Molybdenum epoxidations

N. H. Sweed, Molybdenum epoxidation catalyst recovery, US Patent 4,455,283, June 19, 1984, To Atlantic Richfield Co. 

ARCO has developed a coproduct process which produces KA along with propylene oxide [75-56-9] (95—97). Cyclohexane is oxidized as in the high peroxide process to maximize the quantity of CHHP. The reactor effluent then is concentrated to about 20% CHHP by distilling off unreacted cyclohexane and cosolvent tert-huty alcohol [75-65-0]. This concentrate then is contacted with propylene [115-07-1] in another reactor in which the propylene is epoxidized with CHHP to form propylene oxide and KA. A molybdenum catalyst is employed. The product ratio is about 2.5 kg of KA pet kilogram of propylene oxide. 

The addition of an oxygen atom to an olefin to generate an epoxide is often catalyzed by soluble molybdenum complexes. The use of alkyl hydroperoxides such as tert-huty hydroperoxide leads to the efficient production of propylene oxide (qv) from propylene in the so-called Oxirane (Halcon or ARCO) process (79). 

The tert-huty hydroperoxide is then mixed with a catalyst solution to react with propylene. Some TBHP decomposes to TBA during this process step. The catalyst is typically an organometaHic that is soluble in the reaction mixture. The metal can be tungsten, vanadium, or molybdenum. Molybdenum complexes with naphthenates or carboxylates provide the best combination of selectivity and reactivity. Catalyst concentrations of 200—500 ppm in a solution of 55% TBHP and 45% TBA are typically used when water content is less than 0.5 wt %. The homogeneous metal catalyst must be removed from solution for disposal or recycle (137,157). Although heterogeneous catalysts can be employed, elution of some of the metal, particularly molybdenum, from the support surface occurs (158). References 159 and 160 discuss possible mechanisms for the catalytic epoxidation of olefins by hydroperoxides. 

After epoxidation, propylene oxide, excess propylene, and propane are distilled overhead. Propane is purged from the process propylene is recycled to the epoxidation reactor. The bottoms Hquid is treated with a base, such as sodium hydroxide, to neutralize the acids. Acids in this stream cause dehydration of the 1-phenylethanol to styrene. The styrene readily polymerizes under these conditions (177—179). Neutralization, along with water washing, allows phase separation such that the salts and molybdenum catalyst remain in the aqueous phase (179). Dissolved organics in the aqueous phase ate further recovered by treatment with sulfuric acid and phase separation. The organic phase is then distilled to recover 1-phenylethanol overhead. The heavy bottoms are burned for fuel (180,181). 

It is carried out in the Hquid phase at 100—130°C and catalyzed by a soluble molybdenum naphthenate catalyst, also in a series of reactors with interreactor coolers. The dehydration of a-phenylethanol to styrene takes place over an acidic catalyst at about 225°C. A commercial plant (50,51) was commissioned in Spain in 1973 by Halcon International in a joint venture with Enpetrol based on these reactions, in a process that became known as the Oxirane process, owned by Oxirane Corporation, a joint venture of ARCO and Halcon International. Oxirane Corporation merged into ARCO in 1980 and this process is now generally known as the ARCO process. It is used by ARCO at its Channelview, Texas, plant and in Japan and Korea in joint ventures with local companies. A similar process was developed by Shell (52—55) and commercialized in 1979 at its Moerdijk plant in the Netherlands. The Shell process uses a heterogeneous catalyst of titanium oxide on siHca support in the epoxidation step. Another plant by Shell is under constmction in Singapore (ca 1996). 

The selective oxidation is catalyzed by silver, which is the only good catalyst. Other olefins are not converted selectively to the epoxides in the presence of silver. However, propylene epoxidation is appHed commercially the catalysts are either molybdenum complexes in solution or soHd Ti02—Si02 (see... 

Olefin isomerization can be catalyzed by a number of catalysts such as molybdenum hexacarbonyl [13939-06-5] Mo(CO)g. This compound has also been found to catalyze the photopolymerization of vinyl monomers, the cyclization of olefins, the epoxidation of alkenes and peroxo species, the conversion of isocyanates to carbodiimides, etc. Rhodium carbonylhydrotris(triphenylphosphine) [17185-29-4] RhH(CO)(P(CgH )2)3, is a multifunctional catalyst which accelerates the isomerization and hydroformylation of alkenes. 

Liquid-Phase Epoxidation with Hydroperoxides. Molybdenum, vanadium, and tungsten have been proposed as Hquid-phase catalysts for the oxidation of the ethylene by hydroperoxides to ethylene oxide (205). tert- uty hydroperoxide is the preferred oxidant. The process is similar to the arsenic-catalyzed route, and iacludes the use of organometaUic complexes. 

Recently (79MI50500) Sharpless and coworkers have shown that r-butyl hydroperoxide (TBHP) epoxidations, catalyzed by molybdenum or vanadium compounds, offer advantages over peroxy acids with regard to safety, cost and, sometimes, selectivity, e.g. Scheme 73, although this is not always the case (Scheme 74). The oxidation of propene by 1-phenylethyl hydroperoxide is an important industrial route to methyloxirane (propylene oxide) (79MI5501). 

The molybdenum-catalyzed oxidation of alkynes by /-butyl hydroperoxide has been investigated 73JCS(P1)2851) (the epoxidation of alkenes by this system has become an important reaction Section 5.05.4.2.2(i)) but the formation of oxirenes was excluded. 

Molybdenum compounds Hydrodesulphurization and hydrotreating of petroleum Oxidation of methanol to formaldehdye Epoxidation of olefins Decomposition of alkali metal nitrides Irritation of eyes and respiratory tract Pneumoconiosis... 

As electrophilic substitutes for peracids, the use of borate ester induced decomposition of alkyl hydroperoxides and molybdenum VI peroxy-complexes have been reported in the recent literature. Although these reagents have led to the epoxidation of olefins in greater than 90% yield there are no reports yet of their application to steroid olefins. 

Epoxidation of propylene with ethylbenzene hydroperoxide is carried out at approximately 130°C and 35 atmospheres in presence of molybdenum catalyst. A conversion of 98% on the hydroperoxide has been reported ... 

Epoxidation systems based on molybdenum and tungsten catalysts have been extensively studied for more than 40 years. The typical catalysts - MoVI-oxo or WVI-oxo species - do, however, behave rather differently, depending on whether anionic or neutral complexes are employed. Whereas the anionic catalysts, especially the use of tungstates under phase-transfer conditions, are able to activate aqueous hydrogen peroxide efficiently for the formation of epoxides, neutral molybdenum or tungsten complexes do react with hydrogen peroxide, but better selectivities are often achieved with organic hydroperoxides (e.g., TBHP) as terminal oxidants [44, 45],... 

Molybdenum hexacarbonyl [Mo(CO)6] has been vised in combination with TBHP for the epoxidation of terminal olefins [44]. Good yields and selectivity for the epoxide products were obtained when reactions were performed under anhydrous conditions in hydrocarbon solvents such as benzene. The inexpensive and considerably less toxic Mo02(acac)2 is a robust alternative to Mo(CO)6 [2]. A number of different substrates ranging from simple ot-olefms to more complex terpenes have been oxidized with very low catalytic loadings of this particular molybdenum complex (Scheme 6.2). The epoxidations were carried out with use of dry TBHP (-70%) in toluene. 

The use of molybdenum catalysts in combination with hydrogen peroxide is not so common. Nevertheless, there are a number of systems in which molybdates have been employed for the activation of hydrogen peroxide. A catalytic amount of sodium molybdate in combination with monodentate ligands (e.g., hexaalkyl phosphorus triamides or pyridine-N-oxides), and sulfuric acid allowed the epoxidation of simple linear or cyclic olefins [46]. The selectivity obtained by this method was quite low, and significant amounts of diol were formed, even though highly concentrated hydrogen peroxide (>70%) was employed. 

The molybdenum-catalyzed conversion of alkenes into epoxides by alkyl hydroperoxides is an important commercial process.17,18 The synthetic potential of such reactions in regard to more complex organic molecules has been evaluated19 alkyl hydroperoxides are used as oxidants in the... 

In acyclic secondary -allylic alcohols, epoxidation by the vanadium system shows opposite stereospecificity to that of peracid and molybdenum carbonyl-mediated epoxidation (see Scheme 6)22 The predominance of the erythro isomer in the former process is rationalized22 in terms of the energetically more favorable transition state (6, cf. 5) and in this context the mechanism has analogy in the epoxidation behavior of medium-ring cyclic allylic alcohols.23... 

The reaction of olefin epoxidation by peracids was discovered by Prilezhaev [235]. The first observation concerning catalytic olefin epoxidation was made in 1950 by Hawkins [236]. He discovered oxide formation from cyclohexene and 1-octane during the decomposition of cumyl hydroperoxide in the medium of these hydrocarbons in the presence of vanadium pentaoxide. From 1963 to 1965, the Halcon Co. developed and patented the process of preparation of propylene oxide and styrene from propylene and ethylbenzene in which the key stage is the catalytic epoxidation of propylene by ethylbenzene hydroperoxide [237,238]. In 1965, Indictor and Brill [239] published studies on the epoxidation of several olefins by 1,1-dimethylethyl hydroperoxide catalyzed by acetylacetonates of several metals. They observed the high yield of oxide (close to 100% with respect to hydroperoxide) for catalysis by molybdenum, vanadium, and chromium acetylacetonates. The low yield of oxide (15-28%) was observed in the case of catalysis by manganese, cobalt, iron, and copper acetylacetonates. The further studies showed that molybdenum, vanadium, and... 

The catalyst is preliminarily oxidized to the state of the highest valence (vanadium to V5+ molybdenum to Mo6+). Only the complex of hydroperoxide with the metal in its highest valence state is catalytically active. Alcohol formed upon epoxidation is complexed with the catalyst. As a result, competitive inhibition appears, and the effective reaction rate constant, i.e., v/[olefin][ROOH], decreases in the course of the process due to the accumulation of alcohol. Water, which acts by the same mechanism, is still more efficient inhibitor. Several hypothetical variants were proposed for the detailed mechanism of epoxidation. 

From the energetics point of view, the epoxidation act should occur more easily (with a lower activation energy) in the coordination sphere of the metal when the cleavage of one bond is simultaneously compensated by the formation of another bond. For example, Gould proposed the following (schematic) mechanism for olefin epoxidation on molybdenum complexes [240] ... 

The formation of molybdenum complexes with diols (formed by olefin oxidation) was proved for the use of the molybdenum catalysts. Therefore, the participation of these complexes in the developed epoxidation reaction was assumed [242]. 

Sajus et al. [243,244] synthesized the peroxo complex of molybdenum(VI) and studied its reaction with a series of olefins. This peroxo complex M0O5 was proved to react with olefins with epoxide formation. The selectivity of the reaction increases with a decrease in the complex concentration. It was found to be as much as 95% at epoxidation of cyclohexene by M0O3 in a concentration 0.06 mol L-1 at 288 K in dichloroethylene [244], The rate of the reaction was found to be... 

SMPO [styrene monomer propylene oxide] A process for making propylene oxide by the catalytic epoxidation of propylene. The catalyst contains a compound of vanadium, tungsten, molybdenum, or titanium on a silica support. Developed by Shell and operated in The Netherlands since 1978. 

The transformations discussed in Sects. 2.2-2.3 highlight several important features of the RCM process. Firstly, the compatibility of the ruthenium initiator 3 with a wide range of functional groups including epoxides, vinyl iodides, thia-zoles and alcohols is demonstrated. The versatility of 3 is further illustrated in Sect. 2.3, where it is used to effect RCM of polymer-bound substrates. Previously, the molybdenum complex 1 has been reported to be more sensitive than 3 [19]. Experiments reported here are consistent with this view (Sect. 2.2.3) [14b]. 

A mixed-valent polymolybdate on active carbon was prepared from molybdenum metal and H202, followed by the addition of active carbon to the aqueous solution [114,115], This catalyzed the epoxidation of several alkenes in 2-propanol using H202 as an oxidant, while the efficiency of H202 utilization was very low (< 25%). The epoxidation likely proceeded mainly on the surface of the catalyst because the recovered catalyst showed almost similar catalytic activity. 

Figure 15. Energies (in kcal/mol) of intermediates and TSs of ethene epoxidation by various molybdenum peroxo and hydroperoxo complexes, relative to the energy of MoOtC h tNHjh (2b) +C2H4.

---