version was further developed and licensed by UOR Three plants were operating in 1986. UOP now licenses the Allied-UOP Phenol process, which combines the best features of Cumox and a related process developed by the Allied Chemical Corporation. 

Benezene + propene => cumene oxidation/acid => phenol + acetone... 

In 1952, a techriological breakthrough was found the cumene oxidation route. It was much cheaper, and it quickly proliferated. It is now the primary route, accounting for almost all of U.S. production ... 

There is a compelling reason to integrate PMMA and phenol-formaldehyde because the monomers phenol and acetone are both made from cumene oxidation (previous chapter). Therefore, one makes one mole of phenol for every mole of acetone, and a producer would have to sell one of these monomers if he did not have an integrated process to produce both polymers or some other products. 

The CLD methods for HPLC using isoluminol (190) with microperoxidase catalysis, for determination of lipid hydroperoxides in clinical fluids, have been reviewed. Determination of phospholipids hydroperoxides by luminol (124) CL has been reviewed . A fast RP-HPLC method (retention times 1 to 2 min) for determination of hydroperoxides and other peroxide compounds includes UVD, which is not always effective, and CLD, attained on injection of luminol (124), the CL reagent (Scheme 3), hemin (75a), a catalyst, and NaOH to raise the pH of the solution. A FLD cell may act as CLD cell if the excitation source is turned off. The selectivity of CLD is of advantage over UVD in industrial analysis thus, for example, UVD of a sample from a phenol production line based on cumene oxidation (equation 13) shows peaks for cumyl hydroperoxide (27), unreacted cumene, cumyl alcohol and acetophenone, whereas CLD shows only the 27 peak. The... 

Fermentation and distillation techniques for acetone production were replaced starting in the 1950s with the cumene oxidation process (Figure 2.1). In this process, cumene is oxidized to cumene hydroperoxide, which is then decomposed using acid to acetone and phenol. This is the primary method used to produce phenol, and acetone is produced as a co-product in the process, with a yield of about 0.6 1 of acetone to phenol. 

Phenol and Acetone. Cumene oxidation is presently the only commercially significant route for the production of phenol.927,971-973 In a two-step process974,975 cumene is first oxidized in an autocatalytic, free-radical reaction to cumene hydroperoxide976 [110, Eq. (9.175)] ... 

A substantial amount of a-methylstyrene is produced during the cumene oxidation step in the production of phenol and acetone. Slurry processes applying Raney nickel and a fixed-bed operation with palladium developed by Engelhard326,341 are used to hydrogenate and recycle a-methylstyrene to produce more phenol and acetone. 

Traylor and Russell (30) have shown recently that similar reactions for the cumyloxy radical are important in cumene oxidation at 60 °C., and Hendry (12) has provided some quantitative data. At low concentrations of hydrocarbon, Reaction 9 is favored over Reaction 7 (propagation by tert-BuO ), and significant numbers of methyl radicals are formed and converted to Me02 radicals. Chain termination thus shifts from the slow termination by 2 tert-Bu02 (Reaction 6) to Reaction 10, which has a rate constant several hundredfold larger (21). The apparent order of the oxidation in isobutane is then 3/2 a similar relation applies to gas-phase oxidations and is discussed there. 

Cumene oxidized relatively slowly, at about 1/13 the rate of p-xylene. This was not caused by the formation of phenol, as might be expected by an acid-catalyzed rearrangement of cumene hydroperoxide. No phenol or product clearly derived from phenol, as by radical attack or by oxidation to a quinone, was detected at any time in the reaction mixture. The two major products were a-methylstyrene and 2-phenylpropylene oxide their concentrations increased with time. The group at Shell also observed the formation of a-methylstyrene and 2-phenylpropylene oxide among the products of cumene oxidation in butyric acid at 140°C. with cobalt and manganese catalysts (30). 

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