Methacroleine

Unsaturated aldehydes undergo a similar reaction in the presence of strongly acid ion-exchange resins to produce alkenyUdene diacetates. Thus acrolein [107-02-8] or methacrolein [78-85-3] react with equimolar amounts of anhydride at —10°C to give high yields of the -diacetates from acetic anhydride, useful for soap fragrances. 

There is a significant difference in the toxicological effects of saturated and unsaturated afiphatic aldehydes. As can be seen in Table 6, the presence of the double bond considerably enhances toxicity. The precautions for handling reactive unsaturated aldehydes such as acrolein, methacrolein [78-85-3] and crotonaldehyde should be the same as those for handling other highly active eye and pulmonary irritants, as, for example, phosgene. 

The oxidative dehydration of isobutyric acid [79-31-2] to methacrylic acid is most often carried out over iron—phosphoms or molybdenum—phosphoms based catalysts similar to those used in the oxidation of methacrolein to methacrylic acid. Conversions in excess of 95% and selectivity to methacrylic acid of 75—85% have been attained, resulting in single-pass yields of nearly 80%. The use of cesium-, copper-, and vanadium-doped catalysts are reported to be beneficial (96), as is the use of cesium in conjunction with quinoline (97). Generally the iron—phosphoms catalysts require temperatures in the vicinity of 400°C, in contrast to the molybdenum-based catalysts that exhibit comparable reactivity at 300°C (98). 

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. 

Isobutjiene [115-11-7] or tert-huty alcohol can be converted to methacrylic acid in a two-stage, gas-phase oxidation process via methacrolein as an intermediate. The alcohol and isobutjiene may be used interchangeably in the processes since tert-huty alcohol [75-65-0] readily dehydrates to yield isobutjiene under the reaction conditions in the initial oxidation. Variations of this process have been commercialized by Mitsubishi Rayon and by a joint venture of Sumitomo and Nippon Shokubai. Nippon Kayaku, Mitsui Toatsu, and others have also been active in isobutjiene oxidation research. 

The first-stage catalysts for the oxidation to methacrolein are based on complex mixed metal oxides of molybdenum, bismuth, and iron, often with the addition of cobalt, nickel, antimony, tungsten, and an alkaU metal. Process optimization continues to be in the form of incremental improvements in catalyst yield and lifetime. Typically, a dilute stream, 5—10% of isobutylene tert-huty alcohol) in steam (10%) and air, is passed over the catalyst at 300—420°C. Conversion is often nearly quantitative, with selectivities to methacrolein ranging from 85% to better than 95% (114—118). Often there is accompanying selectivity to methacrylic acid of an additional 2—5%. A patent by Mitsui Toatsu Chemicals reports selectivity to methacrolein of better than 97% at conversions of 98.7% for a yield of methacrolein of nearly 96% (119). 

The oxidation of methacrolein to methacrylic acid is most often performed over a phosphomolybdic acid-based catalyst, usually with copper, vanadium, and a heavy alkaU metal added. Arsenic and antimony are other common dopants. Conversions of methacrolein range from 85—95%, with selectivities to methacrylic acid of 85—95%. Although numerous catalyst improvements have been reported since the 1980s (120—123), the highest claimed yield of methacryhc acid (86%) is still that described in a 1981 patent to Air Products (124). 

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. 

Ca.ta.lysts, A small amount of quinoline promotes the formation of rigid foams (qv) from diols and unsaturated dicarboxyhc acids (100). Acrolein and methacrolein 1,4-addition polymerisation is catalysed by lithium complexes of quinoline (101). Organic bases, including quinoline, promote the dehydrogenation of unbranched alkanes to unbranched alkenes using platinum on sodium mordenite (102). The peracetic acid epoxidation of a wide range of alkenes is catalysed by 8-hydroxyquinoline (103). Hydroformylation catalysts have been improved using 2-quinolone [59-31-4] (104) (see Catalysis). 

The handling of toxic materials and disposal of ammonium bisulfate have led to the development of alternative methods to produce this acid and the methyl ester. There are two technologies for production from isobutylene now available ammoxidation to methyl methacrylate (the Sohio process), which is then solvolyzed, similar to acetone cyanohydrin, to methyl methacrylate and direct oxidation of isobutylene in two stages via methacrolein [78-85-3] to methacryhc acid, which is then esterified (125). Since direct oxidation avoids the need for HCN and NH, and thus toxic wastes, all new plants have elected to use this technology. Two plants, Oxirane and Rohm and Haas (126), came on-stream in the early 1980s. The Oxirane plant uses the coproduct tert-huty alcohol direcdy rather than dehydrating it first to isobutylene (see Methacrylic acid). 

The performance of many metal-ion catalysts can be enhanced by doping with cesium compounds. This is a result both of the low ionization potential of cesium and its abiUty to stabilize high oxidation states of transition-metal oxo anions (50). Catalyst doping is one of the principal commercial uses of cesium. Cesium is a more powerflil oxidant than potassium, which it can replace. The amount of replacement is often a matter of economic benefit. Cesium-doped catalysts are used for the production of styrene monomer from ethyl benzene at metal oxide contacts or from toluene and methanol as Cs-exchanged zeofltes ethylene oxide ammonoxidation, acrolein (methacrolein) acryflc acid (methacrylic acid) methyl methacrylate monomer methanol phthahc anhydride anthraquinone various olefins chlorinations in low pressure ammonia synthesis and in the conversion of SO2 to SO in sulfuric acid production. 

Methyl-4-lomiylcyclohex-2-ene-1-one (5). A mixture of 3 and methacrolein 4 in Ph was refluxed for 24 h. After workup 5 was obtained in 72% yield. 

RSSiMe3 [R = Me, Et, (-CH2-)3], Zn, Et20, 0-25°, 70-95% yield. This method is satisfactory for a variety of aldehydes and ketones and is also suitable for the preparation of 1,3-dithianes. Methacrolein gives the product of Michael addition rather than the thioacetal. The less hindered of two ketones is readily protected using this methodology. ... 

Methacrylonitrile [126-98-7] M 67.1, b 90.3 , d 0.800, n 1.4007, n 1.3954. Washed (to remove inhibitors such as p-rcrt-butylcatechol) with satd aq NaHS03, 1% NaOH in saturated NaCl and then with saturated NaCl. Dried with CaCl2 and fractionally distd under nitrogen to separate from impurities such as methacrolein and acetone. 

Chiral aluminum catalyst 2, prepared from Et2AlCl and a Vaulted biaryl ligand, is reported to be an effective Lewis acid catalyst of the Diels-AIder reaction between methacrolein and cyclopentadiene, affording the adduct in 97.7% ee [4] (Scheme 1.2). Although the Diels-AIder reaction with other a,/ -unsaturated aldehydes has not been described, that only 0.5 mol% loading is sufficient to promote the reaction is a great advantage of this catalyst. 

The Chiral Lewis Acid-catalyzed Diels-Alder Reaction 9 Fig. 1.1 CAB catalyst 3 and methacrolein Me... 

The structure of the complex of (S)-tryptophan-derived oxazaborolidine 4 and methacrolein has been investigated in detail by use of H, B and NMR [6b. The proximity of the coordinated aldehyde and indole subunit in the complex is suggested by the appearance of a bright orange color at 210 K, caused by formation of a charge-transfer complex between the 7t-donor indole ring and the acceptor aldehyde. The intermediate is thought to be as shown in Fig. 1.2, in which the s-cis conformer is the reactive one. 

To overcome these problems with the first generation Brmsted acid-assisted chiral Lewis acid 7, Yamamoto and coworkers developed in 1996 a second-generation catalyst 8 containing the 3,5-bis-(trifluoromethyl)phenylboronic acid moiety [10b,d] (Scheme 1.15, 1.16, Table 1.4, 1.5). The catalyst was prepared from a chiral triol containing a chiral binaphthol moiety and 3,5-bis-(trifluoromethyl)phenylboronic acid, with removal of water. This is a practical Diels-Alder catalyst, effective in catalyzing the reaction not only of a-substituted a,/ -unsaturated aldehydes, but also of a-unsubstituted a,/ -unsaturated aldehydes. In each reaction, the adducts were formed in high yields and with excellent enantioselectivity. It also promotes the reaction with less reactive dienophiles such as crotonaldehyde. Less reactive dienes such as isoprene and cyclohexadiene can, moreover, also be successfully employed in reactions with bromoacrolein, methacrolein, and acrolein dienophiles. The chiral ligand was readily recovered (>90%). 

Mikami et al. have reported that the chiral titanium reagent 12 derived from bi-naphthol and TiCl2(0-i-Pr)2 catalyzes the Diels-Adder reaction of a-bromoacrolein or methacrolein with isoprene or 1-methoxy-l,3-butadiene to afford the cycloadducts with high enantioselectivity [18] (Scheme 1.25). 

Evans et al. reported that the his(oxazolinyl)pyridine (pybox) complex of copper(II) 17 is a selective catalyst of Diels-Alder reactions between a-bromoacrolein or methacrolein and cydopentadiene affording the adducts in high enantioselectivity [23] (Scheme 1.30). Selection of the counter-ion is important to achieve a satisfactory reaction rate and enantioselectivity, and [Cu(pyhox)](ShFg)2 gave the best result. This catalyst is also effective for the Diels-Alder reaction of acrylate dieno-philes (vide infra). 

Evans s bis(oxazolinyl)pyridine (pybox) complex 17, which is effective for the Diels-Alder reaction of a-bromoacrolein and methacrolein (Section 2.1), is also a suitable catalyst for the Diels-Alder reaction of acrylate dienophiles [23] (Scheme 1.33). In the presence of 5 mol% of the Cu((l )-pybox)(SbF5)2 catalyst with a benzyl substituent, tert-butyl acrylate reacts with cyclopentadiene to give the adduct in good optical purity (92% ee). Methyl acrylate and phenyl acrylate underwent cycloadditions with lower selectivities. 

Monodentate dipolarophiles such as acrolein, methacrolein, and a-bromoacrolein could be successfully utilized in the l ,J -DBFOX/Ph-transition metal complex-catalyzed asymmetric nitrone cycloadditions [76]. The reactions of N-benzylideneani-line N-oxide with acrolein in the presence of the nickel(II) aqua complex R,R-DBF0X/Ph-Ni(C104)2 3H20 (10mol%) and MS 4 A produced a mixture of two regioisomers (5-formyl/4-formyl regioisomers ca 3 1). However, enantio-... 

Much like the oxidation of propylene, which produces acrolein and acrylic acid, the direct oxidation of isobutylene produces methacrolein and methacrylic acid. The catalyzed oxidation reaction occurs in two steps due to the different oxidation characteristics of isobutylene (an olefin) and methacrolein (an unsaturated aldehyde). In the first step, isobutylene is oxidized to methacrolein over a molybdenum oxide-based catalyst in a temperature range of 350-400°C. Pressures are a little above atmospheric ... 

In the second step, methacrolein is oxidized to methacrylic acid at a relatively lower temperature range of 250-350°C. A molybdenum-supported compound with specific promoters catalyzes the oxidation. 

Johnson s classic synthesis of progesterone (1) commences with the reaction of 2-methacrolein (22) with the Grignard reagent derived from l-bromo-3-pentyne to give ally lie alcohol 20 (see Scheme 3a). It is inconsequential that 20 is produced in racemic form because treatment of 20 with triethyl orthoacetate and a catalytic amount of propionic acid at 138 °C furnishes 18 in an overall yield of 55 % through a process that sacrifices the stereogenic center created in the carbonyl addition reaction. In the presence of propionic acid, allylic alcohol 20 and triethyl orthoacetate combine to give... 

Of substantial interest for the synthesis of fibre-forming reactive AN copolymers is the use of methacrolein 4 as second monomer, which affords copolymers of type 5, containing aldehyde groups. 

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