Ethylene oxide route

The large volume solvents, trichloroethylene and perchloroethylene, are still chiefly made from acetylene, but appreciable amounts of the former are derived from ethylene. The competitive situation between these source materials runs through the whole chlorinated hydrocarbon picture, and extends on to other compound classes as well—for example, acrylonitrile is just on the threshold of a severalfold expansion, as demand grows for synthetic fibers based thereon. Acrylonitrile can be made either from ethylene oxide and hydrogen cyanide, from acetylene and hydrogen cyanide, or from allylamines. The ethylene oxide route is reported to be the only one in current commercial use, but new facilities now under construction will involve the addition of hydrogen cyanide to acetylene (27). 

The ethylene oxide route to the facility can be represented by a single low population density. 

Despite its own valuable synthetic potential, the use of [ C2]acetylene as a starting material for various building blocks is of much higher relevance. Mercury(II)-catalyzed hydration, for example, gives [ C2]acetaldehyde (Figure 8.5, Route 1) The same reaction carried out in the presence of ammonium persulfate furnishes [ 2] acetic acid (Route 2). Trapping of its mono- or dianion with formaldehyde or carbon dioxide affords [2,3- C2]propynol, [2,3- C2]butyne-l,4-diol, [2,3- C2]propiolic acid " and [2,3- C2]acetylenedicarboxylic acid, respectively (Routes 3-6). UV irradiation of a mixture of HBr and [ C2]acetylene produces l,2-dibromo[ C2]ethane (Route 8) . Reduction with chromium(II) chloride followed by a two-step epoxidation of the initially formed [ C2]ethylene converts [ 2]acetylene into [ C2]ethylene oxide (Route 7) . Finally, catalytic homotrimerization or co-trimerization with other alkynes provides [ " C ]benzene or substituted [ " C ]benzenes, respectively, the central starting materials for the vast majority of substituted benzenoid aromatic compounds (Route 9). 

We saw an example of nucleophilic ring opening of epoxides in Section 15 4 where the reaction of Grignard reagents with ethylene oxide was described as a synthetic route to primary alcohols... 

This reaction is rapidly replacing the former ethylene-based acetaldehyde oxidation route to acetic acid. The Monsanto process employs rhodium and methyl iodide, but soluble cobalt and iridium catalysts also have been found to be effective in the presence of iodide promoters. 

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. 

Poly(ethylene oxide) resins are safely used in numerous pharmaceutical and personal-care appHcations. Poly(ethylene oxide) resins show a low order toxicity in animal studies by all routes of exposure. Because of their high molecular weight, they are poorly adsorbed from the gastrointestinal tract and completely... 

Ethoxylation of alkyl amine ethoxylates is an economical route to obtain the variety of properties required by numerous and sometimes smaH-volume industrial uses of cationic surfactants. Commercial amine ethoxylates shown in Tables 27 and 28 are derived from linear alkyl amines, ahphatic /-alkyl amines, and rosin (dehydroabietyl) amines. Despite the variety of chemical stmctures, the amine ethoxylates tend to have similar properties. In general, they are yellow or amber Hquids or yellowish low melting soHds. Specific gravity at room temperature ranges from 0.9 to 1.15, and they are soluble in acidic media. Higher ethoxylation promotes solubiUty in neutral and alkaline media. The lower ethoxylates form insoluble salts with fatty acids and other anionic surfactants. Salts of higher ethoxylates are soluble, however. Oil solubiUty decreases with increasing ethylene oxide content but many ethoxylates with a fairly even hydrophilic—hydrophobic balance show appreciable oil solubiUty and are used as solutes in the oil phase. 

Ethylene oxide has been produced commercially by two basic routes the ethylene chlorohydrin and direct oxidation processes. The chlorohydrin process was first iatroduced dufing World War I ia Germany by Badische Anilin-und Soda-Eabfik (BASE) and others (95). The process iavolves the reaction of ethylene with hypochlorous acid followed by dehydrochlofination of the resulting chlorohydrin with lime to produce ethylene oxide and calcium chloride. Union Carbide Corp. was the first to commercialize this process ia the United States ia 1925. The chlorohydrin process is not economically competitive, and was quickly replaced by the direct oxidation process as the dominant technology. At the present time, all the ethylene oxide production ia the world is achieved by the direct oxidation process. 

Liquid-Phase Epoxidation with Hydroperoxides. Molybdenum, vanadium, and tungsten have been proposed as Hquid-phase catalysts for the oxidation of the ethylene by hydroperoxides to ethylene oxide (205). tert- uty hydroperoxide is the preferred oxidant. The process is similar to the arsenic-catalyzed route, and iacludes the use of organometaUic complexes. 

Biological. Several recent patents have claimed the production of ethylene oxide from a wide variety of raw materials using enzymatic catalysts (221—224). However, no commercial production routes based on biological mechanisms have been proposed. 

Swallowing ethylene oxide is a highly unlikely route of exposure. However, harmful effects, including coma, death, and severe irritation and ulceration of the mouth and throat, could occur. 

Other Derivatives. Ethylene carbonate, made from the reaction of ethylene oxide and carbon dioxide, is used as a solvent. Acrylonitrile (qv) can be made from ethylene oxide via ethylene cyanohydrin however, this route has been entirely supplanted by more economic processes. Urethane intermediates can be produced using both ethylene oxide and propylene oxide in their stmctures (281) (see Urethane polymers). 

The main route to ethylene oxide is oxygen or air oxidation of ethylene over a silver catalyst. The reaction is exothermic heat control is important ... 

The main route for producing ethylene glycol is the hydration of ethylene oxide in presence of dilute sulfuric acid (Eigure 7-4) ... 

A new route to ethylene glycol from ethylene oxide via the intermediate formation of ethylene carbonate has recently been developed by Texaco. Ethylene carbonate may be formed by the reaction of carbon monoxide, ethylene oxide, and oxygen. Alternatively, it could be obtained by the reaction of phosgene and methanol. 

The reaction occurs at approximately 80-130°C using the proper catalyst. Many catalysts have been tried for this reaction, and there is an indication that the best catalyst types are those of the tertiary amine and quaternary ammonium functionalized resins. This route produces ethylene glycol of a high purity and avoids selectivity problems associated with the hydrolysis of ethylene oxide. 

A direct route for acetone from propylene was developed using a homogeneous catalyst similar to Wacker system (PdCl2/CuCl2). The reaction conditions are similar to those used for ethylene oxidation to acetaldehyde. ... 

An alternative route to PET is by the direct reaction of terephthalic acid and ethylene oxide. The product bis(2-hydroxyethyl)terephthalate reacts in a second step with TPA to form a dimer and ethylene glycol, which is released under reduced pressure at approximately 300°C. 

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. 

The catalytic route, however, is simple and clean, although it does produce a small amount of CO2. Using silver, promoted by small amounts of chlorine, as the catalyst, ethylene oxide is formed directly from C2H4 and O2 at a selectivity of around 90%, with about 10% of the ethylene ending up as CO2. Nowadays all production facilities for ethylene oxide use catalysts. 

Ethylene oxide is an important intermediate for ethylene glycol (antifreeze) and for plastics, plasticizers, and many other products [R.A. van Santen and H.P.C.E. Kui-pers, Adv. Catal. 35 (1987) 265]. In Chapter 1 we explained that the replacement of the traditional manufacturing process - which generated 1.5 mole of byproducts per 1 mole of epoxide - by a catalytic route based on silver catalysts is a major success story with respect to clean chemistry (Fig. 9.16). 

The atom utilization or atom efficiency concept is a useful tool for rapid evaluation of the amount of waste that will be generated by alternative routes to a particular product. It is calculated by dividing the molecular weight of the desired product by the sum total of the molecular weights of all the substances produced in the stoichiometric equation of the reaction(s) in question. The comparison is made on a theoretical (i.e. 100% chemical yield) basis. Fig. 2.8 shows a simple illu.stration of the concept for ethylene oxide manufacture. 

Figure 2.8. Atom efficiencies of routes to ethylene oxide.

The classical chlorohydrin route has an atom efficiency of 25% and is better described as a calcium chloride process, with ethylene oxide as the major by-product. In other words, even if... 

The addition of Grignard reagents to aldehydes, ketones, and esters is the basis for the synthesis of a wide variety of alcohols, and several examples are given in Scheme 7.3. Primary alcohols can be made from formaldehyde (Entry 1) or, with addition of two carbons, from ethylene oxide (Entry 2). Secondary alcohols are obtained from aldehydes (Entries 3 to 6) or formate esters (Entry 7). Tertiary alcohols can be made from esters (Entries 8 and 9) or ketones (Entry 10). Lactones give diols (Entry 11). Aldehydes can be prepared from trialkyl orthoformate esters (Entries 12 and 13). Ketones can be made from nitriles (Entries 14 and 15), pyridine-2-thiol esters (Entry 16), N-methoxy-A-methyl carboxamides (Entries 17 and 18), or anhydrides (Entry 19). Carboxylic acids are available by reaction with C02 (Entries 20 to 22). Amines can be prepared from imines (Entry 23). Two-step procedures that involve formation and dehydration of alcohols provide routes to certain alkenes (Entries 24 and 25). 

The most commonly employed routes for the preparation of the / -sulfatoethylsulfone group, which is the essential structural feature of vinylsulfone reactive dyes, are illustrated in Scheme 8.5. One method of synthesis involves, initially, the reduction of an aromatic sulfonyl chloride, for example with sodium sulfite, to the corresponding sulfinic acid. Subsequent condensation with either 2-chloroethanol or ethylene oxide gives the / -hydroxyethylsulfone, which is converted into its sulfate ester by treatment with concentrated sulfuric acid at 20 30 °C. An alternative route involves treatment of an aromatic thiol with 2-chloroethanol or ethylene oxide to give the /Miydroxyethylsulfonyl compound which may then be converted by oxidation into the /Miydroxyethylsulfone. 

Fig. 7 Synthesis of heterobifunctional PEG. (a) Nagasaki et al. developed a method for the polymerization of EO using an initiator containing defined functionalities [16, 17]. (b) Akiyama et al. further developed a synthetic route to prepare a series of heterobifunctional PEGs [18-21]. After the ring-opening polymerization of ethylene oxide, a second functional group was introduced at the co-end of PEG...

The production of light coloured products with a requirement for low build-up of static electricity requires the addition of an ingredient which is capable of providing the rubber with a low electrical resistance. Quartemary ammonium salts and ethylene oxide condensates provide one route. Of the common plasticisers, phosphate types have the lowest electrical resistance conferring properties in rubbers. Special antistatic plasticisers, such as polyethylene glycol fatty alcohol ethers, are designed to give rubbers with low surface resistivity. 

One more reaction route was shown for the interaction with ethylene oxide [Eq. (102)]. In the present case, one could expect the substitution of the a-oxyalkyl fragment of boryloxyalkylphosphine by /3-oxyalkylphos-phine, as observed for a-oxyalkylphosphines (88IZV155). 

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