Hydroformylation biphasic system

Another interesting recent development is the continuous, Rh-catalyzed hydroformylation of 1-octene in the unconventional biphasic system [BMIM][PF6]/scC02, described by Cole-Hamilton et al. [84]. This specific example is described in more detail, together with other recent work in ionic liquid/scC02 systems, in Section 5.4. 

Betzemeier et al. (1998) have used f-BuOOH, in the presence of a Pd(II) catalyst bearing perfluorinated ligands using a biphasic system of benzene and bromo perfluoro octane to convert a variety of olefins, such as styrene, p-substituted styrenes, vinyl naphthalene, 1-decene etc. to the corresponding ketone via a Wacker type process. Xia and Fell (1997) have used the Li salt of triphenylphosphine monosulphonic acid, which can be solubilized with methanol. A hydroformylation reaction is conducted and catalyst recovery is facilitated by removal of methanol when filtration or extraction with water can be practised. The aqueous solution can be evaporated and the solid salt can be dissolved in methanol and recycled. 

Room temperature ionic liquids (RTILs), such as those based on A,A-dialkylimidazolium ions, are gaining importance (Bradley, 1999). The ionic liquids do not evaporate easily and thus there are no noxious fumes. They are also non-inflammable. Ionic liquids dissolve catalysts that are insoluble in conventional organic chemicals. IFP France has developed these solvents for dimerization, hydrogenation, isomerization, and hydroformylation reactions without conventional solvents. For butene dimerization a commercial process exists. RTILs form biphasic systems with the catalyst in the RTIL phase, which is immiscible with the reactants and products. This system is capable of being extended to a list of organometallic catalysts. Industrial Friedel-Crafts reactions, such as acylations, have been conducted and a fragrance molecule tra.seolide has been produced in 99% yield (Bradley, 1999). 

The use of thermomorphic systems has recently been studied as a way of achieving catalyst separation in homogeneous catalysis. For example, a biphasic hydroformylation catalyst system was developed to take advantage of the unusual solvent characteristics of perfluorocarbons combined with typical organic solvents (4). Fluorous/organic mixtures such as perfiuoromethylcyclohexane... 

Scheme 8.7. Continuous-flow hydroformylation of long chain olefins in the biphasic system IL/SCCO2...

A wide variety of new approaches to the problem of product separation in homogeneous catalysis has been discussed in the preceding chapters. Few of the new approaches has so far been commercialised, with the exceptions of a the use of aqueous biphasic systems for propene hydroformylation (Chapter 5) and the use of a phosphonium based ionic liquid for the Lewis acid catalysed isomerisation of butadiene monoxide to dihydrofuran (see Equation 9.1). This process has been operated by Eastman for the last 8 years without any loss or replenishment of ionic liquid [1], It has the advantage that the product is sufficiently volatile to be distilled from the reactor at the reaction temperature so the process can be run continuously with built in product catalyst separation. Production of lower volatility products by such a process would be more problematic. A side reaction leads to the conversion of butadiene oxide to high molecular weight oligomers. The ionic liquid has been designed to facilitate their separation from the catalyst (see Section 9.7)... 

As outlined in Chapter 5, Section 5.2.3.2 various approaches to overcoming the low rates of the hydroformylation of long chain alkenes in aqueous biphasic systems have been proposed. Some of these, such as the use of microemulsions [24-26] or pH dependent solubility [27], have provided improvements often at the expense of complicating the separation process. Perhaps the most promising new approaches involve the introduction of new reactor designs where improved mixing allows for... 

Propylene carbonate is a good solvent of the rhodium precursor [Rh(acac) (00)2] and the phosphite ligand BIPHEPHOS and can thus be used as the catalyst phase in the investigation of the isomerizing hydroformylation of trans-4-octene to n-nonanal in a biphasic system [24]. As already mentioned, the reaction products can be extracted with the hydrocarbon dodecane. Instead of an additional extraction after the catalytic reaction, we carried out in-situ extraction experiments, where the products are separated from the catalytic propylene carbonate phase while the reaction is still in progress. Conversion of 96% and selectivity of 72% was achieved under comparably mild conditions (p(CO/H2) = 10 bar, T = 125 °C, 4 h, substrate/Rh = 200 1). 

Scheme 4 Hydroformylation of 14 with scC02-soluble Rh catalyst in an inverted biphasic system SCCO2/H2O...

For the rhodium-catalyzed hydroformylation of propylene in an aqueous biphasic system. Cents et al. have shown that the accurate knowledge of the mass transfer parameters in the gas-liquid-liquid system is necessary to predict and optimize the production rate [180]. Choudhari et al. enhanced the reaction rate by a factor of 10-50 by using promoter Ugands for the hydroformylation of 1-octene in a biphasic aqueous system [175]. 

Table 4. /. Hydroformylation in aqueous/organic biphasic systems...

In 1975 Kuntz has described that the complexes formed from various rhodium-containing precursors and the sulfonated phosphines, TPPDS (2) or TPPTS (3) were active catalysts of hydroformylafion of propene and 1-hexene [15,33] in aqueous/organic biphasic systems with virtually complete retention of rhodium in the aqueous phase. The development of this fundamental discovery into a large scale industrial operation, known these days as the Ruhrchemie-Rhone Poulenc (RCH-RP) process for hydroformylation of propene, demanded intensive research efforts [21,28]. Tire final result of these is characterized by the data in Table 4.2 in comparison with cobalt- or rhodium-catalyzed processes taking place in homogeneous organic phases. 

The only other olefin feedstock which is hydroformylated in an aqueous/organic biphasic system is a mixture of butenes and butanes called raffinate-II [8,61,62]. This low-pressure hydroformylation is very much like the RCH-RP process for the production of butyraldehyde and uses the same catalyst. Since butenes have lower solubility in water than propene, satisfactory reaction rates are obtained only with increased catalyst concentrations. Otherwise the process parameters are similar (Scheme 4.3), so much that hydroformylation of raffinate-11 or propene can even be carried out in the same unit by slight adjustment of operating parameters. 

In the hydroformylation of alkenes, the major differences between the [RhH(CO)(PPh3)3], and [RhH(CO)(TPPTS)3] catalysts are the lower activity and higher selectivity of the water-soluble complex in aqueous/organic biphasic systems. Lower activity is not unexpected, since alkenes have limited solubility in water (see 4.1.1.1, Table 3). On the other hand, the higher selectivity towards formation of the linear product deserves more scrutiny. 

In general, the mechanism of alkene hydroformylation with an [RhH(CO)P3] catalyst in water or in aqueous/organic biphasic systems (P = TPPTS) is considered to be analogous [61] to that of the same reaction in homogeneous organic solutions (P = PPh3) [84], a basic version of which is shown on Scheme 4.8. 

The phosphinated ligands 135 and 136 prepared from poly(acrylic acid) and from poly(ethyleneimine), respectively, gave active hydroformylation catalysts in reaction with [Rh(acac)(CO)2]. Under the conditions of Table 4.6 low conversions were observed in aqueous/organic biphasic systems, due to the low solubility of 1-octene. Addition of a surfactant (SDS) or an organic co-solvent (MeOH) led to dramatic increases in the yield of aldehydes, revealing the high intrinsic activity of the catalyst [120]. 

Webb, P.B.and Sellin, M.F. and Kimene, T.E. and Williamson, S. and Slawin, A.M.Z. and Cole-Hamilton, D.J. (2003). Continuous Flow Hydroformylation of Alkenes in Supercritical Fluid-Ionic Liquid Biphasic System. J. Am. Chem. Soc., 125, 15577-15588. 

An ionic liquid was fully immobilized, rather than merely supported, on the surface of silica through a multiple-step synthesis as shown in Fig. 15 (97). A ligand tri(m-sulfonyl)triphenyl phosphine tris(l-butyl-3-methyl-imidazolium) salt (tppti) was prepared so that the catalyst, formed from dicarbonylacetylacetonate rhodium and the ligand (P/Rh = 10), could be soluble in both [BMIMJBFq and [BMIM]PF6. The supported ionic liquid-catalyst systems showed nearly three times higher rate of reaction (rate constant = 65 min ) that a biphasic system for the hydroformylation of 1-hexene at 100°C and 1500 psi in a batch reactor, but the n/i selectivity was nearly constant the same for the two ( 2.4). Unfortunately, both the supported and the biphasic ionic liquid systems exhibited similar metal leaching behavior. 

The OATS concept was tested on the catalytic hydroformylation of 1-octene, a hydrophobic substrate. This reaction was selected because it has previously been shown to be inactive for traditional aqueous biphasic systems (18). The catalyst used was a Rh/TPPTS complex, an industrial water soluble catalyst (22). The application of the OATS concept increased catalytic efficiency by a factor of 65 (TOP increased from 5 h for biphasic to 325 h for monophasic). 

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