Propylene oxide catalyst

The Reaction. Acrolein has been produced commercially since 1938. The first commercial processes were based on the vapor-phase condensation of acetaldehyde and formaldehyde (1). In the 1940s a series of catalyst developments based on cuprous oxide and cupric selenites led to a vapor-phase propylene oxidation route to acrolein (7,8). In 1959 Shell was the first to commercialize this propylene oxidation to acrolein process. These early propylene oxidation catalysts were capable of only low per pass propylene conversions (ca 15%) and therefore required significant recycle of unreacted propylene (9—11). 

Many key improvements and enhancements to the bismuth molybdate based propylene oxidation catalysts have occurred over the past thirty years. These are outlined in the following tabulation. 

With the maturing of the propylene oxidation catalyst area, attention in the 1980s was more focused on reaction process related improvements. 

The first report on the coordination polymerisation of epoxide, leading to a stereoregular (isotactic) polymer, concerned the polymerisation of propylene oxide in the presence of a ferric chloride-propylene oxide catalyst the respective patent appeared in 1955 [13]. In this catalyst, which is referred to as the Pruitt Baggett adduct of the general formula Cl(C3H60)vFe(Cl)(0C3H6),CI, two substituents of the alcoholate type formed by the addition of propylene oxide to Fe Cl bonds and one chlorine atom at the iron atom are present [14]. A few years later, various types of catalyst effective for stereoselective polymerisation of propylene oxide were found and developed aluminium isopropoxide-zinc chloride [15], dialkylzinc-water [16], dialkylzinc alcohol [16], trialkylalumi-nium water [17] and trialkylaluminium-water acetylacetone [18] and trialkyla-luminium lanthanide triacetylacetonate H20 [19]. Other important catalysts for the stereoselective polymerisation of propylene oxide, such as bimetallic /1-oxoalkoxides of the [(R0)2A10]2Zn type, were obtained by condensation of zinc acetate with aluminium isopropoxide in a 1 2 molar ratio of reactants [20-22]. 

When the polymerizations was carried out with a separately prepared ferric chloride-propylene oxide catalyst, the 1-monomer formed a high molecular weight polymer which could be separated into an amorphous fraction with low optical rotation and a crystalline form with the same optical rotation as had been obtained with potassium hydroxide initiation. 

In 1957 Standard Oil of Ohio (Sohio) discovered bismuth molybdate catalysts capable of producing high yields of acrolein at high propylene conversions (>90%) and at low pressures (12). Over the next 30 years much industrial and academic research and development was devoted to improving these catalysts, which are used in the production processes for acrolein, acryUc acid, and acrylonitrile. AH commercial acrolein manufacturing processes known today are based on propylene oxidation and use bismuth molybdate based catalysts. 

Propylene Oxidation. The propylene oxidation process is attractive because of the availabihty of highly active and selective catalysts and the relatively low cost of propylene. The process proceeds in two stages giving first acrolein and then acryUc acid (39) (see Acrolein and derivatives). 

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. 

Chemical Manufacturing. Chemical manufacturing accounts for over 50% of all U.S. caustic soda demand. It is used primarily for pH control, neutralization, off-gas scmbbing, and as a catalyst. About 50% of the total demand in this category, or approximately 25% of overall U.S. consumption, is used in the manufacture of organic intermediates, polymers, and end products. The majority of caustic soda required here is for the production of propylene oxide, polycarbonate resin, epoxies, synthetic fibers, and surface-active agents (6). 

Propylene oxide-based glycerol can be produced by rearrangement of propylene oxide [75-56-9] (qv) to allyl alcohol over triUthium phosphate catalyst at 200—250°C (yield 80—85%) (4), followed by any of the appropriate steps shown in Figure 1. The specific route commercially employed is peracetic acid epoxidation of allyl alcohol to glycidol followed by hydrolysis to glycerol (5). The newest international synthesis plants employ this basic scheme. 

Oxidation Catalysis. The multiple oxidation states available in molybdenum oxide species make these exceUent catalysts in oxidation reactions. The oxidation of methanol (qv) to formaldehyde (qv) is generally carried out commercially on mixed ferric molybdate—molybdenum trioxide catalysts. The oxidation of propylene (qv) to acrolein (77) and the ammoxidation of propylene to acrylonitrile (qv) (78) are each carried out over bismuth—molybdenum oxide catalyst systems. The latter (Sohio) process produces in excess of 3.6 x 10 t/yr of acrylonitrile, which finds use in the production of fibers (qv), elastomers (qv), and water-soluble polymers. 

Polyester resins can also be rapidly formed by the reaction of propylene oxide (5) with phthaUc and maleic anhydride. The reaction is initiated with a small fraction of glycol initiator containing a basic catalyst such as lithium carbonate. Molecular weight development is controlled by the concentration of initiator, and the highly exothermic reaction proceeds without the evolution of any condensate water. Although this technique provides many process benefits, the low extent of maleate isomerization achieved during the rapid formation of the polymer limits the reactivity and ultimate performance of these resins. 

Synthesis. The total aimual production of PO in the United States in 1993 was 1.77 biUion kg (57) and is expected to climb to 1.95 biUion kg with the addition of the Texaco plant (Table 1). There are two principal processes for producing PO, the chlorohydrin process favored by The Dow Chemical Company and indirect oxidation used by Arco and soon Texaco. Molybdenum catalysts are used commercially in indirect oxidation (58—61). Capacity data for PO production are shown in Table 1 (see Propylene oxide). 

Propylene oxide is highly reactive. It reacts exothermically with any substance that has labile hydrogen such as water, alcohols, amines, and organic acids acids, alkahes, and some salts act as catalysts. 

In this process, the fine powder of lithium phosphate used as catalyst is dispersed, and propylene oxide is fed at 300°C to the reactor, and the product, ahyl alcohol, together with unreacted propylene oxide is removed by distihation (25). By-products such as acetone and propionaldehyde, which are isomers of propylene oxide, are formed, but the conversion of propylene oxide is 40% and the selectivity to ahyl alcohol reaches more than 90% (25). However, ahyl alcohol obtained by this process contains approximately 0.6% of propanol. Until 1984, ah ahyl alcohol manufacturers were using this process. Since 1985 Showa Denko K.K. has produced ahyl alcohol industriahy by a new process which they developed (6,7). This process, which was developed partiy for the purpose of producing epichlorohydrin via ahyl alcohol as the intermediate, has the potential to be the main process for production of ahyl alcohol. The reaction scheme is as fohows ... 

Allyl Glycidyl Ether. This ether is used mainly as a raw material for silane coupling agents and epichlorohydrin mbber. Epichlorohydrin mbber is synthesized by polymerizing the epoxy group of epichlorohydrin, ethylene oxide, propylene oxide, and aHyl glycidyl ether, AGE, with an aluminum alkyl catalyst (36). This mbber has high cold-resistance. 

Another subclass of substituted amides that is of great commercial value is the ethoxylated amides. They can be synthesized from alkanolamides by chain extending with ethylene or propylene oxide or by ethoxylation directly from the primary amide (46—48). It was originally beheved that the stepwise addition of ethylene oxide (EO) would produce the monoethano1 amide and then the diethanolamide when sufficient ethylene oxide was added (49), but it has been discovered that only one hydrogen of the amide is substituted with ethylene oxide (50—53). As is typical of most ethylene oxide adducts, a wide distribution of polyethylene oxide chain length is seen as more EO is added. A catalyst is necessary to add ethylene oxide or propylene oxide to a primary or an ethoxylated amide or to ethoxylate a diethoxy alkanolamide synthesized from diethanolamine (54). 

Ethoxylation and Propoxylation. Ethylene oxide [75-21-8] or propylene oxide [75-56-9] add readily to primary fatty amines to form bis(2-hydroxyethyl) or bis(2-hydroxypropyl) tertiary amines secondary amines also react with ethylene or propylene oxide to form 2-hydroxyalkyl tertiary amines (1,3,7,33—36). The initial addition is completed at approximately 170°C. Additional ethylene or propylene oxide can be added by using a basic catalyst, usually sodium or potassium hydroxide. 

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