Phosphoric catalysts

Rare-earth nanomaterials find numerous applications as phosphors, catalysts, permanent magnets, fuel cell electrodes and electrolytes, hard alloys, and superconductors. Yan and coauthors focus on inorganic non-metallic rare-earth nanomaterials prepared using chemical synthesis routes, more specifically, prepared via various solution-based routes. Recent discoveries in s)mthesis and characterization of properties of rare-earth nanomaterials are systematically reviewed. The authors begin with ceria and other rare-earth oxides, and then move to oxysalts, halides, sulfides, and oxysulfides. In addition to comprehensive description of s)mthesis routes that lead to a variety of nanoforms of these interesting materials, the authors pay special attention to summarizing most important properties and their relationships to peculiar structural features of nanomaterials s)mthesized over the last 10-15 years. 

The compounds of groups IIB-IVB are often prepared in poiycrystaliine form as phosphors, catalysts (15.2.2.2) and infrared transmitting materials. Their use as semiconductors is almost exclusively for optoelectronic purposes (i.e., light emission and detection). Thus the phosphor preparation technology has relevance to preparation of these semiconductors in powder form. The most common reactions employed are... 

In the presence of a red phosphorous catalyst, chlorine and bromine react with carboxylic acids to produce a-halo acids. When excess amounts of halogen are used, the number of substituted hydrogens increases. 

Materials consisting of nanometer-sized particles have drawn substantial attention in a wide range of research fields, mostly for their various unique properties originating from their small size or related high specific surface area. For this reason, the nanoscale materials are considered for many applications (e.g., as phosphors, catalysts, or sorbents). This chapter summarizes methods for radiation preparation of various metal oxides and reviews their selected prospective applications. 

As an alternate intermediate, adiponitrile is employed to react with hexamethylene diamine and steam in a multistage distillation column to prepare nylon-6,6 [194]. The process is carried out in the presence of an oxygen-containing phosphorous catalyst at an elevated temperature and pressure. Nylon-6,6 of high molecular weight can be produced by the postpolymerization of lower molecular weight polymer in the molten state in the presence of a phosphonic acid catalyst [195] or in the solid state [196]. In a different approach, a prepolymer is formed in a reactor system. 

Industrially important sihcides have been synthesized by microwave reactions. A notable example is MoSi [13]. Metal phosphates have extensively been studied for applications as phosphors, catalysts and as cathode materials in lithium ion batteries. Several lanthanide orthophosphates, LnPO (Ln=La, Ce, Nd, Sm, Eu, Gd and Tb), are obtained by microwave heating of an aqueous solution of Ln(III) nitrate and NH H PO [14], Highly crystalline ohvine LiFePO nanorods are directly obtained within 5 min by microwave heating of lithium hydroxide, iron acetate and phosphoric acid in tetraethyleneglycol [15]. 

Dysprosium (Dy) Owing to its important thermal neutron cross section, dysprosium is used to produce control rods in nuclear reactors and also as a neutron flux measurement. The alloy Tb Dy Fe, is used as a magnetostrictive material. The alloy Nd-Fe-B is a permanent magnet. Finally, dysprosium is also used as phosphors, catalysts, and garnet microwave devices. 

A plausible reaction mechanism was suggested by the authors on the basis of DFT calculations and in previous modes of activation for this kind of phosphoric catalysts (Scheme 9.11). 

Pinacol upon dehydration with acid catalysts e.g., by distillation from 6A sulphuric acid or upon refluxing for 3—4 hours with 50 per cent, phosphoric acid or hydrated oxalic acid) is transformed into methyl ter<.-butyr ketone or plnacolone ... 

In peptide syntheses, where partial racemization of the chiral a-carbon centers is a serious problem, the application of 1-hydroxy-1 H-benzotriazole ( HBT") and DCC has been very successful in increasing yields and decreasing racemization (W. Kdnig, 1970 G.C. Windridge, 1971 H.R. Bosshard, 1973), l-(Acyloxy)-lif-benzotriazoles or l-acyl-17f-benzo-triazole 3-oxides are formed as reactive intermediates. If carboxylic or phosphoric esters are to be formed from the acids and alcohols using DCC, 4-(pyrrolidin-l -yl)pyridine ( PPY A. Hassner, 1978 K.M. Patel, 1979) and HBT are efficient catalysts even with tert-alkyl, choles-teryl, aryl, and other unreactive alcohols as well as with highly bulky or labile acids. 

Polymerization. Paraldehyde, 2,4,6-trimethyl-1,3-5-trioxane [123-63-7] a cycHc trimer of acetaldehyde, is formed when a mineral acid, such as sulfuric, phosphoric, or hydrochloric acid, is added to acetaldehyde (45). Paraldehyde can also be formed continuously by feeding Hquid acetaldehyde at 15—20°C over an acid ion-exchange resin (46). Depolymerization of paraldehyde occurs in the presence of acid catalysts (47) after neutralization with sodium acetate, acetaldehyde and paraldehyde are recovered by distillation. Paraldehyde is a colorless Hquid, boiling at 125.35°C at 101 kPa (1 atm). 

Nearly all commercial acetylations are realized using acid catalysts. Catalytic acetylation of alcohols can be carried out using mineral acids, eg, perchloric acid [7601-90-3], phosphoric acid [7664-38-2], sulfuric acid [7664-93-9], benzenesulfonic acid [98-11-3], or methanesulfonic acid [75-75-2], as the catalyst. Certain acid-reacting ion-exchange resins may also be used, but these tend to decompose in hot acetic acid. Mordenite [12445-20-4], a decationized Y-zeohte, is a useful acetylation catalyst (28) and aluminum chloride [7446-70-0], catalyzes / -butanol [71-36-3] acetylation (29). 

Early catalysts for acrolein synthesis were based on cuprous oxide and other heavy metal oxides deposited on inert siHca or alumina supports (39). Later, catalysts more selective for the oxidation of propylene to acrolein and acrolein to acryHc acid were prepared from bismuth, cobalt, kon, nickel, tin salts, and molybdic, molybdic phosphoric, and molybdic siHcic acids. Preferred second-stage catalysts generally are complex oxides containing molybdenum and vanadium. Other components, such as tungsten, copper, tellurium, and arsenic oxides, have been incorporated to increase low temperature activity and productivity (39,45,46). 

Polygas Olefins. Refinery propylene and butenes are polymerized with a phosphoric acid catalyst at 200°C and 3040—6080 kPa (30—60 atm) to give a mixture of branched olefins up to used primarily in producing plasticizer alcohols (isooctyl, isononyl, and isodecyl alcohol). Since the olefins are branched (75% have two or more CH groups) the alcohols are also branched. Exxon, BASE, Ruhrchemie (now Hoechst), ICl, Nissan, Getty Oil, U.S. Steel Chemicals (now Aristech), and others have all used this olefin source. 

Propylation of benzene with propylene, catalyzed by supported phosphoric acid (or related catalysts such as AlCl ), gives cumene [98-82-8] in another important industrial process. Cumene (qv), through the intermediacy of cumene hydroperoxide, is used in the manufacture of phenol (qv). Resorcinol similarly can be made from y -diisopropylbenzene (6). 

Hydrogen Chloride as By-Product from Chemical Processes. Over 90% of the hydrogen chloride produced in the United States is a by-product from various chemical processes. The cmde HCl generated in these processes is generally contaminated with impurities such as unreacted chlorine, organics, chlorinated organics, and entrained catalyst particles. A wide variety of techniques are employed to treat these HCl streams to obtain either anhydrous HCl or hydrochloric acid. Some of the processes in which HCl is produced as a by-product are the manufacture of chlorofluorohydrocarbons, manufacture of aUphatic and aromatic hydrocarbons, production of high surface area siUca (qv), and the manufacture of phosphoric acid [7664-38-2] and esters of phosphoric acid (see Phosphoric acid and phosphates). 

The condensation of cyclohexanol or cyclohexene is generally carried out in the presence of phosphoric acid, pyrophosphoric acid, or HY 2eohtes the aromatization of intermediate cyclohexyUiydroquinone [4197-75-5] (19) is realized in the presence of a dehydrogenation catalyst. 

The synthesis of 2,4-dihydroxyacetophenone [89-84-9] (21) by acylation reactions of resorcinol has been extensively studied. The reaction is performed using acetic anhydride (104), acetyl chloride (105), or acetic acid (106). The esterification of resorcinol by acetic anhydride followed by the isomerization of the diacetate intermediate has also been described in the presence of zinc chloride (107). Alkylation of resorcinol can be carried out using ethers (108), olefins (109), or alcohols (110). The catalysts which are generally used include sulfuric acid, phosphoric and polyphosphoric acids, acidic resins, or aluminum and iron derivatives. 2-Chlororesorcinol [6201-65-1] (22) is obtained by a sulfonation—chloration—desulfonation technique (111). 1,2,4-Trihydroxybenzene [533-73-3] (23) is obtained by hydroxylation of resorcinol using hydrogen peroxide (112) or peracids (113). 

In the three-step process acetone first undergoes a Uquid-phase alkah-cataly2ed condensation to form diacetone alcohol. Many alkaU metal oxides, metal hydroxides (eg, sodium, barium, potassium, magnesium, and lanthanium), and anion-exchange resins are described in the Uterature as suitable catalysts. The selectivity to diacetone alcohol is typicaUy 90—95 wt % (64). In the second step diacetone alcohol is dehydrated to mesityl oxide over an acid catalyst such as phosphoric or sulfuric acid. The reaction takes place at 95—130°C and selectivity to mesityl oxide is 80—85 wt % (64). A one-step conversion of acetone to mesityl oxide is also possible. 

Figure 2 illustrates the three-step MIBK process employed by Hibernia Scholven (83). This process is designed to permit the intermediate recovery of refined diacetone alcohol and mesityl oxide. In the first step acetone and dilute sodium hydroxide are fed continuously to a reactor at low temperature and with a reactor residence time of approximately one hour. The product is then stabilized with phosphoric acid and stripped of unreacted acetone to yield a cmde diacetone alcohol stream. More phosphoric acid is then added, and the diacetone alcohol dehydrated to mesityl oxide in a distillation column. Mesityl oxide is recovered overhead in this column and fed to a further distillation column where residual acetone is removed and recycled to yield a tails stream containing 98—99% mesityl oxide. The mesityl oxide is then hydrogenated to MIBK in a reactive distillation conducted at atmospheric pressure and 110°C. Simultaneous hydrogenation and rectification are achieved in a column fitted with a palladium catalyst bed, and yields of mesityl oxide to MIBK exceeding 96% are obtained. 

Suitable catalysts include the hydroxides of sodium (119), potassium (76,120), calcium (121—125), and barium (126—130). Many of these catalysts are susceptible to alkali dissolution by both acetone and DAA and yield a cmde product that contains acetone, DAA, and traces of catalyst. To stabilize DAA the solution is first neutralized with phosphoric acid (131) or dibasic acid (132). Recycled acetone can then be stripped overhead under vacuum conditions, and DAA further purified by vacuum topping and tailing. Commercial catalysts generally have a life of about one year and can be reactivated by washing with hot water and acetone (133). It is reported (134) that the addition of 0.2—2 wt % methanol, ethanol, or 2-propanol to a calcium hydroxide catalyst helps prevent catalyst aging. Research has reported the use of more mechanically stable anion-exchange resins as catalysts (135—137). The addition of trace methanol to the acetone feed is beneficial for the reaction over anion-exchange resins (138). 

Ma.nufa.cture. Mesityl oxide is produced by the Hquid-phase dehydration of diacetone alcohol ia the presence of acidic catalysts at 100—120°C and atmospheric pressure. As a precursor to MIBK, mesityl oxide is prepared ia this manner ia a distillation column ia which acetone is removed overhead and water-saturated mesityl oxide is produced from a side-draw. Suitable catalysts are phosphoric acid (177,178) and sulfuric acid (179,180). The kinetics of the reaction over phosphoric acid have been reported (181). 

The catalyst used in the production of maleic anhydride from butane is vanadium—phosphoms—oxide (VPO). Several routes may be used to prepare the catalyst (123), but the route favored by industry involves the reaction of vanadium(V) oxide [1314-62-1] and phosphoric acid [7664-38-2] to form vanadyl hydrogen phosphate, VOHPO O.5H2O. This material is then heated to eliminate water from the stmcture and irreversibly form vanadyl pyrophosphate, (V(123,124). Vanadyl pyrophosphate is befleved to be the catalyticaHy active phase required for the conversion of butane to maleic anhydride (125,126). 

The methyl a-hydroxyisobutyrate produced is dehydrated to MMA and water in two stages. First, the methyl a-hydroxyisobutyrate is vaporized and passed over a modified zeoHte catalyst at ca 240°C. A second reactor containing phosphoric acid is operated at ca 150°C to promote esterification of any methacrylic acid (MAA) formed in the first reactor (74,75). Methanol is co-fed to improve selectivity in each stage. Conversions of methyl a-hydroxyisobutyrate are greater than 99%, with selectivities to MMA near 96%. The reactor effluent is extracted with water to remove methanol and yield cmde MMA. This process has not yet been used on a commercial scale. 

Isopropylnaphthalenes can be prepared readily by the catalytic alkylation of naphthalene with propjiene. 2-lsopropylnaphthalene [2027-17-0] is an important intermediate used in the manufacture of 2-naphthol (see Naphthalenederivatives). The alkylation of naphthalene with propjiene, preferably in an inert solvent at 40—100°C with an aluminum chloride, hydrogen fluoride, or boron trifluoride—phosphoric acid catalyst, gives 90—95% wt % 2-isopropylnaphthalene however, a considerable amount of polyalkylate also is produced. Preferably, the propylation of naphthalene is carried out in the vapor phase in a continuous manner, over a phosphoric acid on kieselguhr catalyst under pressure at ca 220—250°C. The alkylate, which is low in di- and polyisopropylnaphthalenes, then is isomerized by recycling over the same catalyst at 240°C or by using aluminum chloride catalyst at 80°C. After distillation, a product containing >90 wt % 2-isopropylnaphthalene is obtained (47). 

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