Ethylbenzene decomposition

Sales demand for acetophenone is largely satisfied through distikative by-product recovery from residues produced in the Hock process for phenol (qv) manufacture. Acetophenone is produced in the Hock process by decomposition of cumene hydroperoxide. A more selective synthesis of acetophenone, by cleavage of cumene hydroperoxide over a cupric catalyst, has been patented (341). Acetophenone can also be produced by oxidizing the methylphenylcarbinol intermediate which is formed in styrene (qv) production processes using ethylbenzene oxidation, such as the ARCO and Halcon process and older technologies (342,343). 

Ethylbenzene Hydroperoxide Process. Figure 4 shows the process flow sheet for production of propylene oxide and styrene via the use of ethylbenzene hydroperoxide (EBHP). Liquid-phase oxidation of ethylbenzene with air or oxygen occurs at 206—275 kPa (30—40 psia) and 140—150°C, and 2—2.5 h are required for a 10—15% conversion to the hydroperoxide. Recycle of an inert gas, such as nitrogen, is used to control reactor temperature. Impurities ia the ethylbenzene, such as water, are controlled to minimize decomposition of the hydroperoxide product and are sometimes added to enhance product formation. Selectivity to by-products include 8—10% acetophenone, 5—7% 1-phenylethanol, and <1% organic acids. EBHP is concentrated to 30—35% by distillation. The overhead ethylbenzene is recycled back to the oxidation reactor (170—172). 

Future Methods. A by-product stream containing 60—80% PEA can be obtained from the catalytic air oxidation of ethylbenzene [100-41-4] (100). Perfumery-grade material can be isolated from this stream by complexing the PEA with a metal haUde (such as CaCl2), separation of the adduct, and thermal decomposition followed by distillation. 

The reaction scheme is rather complex also in the case of the oxidation of o-xylene (41a, 87a), of the oxidative dehydrogenation of n-butenes over bismuth-molybdenum catalyst (87b), or of ethylbenzene on aluminum oxide catalysts (87c), in the hydrogenolysis of glucose (87d) over Ni-kieselguhr or of n-butane on a nickel on silica catalyst (87e), and in the hydrogenation of succinimide in isopropyl alcohol on Ni-Al2Oa catalyst (87f) or of acetophenone on Rh-Al203 catalyst (87g). Decomposition of n-and sec-butyl acetates on synthetic zeolites accompanied by the isomerization of the formed butenes has also been the subject of a kinetic study (87h). 

The reaction of olefin epoxidation by peracids was discovered by Prilezhaev [235]. The first observation concerning catalytic olefin epoxidation was made in 1950 by Hawkins [236]. He discovered oxide formation from cyclohexene and 1-octane during the decomposition of cumyl hydroperoxide in the medium of these hydrocarbons in the presence of vanadium pentaoxide. From 1963 to 1965, the Halcon Co. developed and patented the process of preparation of propylene oxide and styrene from propylene and ethylbenzene in which the key stage is the catalytic epoxidation of propylene by ethylbenzene hydroperoxide [237,238]. In 1965, Indictor and Brill [239] published studies on the epoxidation of several olefins by 1,1-dimethylethyl hydroperoxide catalyzed by acetylacetonates of several metals. They observed the high yield of oxide (close to 100% with respect to hydroperoxide) for catalysis by molybdenum, vanadium, and chromium acetylacetonates. The low yield of oxide (15-28%) was observed in the case of catalysis by manganese, cobalt, iron, and copper acetylacetonates. The further studies showed that molybdenum, vanadium, and... 

The active alkoxyl radicals formed by this reaction start new chains. Apparently, the hydroperoxide group penetrates in the polar layer of the micelle and reacts with the bromide anion. The formed hydroxyl ion remains in the aqueous phase, and the MePhCHO radical diffuses into the hydrocarbon phase and reacts with ethylbenzene. The inverse emulsion of CTAB accelerates the decay of hydroperoxide MePhCHOOH. The decomposition of hydroperoxide occurs with the rate constant k = 7.2 x 1011 exp(-91.0/R7) L mol-1 s-1 (T = 323-353 K, CTAB, ethylbenzene [28]). The decay of hydroperoxide occurs more rapidly in an 02 atmosphere, than in an N2 atmosphere. 

The reverse emulsion stabilized by sodium dodecylsulfate (SDS, R0S03 Na+) retards the autoxidation of dodecane [24] and ethylbenzene [21,26,27]. The basis for this influence lies in the catalytic decomposition of hydroperoxides via the heterolytic mechanism. The decay of hydroperoxides under the action of SDS reverse micelles produces olefins with a yield of 24% (T=413 K, 0.02mol L 1 SDS, dodecane, [ROOH]0 = 0.08 mol L 1) [27], The thermal decay gives olefins in negligible amounts. The decay of hydroperoxides apparently occurs in the ionic layer of a micelle. Probably, it proceeds via the reaction of nucleophilic substitution in the polar layer of a micelle. 

The reverse micelles stabilized by SDS retard the autoxidation of ethylbenzene [27]. It was proved that the SDS micelles catalyze hydroperoxide decomposition without the formation of free radicals. The introduction of cyclohexanol and cyclohexanone in the system decreases the rate of hydroperoxide decay (ethylbenzene, 363 K, [SDS] = 10 3mol L [cyclohexanol] =0.03 mol L-1, and [cyclohexanone] = 0.01 mol L 1 [27]). Such an effect proves that the decay of MePhCHOOH proceeds in the layer of polar molecules surrounding the micelle. The addition of alcohol or ketone lowers the hydroperoxide concentration in such a layer and, therefore, retards hydroperoxide decomposition. The surfactant AOT apparently creates such a layer around water moleculesthat is very thick and creates difficulties for the penetration of hydroperoxide molecules close to polar water. The phenomenology of micellar catalysis is close to that of heterogeneous catalysis and inhibition (see Chapters 10 and 20). 

The resulting products, such as sulfenic acid or sulfur dioxide, are reactive and induce an acid-catalyzed breakdown of hydroperoxides. The important role of intermediate molecular sulfur has been reported [68-72]. Zinc (or other metal) forms a precipitate composed of ZnO and ZnS04. The decomposition of ROOH by dialkyl thiophosphates is an autocata-lytic process. The interaction of ROOH with zinc dialkyl thiophosphate gives rise to free radicals, due to which this reaction accelerates oxidation of hydrocarbons, excites CL during oxidation of ethylbenzene, and intensifies the consumption of acceptors, e.g., stable nitroxyl radicals [68], The induction period is often absent because of the rapid formation of intermediates, and the kinetics of decomposition is described by a simple bimolecular kinetic equation... 

Fig. 4. Arrhenius plots for the pressure-dependent flow system decomposition of dimethyl mercury. 1, Gowenlock, Polanyi and Warhurst (7 torr C02+3 torr toluene), Kominar and Price (4.4 torr toluene) 2, Price and Trotman-Dickenson (16 torr toluene, rate coefficients corrected for methyl radicals found as ethylbenzene) 3, Krech and Price (16 torr benzene). O, Lossing and Tickner (6-20 torr helium).

Only a few secondary /3-deuterium KIEs have been measured for homolytic reactions and the mechanistic utility of these, invariably small, KIEs is limited. The first secondary /3-deuterium KIE for a radical reaction was published by Seltzer and Hamilton in 1966. They found a small (kH/k0)p = 1.052 (= 1.017 per D) for the thermal decomposition of the azo-bis(l-phenylethane) (reaction (40)) at 105°C in ethylbenzene and concluded that it was due to hyperconjugation... 

A high carbon monoxide pressure ( 5 atmos.) favours the formation of the butane. Possible mechanisms for its formation include homolytic cleavage of the benzyl-cobalt tetracarbonyl complex and recombination of the radicals to generate 2,3-diphenylbutane and dicobalt octacarbonyl, or a base-catalysed decomposition of the benzylcobalt tetracarbonyl complex (Scheme 8.4). The ethylbenzene and styrene could arise from the phenylethyl radical, or from the n-styrene hydridocobalt tricarbonyl complex. 

By-products formed during their preparation (e.g., ethylbenzene and divinyl-benzenes in styrene acetaldehyde in vinyl acetate) added stabilizers (inhibitors) autoxidation and decomposition products of the monomers (e.g., perox-... 

The induction period in the oxidation of ethylbenzene catalyzed by cobalt and sodium bromide in the presence of 2,6-di-fert-butyl-p-cresol indicates that the direct initiation is negligible compared with the rate of initiation by the cobalt-catalyzed decomposition of hydroperoxide. 

An alternative procedure is to convert the carbonyl compound into the toluene-p-sulphonylhydrazone,12 followed by reduction with either sodium borohydride in acetic acid,13 or with catecholborane, followed by decomposition of the intermediate with sodium acetate or tetrabutylammonium acetate.14 The former method is illustrated by the conversion of undecan-6-one into undecane (Expt 5.6), and the latter by the conversion of acetophenone into ethylbenzene (Expt 6.4, Method B). A feature of these methods is that with a, / -unsaturated ketones, migration of the carbon-carbon multiple bond occurs thus the tosylhydrazone of isophorone gives 3,3,5-trimethylcyclohex-l-ene, and the tosylhydrazone of oct-3-yn-2-one gives octa-2,3-diene. 

An alternative milder procedure is the reduction of the corresponding toluene-p-sulphonylhydrazones with catecholborane, followed by decomposition of the intermediate with sodium acetate in the presence of dimethyl sulphoxide, or with tetrabutylammonium acetate.1 These methods, which do not have the disadvantages of the Clemmensen reduction, are illustrated by the preparation of ethylbenzene from acetophenone (Expt 6.4, Methods A and B). Outline mechanisms for these reactions are given below. 

Generally, the issue of whether a truly solid Cr catalyst has been created for the aforementioned reactions is unresolved. This point is illustrated most clearly by all the work that has been devoted, in vain, to Cr molecular sieves (55-57). Particularly the silicates Cr-silicalite-1 and Cr-sihcahte-2 and the aluminophosphate Cr-AlPO-5 have been investigated. These materials have been employed, among others, for alcohol oxidation with t-BuOOH, for allylic (aut)oxidation of olefins, for the autoxidation of ethylbenzene and cyclohexane, and even for the catalytic decomposition of cyclohexyl hydroperoxide to give mainly cyclohexanone ... 

More recent investigations have shown that these reactions involve metal-catalyzed decomposition of hydroperoxides via the usual redox cycles. Thus, inhibition, polymerization and product studies in the RhCl(Ph3 P)3-catalyzed autoxidation of cyclohexene,136 ethylbenzene,136 and diphenylmethane137 were compatible only with metal-catalyzed decomposition of the alkyl hydroperoxide and not a direct reaction of the metal-dioxygen complex with substrate. Complexes Rh(III) (acac)3, Rh(III) (2-ethylhexanoate)3, and Co(II) (2-ethylhexanoate)2, gave results that were almost the same as those obtained with RhCl(Ph3P)3. The redox cycle may involve Rh(II) and Rh(III) ... 

---