Phenol from toluene

Table XVIII. Manufacture of Phenol from Toluene ...

In particular, the study was centered on the analysis of the behavior in toluene selective oxidation of a series of V-containing micro- and mesoporous materials [mesoporous (MCM-41), MFI (2SM-5) and P type]. The formation of phenol as a by-product has also been observed in some cases. This product does not form in toluene oxidation over vanadium oxide supported on AI2O3 or TiOa [2-6] and is an interesting first example of the possibility of direct synthesis of phenol from toluene using gaseous O2. A further objective of this work therefore was to identify the key aspects in this reaction as well as the possible reaction mechanism. 

The overall reaction network suggested by these experiments is shown in Scheme 1. The higher formation of phenol from toluene on V,-HMS catalysts, especially those with the higher... 

The production of phenol from toluene comprises two main steps ... 

Reading, W. W, How DOW makes phenol from toluene", Hydrocarbon Processing, 43 (11) 173-176 (1964). Pecka, L, Singer, P., Cumene/phenol purifreation by fractions melting" Europ. Chem. News, Large Plant SuppL, 82-84, (27 SepL 1968).. ... 

Figure 5.16 Flow diagram for the synthesis of phenol from toluene...

An additional useful test is to distil the acid or its sodium salt with soda lime. Heat 0.5 g. of the acid or its sodium salt with 0 2 g. of soda lime in an ignition tube to make certain that there is no explosion. Then grind together 0-5 g. of the acid with 3 g. of soda hme, place the mixture in a Pyrex test-tube and cover it with an equal bulk of soda hme. Fit a wide dehvery tube dipping into an empty test-tube. Clamp the tube near the mouth. Heat the soda lime first and then the mixture gradually to a dull-red heat. Examine the product this may consist of aromatic hydrocarbons or derivatives, e.g., phenol from sahcyUc acid, anisole from anisic acid, toluene from toluic acid, etc. 

Separations based upon differences in the chemical properties of the components. Thus a mixture of toluene and anihne may be separated by extraction with dilute hydrochloric acid the aniline passes into the aqueous layer in the form of the salt, anihne hydrochloride, and may be recovered by neutralisation. Similarly, a mixture of phenol and toluene may be separated by treatment with dilute sodium hydroxide. The above examples are, of comse, simple apphcations of the fact that the various components fah into different solubihty groups (compare Section XI,5). Another example is the separation of a mixture of di-n-butyl ether and chlorobenzene concentrated sulphuric acid dissolves only the w-butyl other and it may be recovered from solution by dilution with water. With some classes of compounds, e.g., unsaturated compounds, concentrated sulphuric acid leads to polymerisation, sulphona-tion, etc., so that the original component cannot be recovered unchanged this solvent, therefore, possesses hmited apphcation. Phenols may be separated from acids (for example, o-cresol from benzoic acid) by a dilute solution of sodium bicarbonate the weakly acidic phenols (and also enols) are not converted into salts by this reagent and may be removed by ether extraction or by other means the acids pass into solution as the sodium salts and may be recovered after acidification. Aldehydes, e.g., benzaldehyde, may be separated from liquid hydrocarbons and other neutral, water-insoluble hquid compounds by shaking with a solution of sodium bisulphite the aldehyde forms a sohd bisulphite compound, which may be filtered off and decomposed with dilute acid or with sodium bicarbonate solution in order to recover the aldehyde. 

Synthetic phenol capacity in the United States was reported to be ca 1.6 x 10 t/yr in 1989 (206), almost completely based on the cumene process (see Cumene Phenol). Some synthetic phenol [108-95-2] is made from toluene by a process developed by The Dow Chemical Company (2,299—301). Toluene [108-88-3] is oxidized to benzoic acid in a conventional LPO process. Liquid-phase oxidative decarboxylation with a copper-containing catalyst gives phenol in high yield (2,299—304). The phenoHc hydroxyl group is located ortho to the position previously occupied by the carboxyl group of benzoic acid (2,299,301,305). This provides a means to produce meta-substituted phenols otherwise difficult to make (2,306). VPOs for the oxidative decarboxylation of benzoic acid have also been reported (2,307—309). Although the mechanism appears to be similar to the LPO scheme (309), the VPO reaction is reported not to work for toluic acids (310). 

The second processing step, in which benzoic acid is oxidized and hydrolyzed to phenol, is carried out in two reactors in series. In the first reactor, the benzoic acid is oxidized to phenyl benzoate in the presence of air and a catalyst mixture of copper and magnesium salts. The reactor is operated at 234°C and 147 kPa gauge (1.5 kg/cm g uge). The phenyl benzoate is then hydrolyzed with steam in the second reactor to yield phenol and carbon dioxide. This occurs at 200°C and atmospheric pressure. The overall yield of phenol from benzoic acid is around 88 mol %. Figure 2 shows a simplified diagram for the toluene—benzoic acid process. 

Ammonia is used in the fibers and plastic industry as the source of nitrogen for the production of caprolactam, the monomer for nylon 6. Oxidation of propylene with ammonia gives acrylonitrile (qv), used for the manufacture of acryHc fibers, resins, and elastomers. Hexamethylenetetramine (HMTA), produced from ammonia and formaldehyde, is used in the manufacture of phenoHc thermosetting resins (see Phenolic resins). Toluene 2,4-cHisocyanate (TDI), employed in the production of polyurethane foam, indirectly consumes ammonia because nitric acid is a raw material in the TDI manufacturing process (see Amines Isocyanates). Urea, which is produced from ammonia, is used in the manufacture of urea—formaldehyde synthetic resins (see Amino resins). Melamine is produced by polymerization of dicyanodiamine and high pressure, high temperature pyrolysis of urea, both in the presence of ammonia (see Cyanamides). 

Benzoic Acid. Ben2oic acid is manufactured from toluene by oxidation in the liquid phase using air and a cobalt catalyst. Typical conditions are 308—790 kPa (30—100 psi) and 130—160°C. The cmde product is purified by distillation, crystallization, or both. Yields are generally >90 mol%, and product purity is generally >99%. Kalama Chemical Company, the largest producer, converts about half of its production to phenol, but most producers consider the most economic process for phenol to be peroxidation of cumene. Other uses of benzoic acid are for the manufacture of benzoyl chloride, of plasticizers such as butyl benzoate, and of sodium benzoate for use in preservatives. In Italy, Snia Viscosa uses benzoic acid as raw material for the production of caprolactam, and subsequendy nylon-6, by the sequence shown below. 

Because phenols are weak acids, they can be freed from neutral impurities by dissolution in aqueous N sodium hydroxide and extraction with a solvent such as diethyl ether, or by steam distillation to remove the non-acidic material. The phenol is recovered by acidification of the aqueous phase with 2N sulfuric acid, and either extracted with ether or steam distilled. In the second case the phenol is extracted from the steam distillate after saturating it with sodium chloride (salting out). A solvent is necessary when large quantities of liquid phenols are purified. The phenol is fractionated by distillation under reduced pressure, preferably in an atmosphere of nitrogen to minimise oxidation. Solid phenols can be crystallised from toluene, petroleum ether or a mixture of these solvents, and can be sublimed under vacuum. Purification can also be effected by fractional crystallisation or zone refining. For further purification of phenols via their acetyl or benzoyl derivatives (vide supra). 

Phenol is also produced from chlorobenzene and from toluene via a benzoic acid intermediate (see Reactions and Chemicals from Toluene ). 

Phenol was the first commercial antiseptic its introduction into hospitals in the 1870s led to a dramatic decrease in deaths from postoperative infections. Its use for this purpose has long since been abandoned because phenol burns exposed tissue, but many modern antiseptics are phenol derivatives. Toluene has largely replaced benzene as a solvent because it is much less toxic. Oxidation of toluene in the body gives benzoic acid, which is readily eliminated and has none of the toxic properties of the oxidation products of benzene. Indeed, benzoic acid or its sodium salt (Na+, C6H5COO ions) is widely used as a preservative in foods and beverages, including fruit juices and soft drinks. 

To a solution of 71.9 g (0.276 mol) of chlorotriisopropoxytitanium in 500 ntL of anhyd toluene are added 77.9 g (0.828 mol) of phenol. From the deep red solution, most of the i-PrOH and the solvent is removed by distillation through a 10-cm Vigretlx column. The residue is distilled in a Kugelrohr at 250 C bath temperature at 0.001 Torr to give an oil which crystallizes upon cooling yield 95.8 g (96%). A 0.26M slock solution in THF can be kept as described above. 

Fries MR, LJ Forney, JM Tiedje (1998b) Phenol- and toluene-degrading microbial populations from an aquifer in which successful trichloroethene cometabolism occurred. Appl Environ Microbiol 63 1523-1530. 

About 100 gal of process wastewater is typically generated from 1 t of coke produced.15 These wastewaters from byproduct coke making contain high levels of oil and grease, ammonia nitrogen, sulfides, cyanides, thiocyanates, phenols, benzenes, toluene, xylene, other aromatic volatile components, and polynuclear aromatic compounds. They may also contain toxic metals such as antimony, arsenic, selenium, and zinc. Water-to-air transfer of pollutants may take place due to the escape of volatile pollutants from open equalization and storage tanks and other wastewater treatment systems in the plant. 

Partial reduction of polyarenes has been reported. Use of boron trifluoride hydrate (BF3 OH2) as the acid in conjunction with triethylsilane causes the reduction of certain activated aromatic systems 217,262 Thus, treatment of anthracene with a 4-6 molar excess of BE3 OH2 and a 30% molar excess of triethylsilane gives 9,10-dihydroanthracene in 89% yield after 1 hour at room temperature (Eq. 120). Naphthacene gives the analogously reduced product in 88% yield under the same conditions. These conditions also result in the formation of tetralin from 1-hydroxynaphthalene (52%, 4 hours), 2-hydroxy naphthalene (37%, 7 hours), 1-methoxynaphthalene (37%, 10 hours), 2-methoxynaphthalene (26%, 10 hours), and 1-naphthalenethiol (13%, 6 hours). Naphthalene, phenanthrene, 1-methylnaphthalene, 2-naphthalenethiol, phenol, anisole, toluene, and benzene all resist reduction under these conditions.217 Use of deuterated triethylsilane to reduce 1-methoxynaphthalene gives tetralin-l,l,3-yielding information on the mechanism of these reductions.262 2-Mercaptonaphthalenes are reduced to 2,3,4,5-tetrahydronaphthalenes in poor to modest yields.217 263... 

Phenol has been obtained by distillation from petroleum and synthesis by oxidation of cumene or toluene, and by vapor-phase hydrolysis of chlorobenzene (USITC 1987). In 1995, 95% of U.S. phenol production was based on oxidation of cumene except at one company that used toluene oxidation and a few companies that distilled phenol from petroleum (CMR 1996). In 1995 the total annual capacity of phenol production approached 4.5 billion pounds (CMR 1996). 

As an example, consider phenol as the solute and water and toluene as two solvents. The parameters for phenol are A = 5.7, A = -12.9, A = -18.3, and A5 = 0.0091, whereas Aq is unspecified, but a negative quantity. With the solvent parameters from Tables 2.1 and 2.3, the standard Gibbs energy of solvation of phenol in water becomes Aq + 3.39, and in toluene Ao -1- 4.11 kJ mol". It is seen that As i,Gb is lower in water than in toluene, so that the transfer of phenol from water to toluene entails an increase in AjoItGb. The consequence of this is that phenol prefers water over toluene, since work would be required to make this transfer. It should be remembered that the standard Gibbs energies of solvation refer to the state of infinite dilution of the solute (solute-solute... 

The previous chapters have demonstrated that liquid-liquid extraction is a mass transfer unit operation involving two liquid phases, the raffinate and the extract phase, which have very small mutual solubihty. Let us assume that the raffinate phase is wastewater from a coke plant polluted with phenol. To separate the phenol from the water, there must be close contact with the extract phase, toluene in this case. Water and toluene are not mutually soluble, but toluene is a better solvent for phenol and can extract it from water. Thus, toluene and phenol together are the extract phase. If the solvent reacts with the extracted substance during the extraction, the whole process is called reactive extraction. The reaction is usually used to alter the properties of inorganic cations and anions so they can be extracted from an aqueous solution into the nonpolar organic phase. The mechanisms for these reactions involve ion pah-formation, solvation of an ionic compound, or formation of covalent metal-extractant complexes (see Chapters 3 and 4). Often formation of these new species is a slow process and, in many cases, it is not possible to use columns for this type of extraction mixer-settlers are used instead (Chapter 8). 

It is believed that during transalkylation the aliphatic side chains and bridges transfer from coal, without rearrangement, to the aromatic substrate such as phenol or toluene. A typical reaction is depicted in Scheme I. 

A minor route, which now accounts for 2% of phenol, takes advantage of the usual surplus of toluene from petroleum refining. Oxidation with a number of reagents gives benzoic acid. Further oxidation to p-hydroxybenzoic acid and decarboxylation yields phenol. Here phenol competes with benzene manufacture, also made from toluene when the surplus is large. The last 2% of phenol comes from distillation of petroleum and coal gasification. 

With aromatic compounds conditions can be found so that ring oxidation predominates and phenolic compounds are formed. Benzene is oxidized quantitatively to phenol. Toluene is oxidized to o-cresol, m-xy-lene to l,3-xylen-4-ol, and naphthalene to f-naphthol. The addition of certain additional catalyst, such as molybdenum oxide, promoted coupling reactions and biphenyl was formed from benzene, bi- or poly-tolyl hydrocarbons from toluene, di- and polyxylyls from wi-xylene, and a... 

Kennedy and Stock reported the first use of Oxone for many common oxidation reactions such as formation of benzoic acid from toluene and of benzaldehyde, of ben-zophenone from diphenyhnethane, of frawi-cyclohexanediol Ifom cyclohexene, of acetone from 2-propanol, of hydroquinone from phenol, of e-caprolactone from cyclohexanone, of pyrocatechol from salicylaldehyde, of p-dinitrosobenzene from p-phenylenediamine, of phenylacetic acid from 2-phenethylamine, of dodecylsulfonic acid from dodecyl mercaptan, of diphenyl sulfone from diphenyl sulfide, of triphenylphosphine oxide from triphenylphosphine, of iodoxy benzene from iodobenzene, of benzyl chloride from toluene using NaCl and Oxone and bromination of 2-octene using KBr and Oxone . Thus, they... 

Problem 19.9 Devise practical laboratory syntheses of the following phenols from benzene or toluene and any inorganic or aliphatic compounds (a) m-iodophenol, (b) 3-chloro-4-methylphenol, (c) 2-bromo-4-methylphenol. 

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