Ethylene Wacker process

Formation of acetaldehyde and metallic Pd by passing ethylene into an aqueous solution of PdCl2 was reported by Phillips in 1894 15] and used for the quantitative analysis of Pd(II)[16], The reaction was highlighted after the industrial process for acetaldehyde production from ethylene based on this reaetion had been developed[l,17,18]. The Wacker process (or reaction) involves the three unit reactions shown. The unique feature in the Wacker process is the invention of the in situ redox system of PdCl2-CuCl2. 

Extensive studies on the Wacker process have been carried out in industrial laboratories. Also, many papers on mechanistic and kinetic studies have been published[17-22]. Several interesting observations have been made in the oxidation of ethylene. Most important, it has been established that no incorporation of deuterium takes place by the reaction carried out in D2O, indicating that the hydride shift takes place and vinyl alcohol is not an intermediate[l,17]. The reaction is explained by oxypailadation of ethylene, / -elimination to give the vinyl alcohol 6, which complexes to H-PdCl, reinsertion of the coordinated vinyl alcohol with opposite regiochemistry to give 7, and aldehyde formation by the elimination of Pd—H. 

In addition to these principal commercial uses of molybdenum catalysts, there is great research interest in molybdenum oxides, often supported on siHca, ie, MoO —Si02, as partial oxidation catalysts for such processes as methane-to-methanol or methane-to-formaldehyde (80). Both O2 and N2O have been used as oxidants, and photochemical activation of the MoO catalyst has been reported (81). The research is driven by the increased use of natural gas as a feedstock for Hquid fuels and chemicals (82). Various heteropolymolybdates (83), MoO.-containing ultrastable Y-zeoHtes (84), and certain mixed metal molybdates, eg, MnMoO Ee2(MoO)2, photoactivated CuMoO, and ZnMoO, have also been studied as partial oxidation catalysts for methane conversion to methanol or formaldehyde (80) and for the oxidation of C-4-hydrocarbons to maleic anhydride (85). Heteropolymolybdates have also been shown to effect ethylene (qv) conversion to acetaldehyde (qv) in a possible replacement for the Wacker process. 

Ca.ta.lysis, The most important iadustrial use of a palladium catalyst is the Wacker process. The overall reaction, shown ia equations 7—9, iavolves oxidation of ethylene to acetaldehyde by Pd(II) followed by Cu(II)-cataly2ed reoxidation of the Pd(0) by oxygen (204). Regeneration of the catalyst can be carried out in situ or ia a separate reactor after removing acetaldehyde. The acetaldehyde must be distilled to remove chloriaated by-products. 

Alternatively, the intermediate acetaldehyde (qv) for this process was obtained from ethylene by the Wacker process (9). A small amount of -butyl alcohol is produced in the United States by the Ziegler-Natta chain growth reaction from ethylene [74-85-1] (10). 

A process similar to the Wacker process has been apphed for the oxidation of ethylene with acetic acid to give vinyl acetate, but now the principal apphcations are with a soHd catalyst. 

The palladium chloride process for oxidizing olefins to aldehydes in aqueous solution (Wacker process) apparendy involves an intermediate anionic complex such as dichloro(ethylene)hydroxopalladate(II) or else a neutral aqua complex PdCl2 (CH2=CH2)(H2 0). The coordinated PdCl2 is reduced to Pd during the olefin oxidation and is reoxidized by the cupric—cuprous chloride couple, which in turn is reoxidized by oxygen, and the net reaction for any olefin (RCH=CH2) is then... 

Whereas this reaction was used to oxidize ethylene (qv) to acetaldehyde (qv), which in turn was oxidized to acetic acid, the direct carbonylation of methanol (qv) to acetic acid has largely replaced the Wacker process industrially (see Acetic acid and derivatives). A large number of other oxidation reactions of hydrocarbons by oxygen involve coordination compounds as detailed elsewhere (25). 

The Wacker process for the oxidation of ethylene to acetaldehyde with PdCb/CuCb at 100°C (212°F) with 95 percent yield and 95 to 99 percent conversion per pass. 

A common property of coordinated alkenes is their susceptibility to attack by nucleophiles such as OH , OMe , MeC02, and Cl , and it has long been known that Zeise s salt is slowly attacked by non-acidic water to give MeCHO and Pt metal, while corresponding Pd complexes are even more reactive. This forms the basis of the Wacker process (developed by J. Smidt and his colleagues at Wacker Chemie, 1959-60) for converting ethene (ethylene) into ethanal (acetaldehyde) — see Panel overleaf. 

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. 

Cu(rr) compounds are frequently used in conjunction with Pd(I[) in the oxidation of olefins in the Wacker process. Their role has been viewed as that of catalyst for autoxidation of Pd metal back to Pd(II). Dozono and Shiba report the rate of oxidation of ethylene by a PdCl2-CuCl2 couple to be given by... 

The commercial process for the production of vinyl acetate monomer (VAM) has evolved over the years. In the 1930s, Wacker developed a process based upon the gas-phase conversion of acetylene and acetic acid over a zinc acetate carbon-supported catalyst. This chemistry and process eventually gave way in the late 1960s to a more economically favorable gas-phase conversion of ethylene and acetic acid over a palladium-based silica-supported catalyst. Today, most of the world s vinyl acetate is derived from the ethylene-based process. The end uses of vinyl acetate are diverse and range from die protective laminate film used in automotive safety glass to polymer-based paints and adhesives. 

Palladium-catalyzed oxidation of hydrocarbons has been a matter of intense research for about four decades. The field was initiated by the development of the aerobic oxidation of ethylene to acetaldehyde catalyzed by palladium chloride and co-catalyzed by cupric chloride (the Wacker process, equation l)1. 

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. 

Nippon Steel has developed an interesting liquid-phase process for producing 2-methylpyridine from ethylene and ammonia (74MI1 81MI2, 81MI3). The catalyst is reminiscent of the well-known Wacker process, viz. Pd /Cu redox system [Eq.(5)]. 

However, even with the use of high temperatures and pressures, low productivity and poor selectivity did not make MeOH carbonylation to AcOH attractive commercially compared with processes such as oxidation of butane or naptha fractions or the Pd catalysed oxidation of ethylene (Wacker). 

VAM can be produced starting from ethylene, which is converted to acetic acid via acetaldehyde by two sequential oxidation steps (reactions 1 and 2 in Fig. 2), the first step being the famous Wacker process (reaction 1 in Fig. 2) [14]. 

This chapter has focused on inorganic and heterogeneous catalysts, because historically these are the major systems with which chemical engineers have been concerned. There are number of important homogeneous catalytic processes such as the Wacker process to make vinyl acetate from ethylene and acetic acid, and there are many acid and base homogeneous catalyst systems. 

The complex ion catalyzes various types of organic reactions including oxidation of ethylene to acetaldehyde in aqueous solution (the Wacker Process) ... 

The Wacker process (Eq. 1) was developed nearly 50 years ago [1-3] and represents one of the most successful examples of homogeneous catalysis in industry [4-9]. This palladium-catalyzed method for the oxidation of ethylene to acetaldehyde in aqueous solution employs a copper cocatalyst to facilitate aerobic oxidation of Pd° (Scheme 1). Despite the success of this process, certain features of the reaction have Umited the development of related aerobic oxidation reactions. Many organic molecules are only sparingly sol-... 

In 1960, Moiseev and coworkers reported that benzoquinone (BQ) serves as an effective stoichiometric oxidant in the Pd-catalyzed acetoxylation of ethylene (Eq. 2) [19,20]. This result coincided with the independent development of the Wacker process (Eq. 1, Scheme 1) [Ij. Subsequently, BQ was found to be effective in a wide range of Pd-catalyzed oxidation reactions. Eor example, BQ was used to achieve Wacker-type oxidation of terminal alkenes to methyl ketones in aqueous DMF (Eq. 3 [21]), dehydrogenation of cyclohexanone (Eq. 4 [22]), and alcohol oxidation (Eq. 5 [23]). In the final example, 1,4-naphthoquinone (NQ) was used as the stoichiometric oxidant. 

Palladium-catalyzed addition of oxygen nucleophiles to alkenes dates back to the Wacker process and acetoxylation of ethylene (Sects. 1 and 2). In contrast, catalytic methods for intermolecular oxidative amination of alkenes (i.e., aza-Wacker reactions) have been identified only recently. Both O2 and BQ have been used as oxidants in these reactions. 

Soon after the invention of the Wacker process, the formation of vinyl acetate by the reaction of ethylene with PdCl2 in AcOH in the presence of sodium acetate was reported[106,107], No reaction takes place in the absence of base. The reaction of Pd(OAc)2 with ethylene forms vinyl acetate. 

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 commercially important Wacker process for the oxidation of ethylene is shown in Figure 13.1 (see Shriver, D. F. Atkins, P. W. Langford, . H., Inorganic Chemistry, Oxford University Press, Oxford, 1994, p. 728). 

Figure B13.1. Schematic of the Wacker process for the oxidation of ethylene.

Ethylene can be oxidized to acetaldehyde in high yields similar to the Wacker-process if electrogenerated palladium(ll) is used as catalyst. In this way the copper(II) catalyzed air oxidation of palladium(O) is replaced by the electrooxidation according to Eq. (40). 

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