Terephthalic using homogeneous catalysts

Several large-scale industrial processes use homogeneous catalysts [e.g., hydrofor-mylation, hydrocyanation (DuPont), ethene-oligomerization (SHOP), acetic add (Eastman Kodak), acetic acid anhydride (Tennessee-Eastman), acetaldehyde (Wacker) and terephthalic acid (Amoco)] as well as smaller scale applications [e.g., metolachlor (Novartis), citronellal (Takasago), indenoxide (Merck) and glycidol (ARCO, SIPSY)]. 

Introduction. The production of terephthalic acid (1,4-benzenedicarboxylic acid) has several interesting features. First, it is one of the examples of a homogeneous, radical-catalysed oxidation with the use of dioxygen and cobalt salt initiators. Secondly, it is an example of a catalyst/product separation involving a filtration of the product from the liquid that contains the catalyst. Crystallisation on such a huge scale is not very attractive, but the low solubility of phthalic acid in many solvents and the high boiling point do not allow any other solution. Theoretically, a solvent-solvent extraction would be an option, but we are not aware of a viable combination of solvents. 

Catalytic oxidation is the most important technology for the conversion of hydrocarbon feedstocks (olefins, aromatics and alkanes) to a variety of bulk industrial chemicals.1 In general, two types of processes are used heterogeneous, gas phase oxidation and homogeneous liquid phase oxidation. The former tend to involve supported metal or metal oxide catalysts e.g. in tne manufacture of ethylene oxide, acrylonitrile and maleic anhydride whilst the latter generally employ dissolved metal salts, e.g. in the production of terephthalic acid, benzoic acid, acetic acid, phenol and propylene oxide. 

The first commercial processes for the production of DMT made use of nitric acid oxidation of p-xylene to crude terephthalic acid, followed by esterification with methanol and purification by distillation [3]. Air oxidation of p-xylene displaced the use of nitric acid with the development of the Witten process [5]. In the Witten process, p-xylene is air-oxidized at 140-180 °C and 0.5-2 MPa over a homogeneous cobalt or cobalt/manganese catalyst system to give p-toluic acid, which is then esterified to methyl p-toluate, oxidized again over the cobalt/manganese catalyst, and finally esterified to DMT (see Scheme 1). The four process steps are accomplished in two reactors (see Figure 1). The Witten process uses no solvent. 

---