Isopropylnaphthalene production

Isopropylnaphthalenes produced by alkylation of naphthalene with propjdene have gained commercial importance as chemical intermediates, eg, 2-isopropylnaphthalene [2027-17-OJ, and as multipurpose solvents, eg, mixed isopropylnaphthalenes. Alkylation of naphthalene with alkyl haUdes (except methyl hahdes), acid chlorides, and acid anhydrides proceeds in the presence of anhydrous aluminum chloride by Friedel-Crafts reactions (qv). The products are alkylnaphthalenes or alkyl naphthyl ketones, respectively (see Alkylation). 

Isopropylnaphthalenes can be prepared readily by the catalytic alkylation of naphthalene with propjiene. 2-lsopropylnaphthalene [2027-17-0] is an important intermediate used in the manufacture of 2-naphthol (see Naphthalenederivatives). The alkylation of naphthalene with propjiene, preferably in an inert solvent at 40—100°C with an aluminum chloride, hydrogen fluoride, or boron trifluoride—phosphoric acid catalyst, gives 90—95% wt % 2-isopropylnaphthalene however, a considerable amount of polyalkylate also is produced. Preferably, the propylation of naphthalene is carried out in the vapor phase in a continuous manner, over a phosphoric acid on kieselguhr catalyst under pressure at ca 220—250°C. The alkylate, which is low in di- and polyisopropylnaphthalenes, then is isomerized by recycling over the same catalyst at 240°C or by using aluminum chloride catalyst at 80°C. After distillation, a product containing >90 wt % 2-isopropylnaphthalene is obtained (47). 

Another method of manufacture involves the oxidation of 2-isopropylnaphthalene ia the presence of a few percent of 2-isopropylnaphthalene hydroperoxide/i)ti< 2-22-(y as the initiator, some alkaU, and perhaps a transition-metal catalyst, with oxygen or air at ca 90—100°C, to ca 20—40% conversion to the hydroperoxide the oxidation product is cleaved, using a small amount of ca 50 wt % sulfuric acid as the catalyst at ca 60°C to give 2-naphthalenol and acetone in high yield (70). The yields of both 2-naphthalenol and acetone from the hydroperoxide are 90% or better. 

A process variation of the extraction of 2-isopropylnaphthalene hydroperoxide from the cmde oxidation product with an alkylene glycol has been patented (71). The 2-naphthalenol plant of American Cyanamid, which was using the hydroperoxidation process and had a 14 x 10 t /yr capacity (72), ceased production in 1982, leaving the United States without a domestic producer of 2-naphthol. The 2-naphthol capacity in the Western world is approximately 50 x 10 t/yr, with ACNA, Italy and Hoechst AG, Germany operating the largest plants. China produces about 7 x 10 t/yr. Other important producing countries are Poland, Romania, the former Czechoslovakia, and India (35,52). 

Several biocatalytic processes for the production of (5)-(+)-naproxen (5) have also been developed (see Chapter 19). Direct isomerization of racemic naproxen (4) by a microorganism catalyst, Exophialia wilhansil, was reported to give the (S)-isomer 5 (92%, 100% ee) (Scheme 6.5).2X A 1-step synthesis of (5)-(+)-naproxen (5) by microbial oxidation of 6-methoxy-2-isopropylnaphthalene (12) was developed by IBIS (Scheme 6.6).29 In both cases, typical bioprocess-related issues such as productivity, product isolation, and biocatalyst production have apparently prevented them from rapid commercialization. 

Alkylates made specifically as feedstocks for synthetic petroleum sulphonates are typically long chain (average C chain > 16) and may use propylene oligomers which result in branched chains. Naphthalene products use the same propylene technology but tend to shorter chains (di-isopropylnaphthalene, di-nonylnaphthalene). 

The process developed by Kureha Chemical to produce diisopropylnaphthalene mixtures operates in a manner similar to that of benzene alkylation it comprises three stages consisting of transalkylation, alkylation and distillation of the reaction product. Naphthalene and recycled tri- and tetra-isopropylnaphthalenes first react in a transalkylation stage the product is then fed together with recycled mono-isopropylnaphthalenes to a second stage where the reaction with propene produces mainly diisopropylnaphthalenes. The reaction mixture is split by vacuum distillation. The reaction is performed at 7 bar and 200 using a silica-alumina catalyst. Figure 9.16 shows the flow sheet for the Kureha process. 

Other possible applications for isopropylnaphthalenes are the production of 2,6-naphlhalenedicarboxylic acid (see Chapter 10.2), and the manufacture of 2-isopropenylnaphthalene, which can be used as a vinylogous monomer to produce polymers with a high glass-transition temperature. 

Zawadiak et al. [620] studied the retention of three oxidation products of 2-isopropylnaphthalene (IPN), l-(2-naphthyl)ethanone, 2-(2-naphthyI)-2-propanol,... 

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