DuPont adiponitrile process

The hydrocyanation of alkenes [1] has great potential in catalytic carbon-carbon bond-formation because the nitriles obtained can be converted into a variety of products [2]. Although the cyanation of aryl halides [3] and carbon-hetero double bonds (aldehydes, ketones, and imines) [4] is well studied, the hydrocyanation of alkenes has mainly focused on the DuPont adiponitrile process [5]. Adiponitrile is produced from butadiene in a three-step process via hydrocyanation, isomerization, and a second hydrocyanation step, as displayed in Figure 1. This process was developed in the 1970s with a monodentate phosphite-based zerovalent nickel catalyst [6],... 

Liquid/liquid extraction of the catalyst, as in the DuPont adiponitrile process, where the nickel complex is extracted out of the product mixture after the reaction, with a solvent (see Section 7.7). In Shell s SHOP process the soluble nickel catalyst is also extracted from the reaction medium with a highly polar solvent, and reused (see Section 7.4.1). 

The most outstanding example for the applieation of homogeneously catalyzed hydrocyanation is the DuPont adiponitrile process. About 75 % of the world s demand for adiponitrile is covered by hydrocyanation of butadiene in the presence of nickel(O) phosphite species. This process is discussed for the addition of HCN to dienes as an example, because in this case a well-founded set of data is available. Though it was Taylor and Swift who referred to hydrocyanation of butadiene for the first time [45], it was to Drinkard s credit that this principle was fully exploited for the development of the DuPont adiponitrile process [18]. The overall process is described as the addition of two equivalents of HCN to butadiene in the presence of a tetrakisphosphite-nickel(O) catalyst and a Lewis acid promoter. A phosphine-containing ligand system for the catalyst is not suitable, since addition of HCN to the tetrakisphosphine-nickel complex results in the formation of hydrogen and the non-aetive dicyano complex [67], In general the reaction can... 

The hydrocyanation of alkenes and dienes has similarly provided an exceptionally useful process for the conversion of simple feedstocks into more complex structures. [Caution Hydrogen cyanide is a highly toxic gas.] The process is best known as a key step in the DuPont adiponitrile process, which involves the dihydrocyanation of 1,3-butadiene (Scheme 3-95). The overall sequence first involves butadiene hydrocyanation to afford a mixture of 3-pentenenitrile and 2-methyl-3-butenenitrile. The unwanted branched isomer 2-methyl-3-butenenitrile is isomerized to 3-pentenenitrile under different conditions, and then 3-pentenenitrile is isomerized to 4-pentenenitrile in a subsequent nickel-catalyzed process in the presence of Lewis acidic additives. Finally, hydrocyanation of the remaining alkene generates the desired product adiponitrile, which serves as a precursor for nylon. A vast number of studies describing the optimization and mechanistic study of this process has appeared, and the interested reader is referred to the many excellent studies describing the details of this process. " ... 

Addition of HCN to unsaturated compounds is often the easiest and most economical method of making organonitnles. An early synthesis of acrylonitrile involved the addition of HCN to acetylene. The addition of HCN to aldehydes and ketones is readily accompHshed with simple base catalysis, as is the addition of HCN to activated olefins (Michael addition). However, the addition of HCN to unactivated olefins and the regioselective addition to dienes is best accompHshed with a transition-metal catalyst, as illustrated by DuPont s adiponitrile process (6—9). 

Pentenenitnles are produced as intermediates and by-products in DuPont s adiponitrile process. 3-Pentenenitrile [4635-87-4] is the principal product isolated from the isomerisation of 2-methyl-3-butenenitrile (see eq. 4). It is entirely used to make adiponitrile. i7j -2-Pentenenitrile [25899-50-7] is a by-product isolated from the second hydrocyanation step. Some physical properties are Hsted in Table 13. 

Pentenenitriles are produced as intermediates and by-products in DuPont s adiponitrile process. 3-Pentenenilrile is the principal product isolated from the isomerization of 2-mcthyl-3-butcnenitrilc. 

Methylglutaronitrile (2,3-dicyanobutane) [4553-62-2], MGN, is a by-product of DuPont s adiponitrile process. The oral LD5Q (rats) is 400 mg/kg (29). Some physical properties are listed in Table 12. 

DuPont s process for adiponitrile, used in the manufacture of Nylon from butadiene and HCN, contains a step in which a branched chain (2-methyl-3-butenenitrile) is converted to a straight chain olefin... 

The hydrocyanation of butadienes is the basis of DuPont s process for the production of adiponitrile [hexanedinitrile (19), Scheme llj.l l The first step of the process involves hydrocyanation of huta-1,3-diene to produce an isomeric mixture of pentenenitriles. In a second step, nickel-catalyzed double-bond isomerization occurs to produce pent-4-eneni-trile followed by alkene hydrocyanation to produce adiponitrile (19). The details of the al-kene hydrocyanation reaction are discussed in further detail in Section 1.1.4.5. 

Adiponitrile is made commercially by several different processes utilizing different feedstocks. The original process, utilizing adipic acid (qv) as a feedstock, was first commercialized by DuPont in the late 1930s and was the basis for a number of adiponitrile plants. However, the adipic acid process was abandoned by DuPont in favor of two processes based on butadiene (qv). During the 1960s, Monsanto and Asahi developed routes to adiponitrile by the electrodimerization of acrylonitrile (qv). 

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. 

Hydrocyanation represents a reaction of considerable economic importance largely due to the value of the DuPont process involving HCN addition to butadiene to afford adiponitrile.61,62 The mechanism is well known, and involves (i) oxidative addition of H-CN to a coordinatively unsaturated metal complex, (ii) coordination of an alkene to the H-M-CN species, (iii) migratory... 

Isomerisation is also an important step in the DuPont process for making adiponitrile (Chapter 11) in which internal pentenenitriles must be converted to the terminal alkene. The catalyst is the same as that used for the hydrocyanation reaction, namely nickel(II) hydrides containing phosphite ligands. 

The transition metal catalysed addition of HCN to alkenes is potentially a very useful reaction in organic synthesis and it certainly would have been more widely applied in the laboratory if its attraction were not largely offset by the toxicity of HCN. Industrially the difficulties can be minimised to an acceptable level and we are not aware of major accidents. DuPont has commercialised the addition of HCN to butadiene for the production of adiponitrile [ADN, NC(CH2)4CN], a precursor to 1,6-hexanediamine, one of the components of 6,6-nylon and polyurethanes (after reaction with diisocyanates). The details of the hydrocyanation process have not been released, but a substantial amount of related basic chemistry has been published. The development of the ligand parameters % and 0 by Tolman formed part of the basic studies carried out in the Du Pont labs related to the ADN process [1],... 

Byproducts of large industrial-scale processes are valorized for instance, in the DuPont process for adiponitrile, the byproduct a-methylglutaronitrile is upgraded to p-picoline and further to niacinamide. 

Among other nonaddition processes, adiponitrile may be manufactured by the direct hydrocyanation of 1,3-butadiene (DuPont process).169 172,187 196 A homogeneous Ni(0) complex catalyzes both steps of addition of HCN to the olefinic bonds (Scheme 6.4). The isomeric monocyano butenes (20 and 21) are first formed in a ratio of approximately 1 2. All subsequent steps, the isomerization of 20 to the desired 1,4-addition product (21), a further isomerization step (double-bond migration), and the addition of the second molecule of HCN, are promoted by Lewis acids (ZnCl2 or SnCl2). Without Lewis acids the last step is much slower then the addition of the first molecule of HCN. Reaction temperatures below 150°C are employed. 

Hydrogen cyanide can be added across olefins in the presence of Ni, Co, or Pd complexes (Scheme 56) (123). Conversion of butadiene to adiponitrile is a commercial process at DuPont Co. The reaction appears to occur via oxidative addition of hydrogen cyanide to a low-valence metal, olefin insertion to the metal-hydrogen bond, and reductive elimination of the nitrile product. The overall reaction proceeds with cis... 

Adiponitrile is made commercially by several different processes utilizing different feedstocks. The reaction of adipic acid with ammonia in either liquid or vapor phase produces adipamide as an intermediate, which is subsequently dehydrated to adiponitrile. The most widely used catalysts are based on phosphorus-containing compounds. Vapor-phase processes involve the use of fixed catalyst beds whereas, in liquid-gas processes, the catalyst is added to the feed. DuPont currently practices a buiadiene-to-adiponitdle route based on direct addition of HCN to butadiene. 

Similarly, DuPont employs a nitrile hydratase (as whole cells of P. chlororaphis B23) to convert adiponitrile to 5-cyanovaleramide, a herbicide intermediate [122]. In the Lonza nitrotinamide (vitamin B6) process [123] the final step (Fig. 1.42) involves the nitrile hydratase (whole cells of Rh. rhodocrous) catalysed hydration of 3-cyanopyridine. Here again the very high product purity is a major advantage as conventional chemical hydrolysis affords a product contaminated with nicotinic acid, which requires expensive purification to meet the specifications of this vitamin. 

Alternatively, caprolactam can be produced from butadiene, via homogeneous nickel-catalysed addition of HCN (DuPont process) followed by selective catalytic hydrogenation of the adiponitrile product to the amino nitrile and vapor phase hydration over an alumina catalyst (Rhodia process) as shown in Fig. 1.49 [137]. 

Adiponitrile is an important intermediate for the manufacture of hexa-methylenediamine (Section 3.4), which, together with adipic acid, is used to produce nylon 6,6. Although adiponitrile is still largely produced from adipic acid, obtained by vapour phase oxidation of cyclohexane (Section 2.2), it is also manufactured from butadiene by DuPont on the basis of the process first patented in 1970 (Equations 24-26). Conversion is 99% with >90% selectivity to adiponitrile. 

Hydrocyanation is the addition of HCN across a C=C bond. In 1971, Dupont reported a new process that added two equivalents of HCN, in an anti-Markovnikov manner, to 1,3-butadiene to yield adiponitrile (equation 9.38).96 The process is catalyzed overall by a Ni(0) triarylphosphite complex. 

---