Industrial synthesis nylon

An amino acid protected only at the N atom and a different amino acid in which only the C02H group is protected do not react with each other to form a peptide bond. On the contrary, they form an ammonium carboxylate in a fast acid/base reaction (Figure 6.29). Ammonium car-boxylates can in principle be converted into amides by strong heating. Thus, for example, in the industrial synthesis of nylon-6,6, the diammonium dicarboxylate obtained from glutamic acid and hexamethylenediamine is converted to the polyamide at 300 °C. However, this method is not suitable for peptide synthesis because there would be too many undesired side reactions. 

Two important commercial diacids are adipic acid (hexanedioic acid) and tere-phthalic acid (benzene-1,4-dicarboxylic acid). Adipic acid is used in making nylon 66, and terephthalic acid is used to make polyesters. The industrial synthesis of adipic acid uses benzene as the starting material. Benzene is hydrogenated to cyclohexane, whose oxidation (using a cobalt/acetic acid catalyst) gives adipic acid. Terephthalic acid is produced by the direct oxidation of para-xylene in acetic acid using a cobalt-molybdenum catalyst. 

The new synthetic route to ibuprofen is an important example of how ideas of green chemistry can influence for the better the industrial synthetic methods used, not only from the point of view of economic efficiency, but also by introducing more effective methods of science and technology. Improved methods of synthesis for hexan-l,6-dioic acid (adipic aid) and cis-butenediol acid (maleic anhydride) - important for the industrial synthesis of nylon and polyesters respectively - are two other examples of the impact of a greener synthetic approach to industrial chemistry. 

Caprolactam, a white solid that melts at 69°C, can be obtained either in a fused or flaked form. It is soluble in water, ligroin, and chlorinated hydrocarbons. Caprolactam s main use is to produce nylon 6. Other minor uses are as a crosslinking agent for polyurethanes, in the plasticizer industry, and in the synthesis of lysine. 

In 1930, DuPont launched the synthetic fiber industry with the discovery of nylon-6,6.2 In 1938, a pilot plant for nylon-6,6 production was put into operation, and in 1939, production was commenced at a large-scale plant in Seaford, Delaware. The classical method for the synthesis of nylon-6,6 involves a two-step process. In the first step, hexamethylene diamine (HMDA) is reacted with adipic acid (AA) to form a nylon salt. Polymerization of the aqueous salt solution is carried out at temperatures in the range of about 210-275°C at a steam pressure of about 1.7 MPa. When 275°C is reached, the pressure is reduced to atmospheric pressure and heating is continued to drive the reaction to completion. 

The total hydrogenation of benzene derivatives represents an important industrial catalytic transformation, in particular with the conversion of benzene into cyclohexane, a key intermediate in adipic acid synthesis, which is used in the production of Nylon-6,6 (Scheme 1). This reaction is still the most important industrial hydrogenation reaction of monocyclic arenes [1]. 

Pure xylan is not employed in industry. but crude xylan or pentosans are of industrial importance. Xylan has been proposed as a textile size but is not employed as yet for this purpose.130 Perhaps the largest use of pentosans is in their conversion to furfural, which has many applications and serves as the source of other furan derivatives. At the present time, large quantities of furfural are used in the extractive purification of petroleum products, and recently a large plant has been constructed to convert furfural by a series of reactions to adipic acid and hexamethylene-diamine, basic ingredients in the synthesis of nylon. In commercial furfural manufacture, rough ground corn cobs are subjected to steam distillation in the presence of hydrochloric acid. As mentioned above, direct preferential hydrolysis of the pentosan in cobs or other pentosan-bearing products could be used for the commercial manufacture of D-xylose. 

Oxidation is the first step for producing molecules with a very wide range of functional groups because oxygenated compounds are precursors to many other products. For example, alcohols may be converted to ethers, esters, alkenes, and, via nucleophilic substitution, to halogenated or amine products. Ketones and aldehydes may be used in condensation reactions to form new C-C double bonds, epoxides may be ring opened to form diols and polymers, and, finally, carboxylic acids are routinely converted to esters, amides, acid chlorides and acid anhydrides. Oxidation reactions are some of the largest scale industrial processes in synthetic chemistry, and the production of alcohols, ketones, aldehydes, epoxides and carboxylic acids is performed on a mammoth scale. For example, world production of ethylene oxide is estimated at 58 million tonnes, 2 million tonnes of adipic acid are made, mainly as a precursor in the synthesis of nylons, and 8 million tonnes of terephthalic acid are produced each year, mainly for the production of polyethylene terephthalate) [1]. 

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],... 

Industry, in fact, has a major interest in these diesters as building blocks for nylon 6,6 and nylon 7,7 in the production of polyesters and polyamides. However, their present synthesis raises an environmental concern. For instance, the oxidation of cyclohexanone by nitric acid (for the preparation of adipic acid), accounts for more than 10% of the total yearly release of N2O, which is among the main gases responsible for the greenhouse effect. The reaction of Scheme 4.14 represents an eco-friendly alternative synthesis of a,(i)-diesters which uses green reagents and, relevantly, has a 100% atom economy. The overall process is mechanistically described as a retro-Claisen condensation. 

A synthesis of great industrial interest is the electrochemical anodic reductive dimerisation of two molecules of acrylonitrile to give adiponitrile, from which adipic acid and 1,6-hexanediamine are prepared by hydrolysis and reduction, respectively, of the two nitrile groups. Polycondensation of the resulting products leads to Nylon 66 (Scheme 5.27). 

SOURCE - Chemical or industrial supply. Home synthesis. Cyanides are widely used in the plastics industry for the production of materials such as nylon. 

Homolytic liquid-phase processes are generally well suited to the synthesis of carboxylic acids, viz. acetic, benzoic or terephthalic acids which are resistant to further oxidation. These processes operate at high temperature (150-250°C) and generally use soluble cobalt or manganese salts as the main catalyst components. High conversions and selectivities are usually obtained with methyl-substituted aromatic hydrocarbons such as toluene and xylenes.95,96 The cobalt-catalyzed oxidation of cyclohexane by air to a cyclohexanol-cyclohexanone mixture is a very important industrial process since these products are intermediates in the manufacture of adipic acid (for nylon 6,6) and caprolactam (nylon 6). However, the conversion is limited to ca. 10% in order to prevent consecutive oxidations, with roughly 70% selectivity.97... 

Adipodinitrile is an intermediate for hexamethylenediamine, the amine component of nylon 66. The electrochemical process is economically superior to the synthesis of adipodinitrile from cyclohexanone. Today, it essentially competes with the addition reaction of HCN to butadiene. The total capacity of the electrochemical ADN synthesis is currently about 250,000 tonnes/year. The process is industrially fully developed. Recent work 34 347) is aimed at reducing the oxygen evolution potential at the anode in order to save further energy. 

The most famous application of electrochemistry to industry in modem times is the synthesis of nylon, (a) What step in the synthesis is electrochemical (b) Is the synthesis in an aqueous solution (c) What part is played by NEt (d) Would the cell concerned have to have a membrane and if so, when (Bockris)... 

Industrial uses of HCN are for synthesis of methyl methacrylate and to form adiponitrile (for adipic acid and nylon) by addition to 1,3-butadiene in the presence of nickel(O) phosphite complexes. Waste HCN is also oxidatively hydrolyzed to give oxamide for use as fertilizer. 

This type of reaction is now of major industrial importance because it constitutes a straiglitforward synthesis of nitriles. Wlien it is applied to a diolefm, such as butadiene, it leads to the formation of dinitriles, which are precursors of valuable monomers for the preparation of polymers (butadiene leads to adipo-nilrile. a nylon-b, fvprecursor). Du Font developed the first commercial process using butadiene and HCN for adiponitrile synthesis from butadiene, but this process does nut proceed through a hydrocyanation reaction it is. in fact, a copper-catalyzed halogenation reaction followed by a cyanaikm reaction (tquaiion (16)) of the chlorinated intermediate (Fquation (17)). 

The salts of hydrazoic acid, M+Ns, have already been discussed in Section 3.2.4, but a variety of other alkali pseudohalides exist. The most important of these are the cyanides M+CN , preparable by neutralization of HCN with the appropriate alkali base. NaCN and KCN reached such industrial importance that alternative bulk syntheses have been developed (e.g. equation 10). This Castner process fed the gold extraction industry and continued to feed the electroplating and nylon synthesis markets until cheaper routes directly to HCN were found. In cases where the alkali cyanides are still required, the simple neutralization route is now most economic. 

Until recently, the feedstock for all polymer synthesis has been petroleum that is, the monomers for virtually all polymer syntheses are made from crude oil, a nonrenewable raw material. As an example, nylon 6,6 is prepared industrially from adipic acid [HOOC(CH2)4COOHl and 1,6-diaminohexane [H2N(CH2)6NH2J, both of which originate from benzene, a product of petroleum refining (Figure 30.8). 

The chemistry of ammonia and the ammonium ion is vast ammonia is of immense industrial importance and is produced in larger molar quantities than any other chemical. More than 80% of the ammonia produced is used in fertilizers, with additional uses including the synthesis of explosives, the manufacture of synthetic fibers (such as rayon, nylon, and polyurethanes), and the synthesis of a wide variety of organic and inorganic compounds. As described in Chapter 6, liquid ammonia is used extensively as a nonaqueous ionizing solvent. 

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