MAAs

Warnatz J, Maas U and Dibble R W 1999 Combustion Physioal and Chemioal Fundamentals, Modelling and Simulation, Experiments, Polutant Formation 2nd edn (Heidelberg Springer)... 

Maas U and Pope S B 1992 Simplifying chemical kinetics intrinsic low-dimensional manifolds in composition space Comb. Flame 88 239... 

Acrylics. Acetone is converted via the intermediate acetone cyanohydrin to the monomer methyl methacrylate (MMA) [80-62-6]. The MMA is polymerized to poly(methyl methacrylate) (PMMA) to make the familiar clear acryUc sheet. PMMA is also used in mol ding and extmsion powders. Hydrolysis of acetone cyanohydrin gives methacrylic acid (MAA), a monomer which goes direcdy into acryUc latexes, carboxylated styrene—butadiene polymers, or ethylene—MAA ionomers. As part of the methacrylic stmcture, acetone is found in the following major end use products acryUc sheet mol ding resins, impact modifiers and processing aids, acryUc film, ABS and polyester resin modifiers, surface coatings, acryUc lacquers, emulsion polymers, petroleum chemicals, and various copolymers (see METHACRYLIC ACID AND DERIVATIVES METHACRYLIC POLYMERS). 

Methyl acetoacetate (MAA) and ethyl acetoacetate (EAA) are the most widely used esters they are found ia the pharmaceutical, agricultural, and allied industries. Both esters are used extensively as amine protecting agents ia the manufacture of antibiotics and synthetic sweeteners (Dane Salts) (147). Principal outiets for MAA are the manufacture of the organophosphoms insecticide dia2inon [33341-5] (148,149) and the uracil herbicides bromacil [31440-9] and terbacil [5902-51-2] (150,151) (see Insect conztiol technology Herbicides). 

MAA and EAA are stable Hquids, and are shipped in nonretumable 208-L (55-gal) polyethylene-lined dmms. For bulk shipments, insulated stainless steel tank containers and tmcks provide secure protection. 2-Acetoacetoxyethyl methacrylate is a Hquid stabili2ed with radical inhibitors such as BHT [128-37-0] and has a shelf life of approximately three months. Shipment is in 60- or 208-L polyethylene-lined dmms. Acetoacetaryhdes are nicely crystalline, stable soHds and are shipped in 208-L dmms with polyethylene liners. 

Total U.S. annual production of MAA and EAA combined is estimated to be 6000—7000 metric tons. The list prices at the end of 1992 for large volumes were 2.75/kg for MAA and 3.00/kg for EAA. There are only two U.S. producers of these esters at this time, Tennessee Eastman Co. in Kingsport, Teimessee, and Lon2a Inc. in Bayport, Texas. 

The methyl a-hydroxyisobutyrate produced is dehydrated to MMA and water in two stages. First, the methyl a-hydroxyisobutyrate is vaporized and passed over a modified zeoHte catalyst at ca 240°C. A second reactor containing phosphoric acid is operated at ca 150°C to promote esterification of any methacrylic acid (MAA) formed in the first reactor (74,75). Methanol is co-fed to improve selectivity in each stage. Conversions of methyl a-hydroxyisobutyrate are greater than 99%, with selectivities to MMA near 96%. The reactor effluent is extracted with water to remove methanol and yield cmde MMA. This process has not yet been used on a commercial scale. 

MMA and MAA can be produced from ethylene [74-85-1/ as a feedstock via propanol, propionic acid, or methyl propionate as intermediates. Propanal may be prepared by hydroformylation of ethylene over cobalt or rhodium catalysts. The propanal then reacts in the Hquid phase with formaldehyde in the... 

Propionic acid is accessible through the Hquid-phase carbonylation of ethylene over a nickel carbonyl catalyst (104), or via ethylene and formic acid over an iridium catalyst (105). Condensation of propionic acid with formaldehyde over a supported cesium catalyst gives MAA directiy with conversions of 30—40% and selectivities of 80—90% (106,107). Catalyst lifetime can be extended by adding low levels (several ppm) of cesium to the feed stream (108). 

The reaction of methyl propionate and formaldehyde in the gas phase proceeds with reasonable selectivity to MMA and MAA (ca 90%), but with conversions of only 30%. A variety of catalysts such as V—Sb on siUca-alumina (109), P—Zr, Al, boron oxide (110), and supported Fe—P (111) have been used. Methjial (dimethoxymethane) or methanol itself may be used in place of formaldehyde and often result in improved yields. Methyl propionate may be prepared in excellent yield by the reaction of ethylene and carbon monoxide in methanol over a mthenium acetylacetonate catalyst or by utilizing a palladium—phosphine ligand catalyst (112,113). 

Only with propanal are very high conversions (99%) and selectivity (> 98 0) to MMA and MAA possible at this time. Although nearly 95% selective, the highest reported conversions with propionic acid or methyl propionate are only 30—40%. This results in large recycle streams and added production costs. The propanal route suffers from the added expense of the additional step required to oxidize methacrolein to methacrylic acid. 

In typical processes, the gaseous effluent from the second-stage oxidation is cooled and fed to an absorber to isolate the MAA as a 20—40% aqueous solution. The MAA may then be concentrated by extraction into a suitable organic solvent such as butyl acetate, toluene, or dibutyl ketone. Azeotropic dehydration and solvent recovery, followed by fractional distillation, is used to obtain the pure product. Water, solvent, and low boiling by-products are removed in a first-stage column. The column bottoms are then fed to a second column where MAA is taken overhead. Esterification to MMA or other esters is readily achieved using acid catalysis. 

Several variations of the above process are practiced. In the Sumitomo-Nippon Shokubai process, the effluent from the first-stage reactor containing methacrolein and methacrylic acid is fed directiy to the second-stage oxidation without isolation or purification (125,126). In this process, overall yields are maximized by optimizing selectivity to methacrolein plus methacrylic acid in the first stage. Conversion of isobutjiene or tert-huty alcohol must be high because no recycling of material is possible. In another variation, Asahi Chemical has reported the oxidative esterification of methacrolein directiy to MMA in 80% yield without isolation of the intermediate MAA (127,128). 

MAA and MMA may also be prepared via the ammoxidation of isobutylene to give meth acrylonitrile as the key intermediate. A mixture of isobutjiene, ammonia, and air are passed over a complex mixed metal oxide catalyst at elevated temperatures to give a 70—80% yield of methacrylonitrile. Suitable catalysts often include mixtures of molybdenum, bismuth, iron, and antimony, in addition to a noble metal (131—133). The meth acrylonitrile formed may then be hydrolyzed to methacrjiamide by treatment with one equivalent of sulfuric acid. The methacrjiamide can be esterified to MMA or hydrolyzed to MAA under conditions similar to those employed in the ACH process. The relatively modest yields obtainable in the ammoxidation reaction and the generation of a considerable acid waste stream combine to make this process economically less desirable than the ACH or C-4 oxidation to methacrolein processes. 

Polymerizations of methacrylic acid and derivatives are very energetic (MAA, 66.1 kj/mol MMA, 57.5 kJ/mol = 13.7 kcal/mol). The potential for the rapid evolution of heat and generation of pressure presents an explosion hazard if the materials are stored ia closed or poorly vented containers. 

Microstructure. Interest in PVP microstmcture and the potential for tacticity has been reviewed (39,40). PVP generated by free radicals has been shown to be atactic except when polymerization is conducted in water. In this case some syndiotacticity is observed (40). In the presence of syndiotactic templates of poly(methacryhc acid) (or poly(MAA)), VP will apparentiy polymerize with syndiotactic microstmcture, although proof is lacking (41—45). The reverse, polymerization of MAA in the presence of PVP, affords, as expected, atactic poly(MAA) (46,47). 

These monomers impart hydrophilicity as a result of the presence of polar —OH and —CONH— groups. Acid-containing monomers, such as methacrylic acid [79-41-4] (MAA), and 2-acrylamido-2-methylpropanesulfonic acid [15214-89-8] provide ionic character at pH above 7.0 and contribute a large amount of water absorption. 

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