Oxidation Wacker process

Interesting properties may also be obtained when using a mixed addenda system in the presence of a co-catalyst The best known system [34d] is the V-substituted phosphomolybdate in conjunction with Pd for the oxidation of olefins to carbonyl compounds. This is analogous to the Wacker oxidation process based on CUCI2 and Pd. Unlike the Wacker process, the HPA system works at very low chloride concentration, or even in its absence. In addition the HPA is more active and selective and less corrosive. Other examples of such two-component catalytic systems include TF /TP, PT /Pt ", Ru"7Ru ", Br 7Br" and l /h-... 

Jiro Tsuji carried out many mechanistic and synthetic studies on the initial Wacker oxidation process.7-" It is now known as the Wacker-Tsuji oxidation for the oxidation of terminal olefin 1 to the corresponding methyl ketone 2 with oxygen in the presence of a catalytic amount of palladium and one equivalent of copper salt.12-" Nowadays, the Wacker-Tsuji oxidation is a standard methodology for transforming the terminal olefin to the corresponding methyl ketone.17 The reaction is so widely used that Tsuji declared that a terminal olefin could be viewed as a masked methyl ketone."... 

Oxidation of ethylene to acetaldehyde, the Wacker oxidation process, is one of the most important processes in the current chemical industry. The Wacker oxidation is catalyzed by redox couples of Pd /Pd° and Cu VCu in HCl solutions. This catalytic oxidation Eq. 1 can be decomposed into oxidation of ethylene to acetaldehyde with water at an anode Eq. 2 and reduction of O2 to water at a cathode Eq. 3. 

The following procedure may prove to be one of the largest advances in the field of MDMA chemistry since the perfection and dissemination of the Wacker oxidation procedure for producing MDP2P. This reaction is based on a published process that somehow has escaped discovery by underground chemistry until... 

Acetaldehyde, first used extensively during World War I as a starting material for making acetone [67-64-1] from acetic acid [64-19-7] is currendy an important intermediate in the production of acetic acid, acetic anhydride [108-24-7] ethyl acetate [141-78-6] peracetic acid [79-21 -0] pentaerythritol [115-77-5] chloral [302-17-0], glyoxal [107-22-2], aLkylamines, and pyridines. Commercial processes for acetaldehyde production include the oxidation or dehydrogenation of ethanol, the addition of water to acetylene, the partial oxidation of hydrocarbons, and the direct oxidation of ethylene [74-85-1]. In 1989, it was estimated that 28 companies having more than 98% of the wodd s 2.5 megaton per year plant capacity used the Wacker-Hoechst processes for the direct oxidation of ethylene. 

The direct oxidation of ethylene is used to produce acetaldehyde (qv) ia the Wacker-Hoechst process. The catalyst system is an aqueous solution of palladium chloride and cupric chloride. Under appropriate conditions an olefin can be oxidized to form an unsaturated aldehyde such as the production of acroleia [107-02-8] from propjiene (see Acrolein and derivatives). 

Another attractive commercial route to MEK is via direct oxidation of / -butenes (34—39) in a reaction analogous to the Wacker-Hoechst process for acetaldehyde production via ethylene oxidation. In the Wacker-Hoechst process the oxidation of olefins is conducted in an aqueous solution containing palladium and copper chlorides. However, unlike acetaldehyde production, / -butene oxidation has not proved commercially successflil because chlorinated butanones and butyraldehyde by-products form which both reduce yields and compHcate product purification, and also because titanium-lined equipment is required to withstand chloride corrosion. 

The most important reaction based on Pdn-catalysis is the Wacker oxidation [171], which is used industrially for the synthesis of acetaldehyde, starting from ethane. This process can be combined with a Heck reaction and has been used by Tietze and coworkers [172] for an efficient enantioselective synthesis of vitamin E (6/1-... 

Heyden-Wacker A process for making phthalic anhydride by the catalytic oxidation of naphthalene or o-xylene. Offered by Lurgi. 

The phenolic oxygen on 2-allyl-4-bromophenol (7) readily underwent oxypalladation using a catalytic amount of PdCl2 and three equivalents of Cu(OAc)2, to give the corresponding benzofuran 8. This process, akin to the Wacker oxidation, was catalytic in terms of palladium, and Cu(OAc)2 served as oxidant [17]. Benzofuran 10, a key intermediate in Kishi s total synthesis of aklavinone [18], was synthesized via the oxidative cyclization of phenol 9 using stoichiometric amounts of a Pd(II) salt. 

Other methods for the preparation of acetic acid are partial oxidation of butane, oxidation of ethanal -obtained from Wacker oxidation of ethene-, biooxidation of ethanol for food applications, and we may add the same carbonylation reaction carried out with a cobalt catalyst or an iridium catalyst. The rhodium and iridium catalysts have several distinct advantages over the cobalt catalyst they are much fester and fer more selective. In process terms the higher rate is translated into much lower pressures (the cobalt catalyst is operated by BASF at pressures of 700 bar). For years now the Monsanto process (now owned by BP) has been the most attractive route for the preparation of acetic acid, but in recent years the iridium-based CATTVA process, developed by BP, has come on stream. 

At present the Wacker reaction should be regarded as a relatively slow process, with only a few hundred turnovers per hour at elevated temperatures and pressures. For internal alkenes the rate is one or two orders of magnitude lower and the reaction affords mixtures of products due to isomerisation. In the absence of isomerisation, the product of the Wacker oxidation of a 1-alkene is a... 

Heterolytic liquid-phase oxidation processes are more recent than homolytic ones. The two major applications are the Wacker process for oxidation of ethylene to acetaldehyde by air, catalyzed by PdCl2-CuCl2 systems,98 and the Arco oxirane" or Shell process100 for epoxidation of propylene by f-butyl or ethylbenzene hydroperoxide catalyzed by molybdenum or titanium complexes. These heterolytic reactions require less drastic conditions than the homolytic ones... 

The recent dramatic increase in the price of petroleum feedstocks has made the search for high selectivities more urgent. Several new processes based on carbon monoxide sources are currently competing with older oxidation processes.103,104 The more straightforward synthesis of acetic acid from methanol carbonylation (Monsanto process) has made the Wacker process obsolete for the manufacture of acetaldehyde, which used to be one of the main acetic acid precursors. Several new methods for the synthesis of ethylene glycol have also recently emerged and will compete with the epoxidation of ethylene, which is not sufficiently selective. The direct synthesis of ethylene... 

In addition to the cr-v equilibrium, an exchange between the n complex (45) and free acetaldehyde has been demonstrated using, 4C-labeled acetaldehyde (46, 48). After 45 hours at room temperature, 0.46% exchange was observed. While this appears quite small, one must remember that the free vinyl alcohol/acetaldehyde ratio has been estimated to have an upper limit of only 10-7 and that in the Wacker Process the equilibrium between 7r-coordinated and free vinyl alcohol would be shifted considerably in favor of free vinyl alcohol by the overpressure of ethylene. Thus, the behavior of the ir-vinyl alcohol complexes (45) and (48) seem to support the importance of such complexes as intermediates in the Wacker and similar olefin oxidation processes. 

Terminal alkenes can be selectively oxidized to aldehydes by reaction with oxygen, using a palladium-copper catalyst in tertiary butanol (equation 35)160. This reaction is contrary to the normal oxidation process which yields a ketone as the major product. The palladium(II) oxidation of terminal alkenes to give methyl ketones is known as the Wacker process. It is a very well established reaction in both laboratory and industrial synthesis161162. The Wacker oxidation of alkenes has been used in the key step in the synthesis of the male sex pheromone of Hylotrupes bajulus (equation 36)163. 

The cycle approach for oxidation has been adopted at an industrial level for the Wacker-Chemie process for acetaldehyde production, in which ethylene is first put in contact with the oxidized catalyst solution, containing palladium chloride, and in the second step the solution containing the reduced catalyst is sent to a regeneration reactor containing cupric chloride and inside which also air is fed. The regenerated catalyst solution is returned to the first oxidation stage. Another industrial application is the Lummus process for the anaerobic ammoxidation of o-xylene to o-phthaloni-trile [68]. Du Pont has developed the oxidation of n-butane to maleic anhydride catalyzed by V/P/O, in a CFBR reactor, and built a demonstration unit in Spain [69] however, a few years ago the plant was shut down, due to the bad economics. 

The Wacker Oxidation is an industrial process, which allows the synthesis of ethanal from ethene by palladium-catalyzed oxidation with oxygen. Copper serves as redox cocatalyst. 

To overcome the problems encountered in the homogeneous Wacker oxidation of higher alkenes several attempts have been undertaken to develop a gas-phase version of the process. The first heterogeneous catalysts were prepared by the deposition of palladium chloride and copper chloride on support materials, such as zeolite Y [2,3] or active carbon [4]. However, these catalysts all suffered from rapid deactivation. Other authors applied other redox components such as vanadium pentoxide [5,6] or p-benzoquinone [7]. The best results have been achieved with catalysts based on palladium salts deposited on a monolayer of vanadium oxide spread out over a high surface area support material, such as y-alumina [8]. Van der Heide showed that with catalysts consisting of H2PdCU deposited on a monolayer vanadium oxide supported on y-alumina, ethene as well as 1-butene and styrene... 

Deactivation of heterogeneous Wacker oxidation catalysts is mainly caused by sintering of the vanadium oxide redox layer, resulting in the accumulation of (inactive) Pd(0), and hence in lower catalytic activity in the oxidation of 1-butene. The sintering process is... 

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