Methacrylic acid, from oxidation

Dehydrogenation of Propionates. Oxidative dehydrogenation of propionates to acrylates employing vapor-phase reactions at high temperatures (400—700°C) and short contact times is possible. Although selective catalysts for the oxidative dehydrogenation of isobutyric acid to methacrylic acid have been developed in recent years (see Methacrylic ACID AND DERIVATIVES) and a route to methacrylic acid from propylene to isobutyric acid is under pilot-plant development in Europe, this route to acrylates is not presentiy of commercial interest because of the combination of low selectivity, high raw material costs, and purification difficulties. 

Important classes of reactions not included in the above list, because they are not yet used on a commercial scale, are (i) the oxidative dehydrogenation of C2-C5 alkanes, (ii) the selective oxidation of alkanes, such as the synthesis of maleic and phthalic anhydride from n-pentane and methacrolein or methacrylic acid from isobutene, and (iii) propane ammoxidation to acrylonitrile [317-319]. 

Unsaturated organic acids(e.g., acrylic acid, CH2=CHC(0)0H and its derivatives) are produced as minor products in the ozonolysis of dienes, and from the OH-initiated oxidation of unsaturated aldehydes. The most important examples in the atmosphere involve the formation of methacrylic and acrylic acids from the ozonolysis of isoprene (Orzechowska and Paulson, 2005a) and the formation of methacrylic acid from the oxidation of methacrolein, itself a by-product of isoprene oxidation ... 

Processes have been developed whereby the oxygen is suppHed from the crystal lattice of a metal-oxide catalyst (5) (see Acrylonitrile Methacrylic acid AND derivatives). 

Poly(acrylic acid) and Poly(methacrylic acid). Poly(acryHc acid) (8) (PAA) may be prepared by polymerization of the monomer with conventional free-radical initiators using the monomer either undiluted (36) (with cross-linker for superadsorber appHcations) or in aqueous solution. Photochemical polymerization (sensitized by benzoin) of methyl acrylate in ethanol solution at —78° C provides a syndiotactic form (37) that can be hydrolyzed to syndiotactic PAA. From academic studies, alkaline hydrolysis of the methyl ester requires a lower time than acid hydrolysis of the polymeric ester, and can lead to oxidative degradation of the polymer (38). Po1y(meth acrylic acid) (PMAA) (9) is prepared only by the direct polymerization of the acid monomer it is not readily obtained by the hydrolysis of methyl methacrylate. 

Propylene-Based Routes. The strong acid-catalyzed carbonylation of propylene [115-07-1] to isobutyric acid (Koch reaction) followed by oxidative dehydration to methacrylic acid has been extensively studied since the 1960s. The principal side reaction in the Koch reaction is the formation of oligomers of propylene. Increasing yields of methacrylic acid in the oxydehydration step is the current focus of research. Isobutyric acid may also be obtained via the oxidation of isobutyraldehyde, which is available from the hydroformylation of propylene. The -butyraldehyde isomer that is formed in the hydroformylation must be separated. 

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. 

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). 

When equal amounts of solutions of poly(ethylene oxide) and poly(acryhc acid) ate mixed, a precipitate, which appears to be an association product of the two polymers, forms immediately. This association reaction is influenced by hydrogen-ion concentration. Below ca pH 4, the complex precipitates from solution. Above ca pH 12, precipitation also occurs, but probably only poly(ethylene oxide) precipitates. If solution viscosity is used as an indication of the degree of association, it appears that association becomes mote pronounced as the pH is reduced toward a lower limit of about four. The highest yield of insoluble complex usually occurs at an equimolar ratio of ether and carboxyl groups. Studies of the poly(ethylene oxide)—poly(methacryhc acid) complexes indicate a stoichiometric ratio of three monomeric units of ethylene oxide for each methacrylic acid unit. 

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. 

Neoprene AF ( 963). It is a polychloroprene modified with methacrylic acid. Although it is a slow-crystallizing elastomer, the cohesive strength develops very rapidly and it has improved creep resistance at high temperature compared with Neoprene AC or AD. The improved properties of Neoprene AF are derived from the interaction between the carboxyl functionality with the metal oxides added in the solvent-borne polychloroprene adhesives. 

Acrylic acid (AA) and methacrylic acid (MAA) (purchased from Merck) are freed from inhibitor on a neutral aluminium oxid column and distilled. Acrylamide (AM) from Kebo, Stockholm, is recrystallized once from chloroform solution before use. Other monomers of analytical grade were purchased from Merck and used as received crotonic acid (CA), tiglic acid (TA), 3-methyl crotonic acid (3-MCA), and a-methyl cinnamic acid (oi-MCia) (Table 1). Benzophenone (analytical grade, Kebo) and acetone (spectroscope grade, Merck) were used as supplied. 

Figure 14.2 shows the simplified flow sheet of the process, as reported in patents issued to Sumitomo. CO2 is maintained in the recycle loop to act as a ballast component the desired concentration of CO2 is obtained by combustion of CO, while excess CO2 is separated. Methacrolein is separated and recycled to the oxidation reactor. An overall recycle yield of 52% to methacrylic acid is reported, with a recycle conversion of 96% and a per-pass isobutane conversion of 10%. The heat of reaction produced, mainly deriving from the combustion reaction, is recovered as steam. 

It was proposed that the increase in activity during the equilibration period was due to the generation of new active sites,consisting of the Mo species located in the cationic position in the secondary framework of the POM. A similar hypothesis was formulated by other authors for the methacrolein oxidation to methacrylic acid." " More generally, it is currently believed that for exothermic reactions, and specifically for oxidations, the true working state of the POM, does not correspond to its crystalline form." The presence of steam and the large amount of heat released provoke an incipient surface decomposition, which leads to the expulsion of the Mo species from the anion as a metastable defective... 

Ethylene-Based (C-2> Routes. MMA and MAA can be produced from ethylene as a feedstock via propanol, propionic acid, or melhyl propionate as intermediates. Propanal may be prepared by hydrofonnylalion of ethylene over cobalt or rhodium catalysts. The propanal then reads in the liquid phase with formaldehyde in the presence of a secondary amine and. optionally, a carboxylic acid. The reaction presumably proceeds via a Mannich base intermediate which is cracked to yield methacrolcin. Alternatively, a gas-phase, crossed akin I reaelion with formaldehyde cataly zed by molecular sieves [Pg.988]

This reaction is another possible route for the production of methacrylic acid, since isobutyric acid can be obtained by an oxo process from propene and CO. Heteropoly compounds and iron phosphates are so far the most efficient catalysts for the reaction. The favorable role of the presence of an a-methyl group is remarkable for oxidative dehydrogenation, as the heteropoly compounds are not good catalysts for the dehydrogenation of propionic acid (338, 339). 

In the dehydrogenation of isobutyric acid, the by-products in addition to CO and C02 are propylene and acetone. Two reaction mechanisms were proposed (340, 341) and the latter is shown in Scheme 9 (340). The formation of methacrylic acid and acetone involves a common intermediate The El elimination of a proton from I yields the methacrylic acid while a nucleophilic SN1 attack of oxide ion produces C02 and acetone (344). On the other hand. 

Heteropoly catalysts have significant activities for the oxidation of isobutane into methacrolein and methacrylic acid. The yield increased up to 6% by vanadium substitution or salt formation, as follows. With Cs2.5Ni0.08H0.34+JrPV,Mo12 - O40, the highest conversion and selectivity were observed at x 1 (355). Increases in the reaction temperature to 613 K led to increased yields, up to 9.0%. A similar increase in the yield resulted from the substitution of As for P as a heteroatom or from the addition of various transition metals (106, 356). 

The ionic aggregates present in an ionomer act as physical crosslinks and drastically change the polymer properties. The blending of two ionomers enhances the compatibility via ion-ion interaction. The compatibilisation of polymer blends by specific ion-dipole and ion-ion interactions has recently received wide attention [93-96]. FT-IR spectroscopy is a powerful technique for investigating such specific interactions [97-99] in an ionic blend made from the acid form of sulfonated polystyrene and poly[(ethyl acrylate - CO (4, vinyl pyridine)]. Datta and co-workers [98] characterised blends of zinc oxide-neutralised maleated EPDM (m-EPDM) and zinc salt of an ethylene-methacrylic acid copolymer (Zn-EMA), wherein Zn-EMA content does not exceed 50% by weight. The blend behaves as an ionic thermoplastic elastomer (ITPE). Blends (Z0, Z5 and Z10) were prepared according to the following formulations [98] ... 

Osada202 described the mechanochemical system of poly(methacrylic acid)-poly(ethylene oxide) by utilizing intermacromolecular complexation between the two component polymers (Fig. 51). The PMAA membrane is contracted by more than 90% of its original length when heated from 10 to 60 °C. When decreasing the temperature, the membrane almost completely recovers its original state. The work spent per a contraction is about 5 x 10 3 cal/g of membrane. 

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