Phosgene preparation

A summary of recently filed patent applications and granted patents regarding phosgene preparation is presented in Table 2.1. 

Crystalline solid m.p. 35-36 "C, b.p. 154--156 C, prepared by oxidizing A,A -dicycIo-hexylthiourea with HgO in carbon disulphide solution, also obtained from cyclohexylamine and phosgene at elevated temperatures. Used as a mild dehydrating agent, especially in the synthesis of p>eptides from amino-acids. Potent skin irritant. 

Nacconate 100 A lachrymatory liquid b.p. 25l°C. Manufactured from phosgene and 2,4-diaminotoJuene. Used for preparing polyurethane foams and other elastomers by reaction with polyhydroxy compounds. Produces skin irritation and causes allergic eczema and bronchial asthma. 

A contact insecticide with the trade name Sevin . White solid, m.p. 142 C. It is prepared by reaction of I-naphthol with methyl isocyanate or with phosgene and a base. 

CaHjNCO, PhNCO. A pungent lachrymatory almost colourless liquid m.p. — 33 "C, b.p. 162°C. Used as a dehydrating agent and for characterization of alcohols. Prepared from aniline and phosgene in the presence of hydrogen chloride. 

Michler s ketone is prepared industrially by the interaction of phosgene (COCl,) and dimethyl aniline. 

The cyclic carbonate of benzoin (4,5-diphenyl-l,3-dioxol-2-one, prepared from benzoin and phosgene) blocks both hydrogen atoms of primary amines after dehydration acid stable, easily crystallizable Sheehan oxazolinones are formed, which are also called Ox derivatives. The amine is quantitatively deblocked by catalytic hydrogenation in the presence of 1 equiv. of aqueous acid (J.C Sheehan, 1972, 1973 M.J. Miller, 1983). An intelligent application to syntheses of acid labile -lactams is given in the previous section (p. 161). 

Urea derivadves are of general interest in medicinal chemistry. They may be obtained cither from urea itself (barbiturates, sec p. 306) or from amines and isocyanates. The latter are usually prepared from amines and phosgene under evolution of hydrogen chloride. Alkyl isocyanates are highly reactive in nucleophilic addidon reactions. Even amides, e.g. sulfonamides, are nucleophilic enough to produce urea derivatives. 

Other acetyl chloride preparations include the reaction of acetic acid and chlorinated ethylenes in the presence of ferric chloride [7705-08-0] (29) a combination of ben2yl chloride [100-44-7] and acetic acid at 85% yield (30) conversion of ethyUdene dichloride, in 91% yield (31) and decomposition of ethyl acetate [141-78-6] by the action of phosgene [75-44-5] producing also ethyl chloride [75-00-3] (32). The expense of raw material and capital cost of plant probably make this last route prohibitive. Chlorination of acetic acid to monochloroacetic acid [79-11-8] also generates acetyl chloride as a by-product (33). Because acetyl chloride is cosdy to recover, it is usually recycled to be converted into monochloroacetic acid. A salvage method in which the mixture of HCl and acetyl chloride is scmbbed with H2SO4 to form acetyl sulfate has been patented (33). 

Rea.ctlons, The chemistry of butanediol is deterrnined by the two primary hydroxyls. Esterification is normal. It is advisable to use nonacidic catalysts for esterification and transesterification (122) to avoid cycHc dehydration. When carbonate esters are prepared at high dilutions, some cycHc ester is formed more concentrated solutions give a polymeric product (123). With excess phosgene the usefiil bischloroformate can be prepared (124). 

Rea.ctlons, As with other tertiary alcohols, esterification with carboxyUc acids is difficult and esters are prepared with anhydrides (181), acid chlorides (182), or ketene (183). Carbamic esters may be prepared by treatment with an isocyanate (184) or with phosgene followed by ammonia or an amine (185). 

Brominated C rbon te Oligomers. There are two commercial brominated carbonate oligomer (BrCO) products. Both are prepared from tetrabromobisphenol A and phosgene. One has phenoxy end caps [28906-13-0] and the other trihromophenoxy [71342-77-3] end caps. These are used primarily in PBT and polycarbonate/acrylonittile—butadiene—styrene (PC/ABS) blends. 

Preparation of Arylcarboxylic Acids and Derivatives. The general Friedel-Crafts acylation principle can be successfully appHed to the preparation of aromatic carboxyUc acids. Carbonyl haUdes (phosgene, carbonyl chloride fluoride, or carbonyl fluoride) [353-50-4] are diacyl haUdes of carbonic acid. Phosgene [75-44-5] or oxalyl chloride [79-37-8] react with aromatic hydrocarbons to give aroyl chlorides that yield acids on hydrolysis (133) ... 

Ketone formation can also be avoided if one of the functional acyl halogens ia phosgene is blocked. Carbamyl chlorides, readily obtained by the reaction of phosgene with ammonia or amines, are suitable reagents for the preparation of amides ia direct Friedel-Crafts acylation of aromatics. The resulting amides can be hydroly2ed to the corresponding acids (134) ... 

Preparation from Amines. The most common method of preparing isocyanates, even on a commercial scale, involves the reaction of phosgene [75-44-5] and aromatic or aUphatic amine precursors. The initial reaction step, the formation of N-substituted carbamoyl chloride (1), is highly exothermic and is succeeded by hydrogen chloride elimination which takes place at elevated temperatures. 

Oligomers of phosgene, such as diphosgene [503-38-8] (COCl2)2, have found use in the laboratory preparation of isocyanates. Carbamoyl chlorides, A[,A/-disubstituted ureas, dimethyl- and diphenylcarbonates, and arylsulfonyl isocyanates have also been used to convert amines into urea intermediates, which are subsequendy pyroly2ed to yield isocyanates. These methods have found appHcations for preparation of low boiling point aUphatic isocyanates (2,9,17). 

More convenient is the use of aryl a2ides which are readily converted into isocyanates upon heating in nonreactive solvents via the loss of nitrogen. The latter method is useful for the synthesis of isocyanates with additional substituents which could not be prepared with phosgene (20). 

For methylene diphenyl diisocyanate (MDI), the initial reaction involves the condensation of aniline [62-53-3] (21) with formaldehyde [50-00-0] to yield a mixture of oligomeric amines (22, where n = 1, 2, 3...). For toluene diisocyanate, amine monomers are prepared by the nitration (qv) of toluene [108-88-3] and subsequent hydrogenation (see Amines byreduction). These materials are converted to the isocyanate, in the majority of the commercial aromatic isocyanate phosgenation processes, using a two-step approach. 

Low boiling isocyanates, such as methyl isocyanate [624-83-9] are difficult to prepare via conventional phosgenation due to the fact that the A/-alkyl carbamoyl chlorides are volatile below their decomposition poiat. Interestingly, A/-ethyl carbamoyl chloride decomposes at its boiling poiat whereas the A/-propyl carbamoyl chloride is thermoly2ed cleanly into isocyanate and hydrogen chloride. 

Commercially important arenesulfonyl isocyanates are not directly accessible from the corresponding sulfonamides via phosgenation due to lack of reactivity or by-product formation at elevated temperatures. A convenient method for their preparation consists of the reaction of alkyl isocyanates with sulfonamides to produce mixed ureas which, upon phosgenation, yield a mixture of alkyl and arenesulfonyl isocyanates. The desired product can be obtained by simple distillation (16). Optionally, the oxalyl chloride route has been employed for the synthesis of arenesulfonyl isocyanate (87). 

Naphthol is mainly used in the manufacture of the insecticide carbaryl (59), l-naphthyl A/-methyicarbamate/ iJ-2j5 - (Sevin) (22), which is produced by the reaction of 1-naphthol with methyl isocyanate. Methyl isocyanate is usually prepared by treating methylamine with phosgene. Methyl isocyanate is a very toxic Hquid, boiling at 38°C, and should not be stored for long periods of time (Bhopal accident, India). India has developed a process for the preparation of aryl esters of A/-alkyl carbamic acids. Thus l-naphthyl methylcarbamate is prepared by refluxing 1-naphthol with ethyl methylcarbamate and POCl in toluene (60). In 1992, carbaryl production totaled > 11.4 x 10 t(35). Rhc ne-Poulenc, at its Institute, W. Va., facihty is the only carbaryl producer in United States. 

An important direct use of phosgene is in the preparation of polymers. Polycarbonate is the most significant and commercially valuable material (see Polycarbonates). However, the use of phosgene has been described for other polymer systems, eg, fiber-forming polymeric polyketones and polyureas (90,91). 

Polycarbonates are prepared commercially by two processes Schotten-Baumaim reaction of phosgene (qv) and an aromatic diol in an amine-cataly2ed interfacial condensation reaction or via base-cataly2ed transesterification of a bisphenol with a monomeric carbonate. Important products are also based on polycarbonate in blends with other materials, copolymers, branched resins, flame-retardant compositions, foams (qv), and other materials (see Flame retardants). Polycarbonate is produced globally by several companies. Total manufacture is over 1 million tons aimuaHy. Polycarbonate is also the object of academic research studies, owing to its widespread utiUty and unusual properties. Interest in polycarbonates has steadily increased since 1984. Over 4500 pubflcations and over 9000 patents have appeared on polycarbonate. Japan has issued 5654 polycarbonate patents since 1984 Europe, 1348 United States, 777 Germany, 623 France, 30 and other countries, 231. 

---