Wacker oxidations copper® chloride

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. 

With the growing prominence of the petrochemicals industry this technology was, in turn, replaced by direct air oxidation of naphtha or butane. Both these processes have low selectivities but the naphtha route is still used since it is a valuable source of the co-products, formic and propanoic acid. The Wacker process, which uses ethylene as a feedstock for palladium/copper chloride catalysed synthesis of acetaldehyde, for which it is still widely used (Box 9.1), competed with the direct oxidation routes for a number of years. This process, however, produced undesirable amounts of chlorinated and oxychlorinated by-products, which required separation and disposal. 

Wacker (1) A general process for oxidizing aliphatic hydrocarbons to aldehydes or ketones by the use of oxygen, catalyzed by an aqueous solution of mixed palladium and copper chlorides. Ethylene is thus oxidized to acetaldehyde. If the reaction is conducted in acetic acid, the product is vinyl acetate. The process can be operated with the catalyst in solution, or with the catalyst deposited on a support such as activated caibon. There has been a considerable amount of fundamental research on the reaction mechanism, which is believed to proceed by alternate oxidation and reduction of the palladium ... 

The more expedient, direct catalytic oxidation route to acetone was developed in Germany in the 1960s. If you had been in charge of building the acetone business from scratch, you d probably not have built any IPA-to-acetone plants if you had known about the Wacker process. It s a catalytic oxidation of propylene at 200—250°F and 125—200 psi over palladium chloride with a cupric (copper) chloride promoter. The yields are 91-94%. The hardware for the Wacker process is probably less than for the combined IPA/acetone plants. But once the latter plants were built, the economies of the Wacker process were not sufficient to shut them down and start all over. So the new technology never took hold in the United States. 

The previous examples involve reduction (hydrogenation) of organic molecules, but transition metal complexes can also catalyze oxidation. For example, the Wacker process, which has been widely used to convert ethylene to acetaldehyde, depends on catalysis by palladium(II) in the presence of copper(II) in aqueous HC1. The role of the copper chloride is to provide a means of using air to reoxidize the palladium to palladium(II). Once again, Zeise-type coordination of the ethylene to the metal center is believed to be involved ... 

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... 

However, all these systems suffer from high concentrations of chloride ion, so that substantial amounts of chlorinated by-products are formed. For these reasons there is a definite need for chloride- and copper-free systems for Wacker oxidations. One such system has been recently described, viz., the aerobic oxidation of terminal olefins in an aqueous biphasic system (no additional solvent)... 

Copper chloride complexes can be used as catalysts in a number of organic reactions. Examples include the Wacker process, which is the oxidization of ethylene to acetaldehyde by oxygen and aqueous Cu and Pd precatalysts (or, alternatively using iron catalysts) plus the synthesis of acrylonitrile from acetylene and hydrogen cyanide using CuCl. Cuprous chloride has also been used as a desulfiuizmg and... 

Oxidation. Terminally silylated homopropargylic alcohols give y-lactones. The Wacker oxidation can be carried out using substoichiometric Cu(OAc instead of the copper chloride. This modified procedure is operationally simpler and avoids hydrolysis of acetonide when it is present. 

Direct oxidation of n-butenes by the Wacker/Hoechst process, in the presence of palladium and copper chlorides, around 110°C, at 13.10 Pa absolute, with a yield of 85 to 88 molar per cent (see Section 103.3). 

The applications reported for polymer-supported, soluble oxidation catalysts are the use of poly(vinylbenzyl)trimethylammonium chloride for the autooxidation of 2,6-di-tert-butylphenol [8], of copper polyaniline nanocomposites for the Wacker oxidation reaction [9], of cationic polymers containing cobalt(II) phthalocyanate for the autooxidation of 2-mercaptoethanol [10] and oxidation of olefins [11], of polymer-bound phthalocyanines for oxidative decomposition of polychlorophenols [12], and of a norbornene-based polymer with polymer-fixed manganese(IV) complexes for the catalytic oxidation of alkanes [13], Noncatalytic processes can also be found, such as the use of soluble polystyrene-based sulfoxide reagents for Swern oxidation [14], The reactions listed above will be described in more detail in the following paragraphs. 

The process of choice for acetaldehyde production is ethylene oxidation according to the so-called Wacker-Hoechst process [route (c) in Topic 5.3.2]. The reaction proceeds by homogeneous catalysis in an aqueous solution of HQ in the presence of palladium and copper chloride complexes. The oxidation of ethylene occurs in a stoichiometric reaction of PdQ2 with ethylene and water that affords acetaldehyde, metallic palladium (oxidation state 0), and HQ [step (a) in Scheme 5.3.5). The elemental Pd is reoxidized in the process by Cu(II) chloride that converts in this step into Cu(I) chloride [step (b) in Scheme 5.3.5). The Cu(II) chloride is regenerated by oxidation with air to finally close the catalytic cycle [step (c) in Scheme 5.3.5). 

Wacker process 1. A catalytic process used to oxidize aliphatic hydrocarbons such as ethylene to ethanol, aldehydes, and ketones using oxygen. The process uses an aqueous solution of mixed palladium and copper chlorides either in solution or on a support of activated carbon through which the ethylene is bubbled. The process was invented in 1957 and is named after the chemical company. 2. A process used for the production of sodium salicylate through the reaction of sodium phenate and carbon dioxide. 

The Wacker oxidation of ethene to ethanal is an important industrial process for the oxygenation of a hydrocarbon feedstock. Essentially, the same process may be used to convert 1-alkenes to methyl ketones. The stoichiometry of the process is shown in Figure 23.23. The reaction is catalytic in both palladium and copper the ultimate oxidant is (inexpensive) molecular oxygen. A proposed mechanism is shown in Figure 23.24 the main controversy has been as to whether the attack of water on the coordinated alkene is external or via prior coordination of the water to palladium. Current thinking is that external attack predominates in high concentrations of chloride ion and internal attack when [CT] is low. Different details of mechanisms under the two conditions are supported by different reaction kinetics. 

The metal-catalysed autoxidation of alkenes to produce ketones (Wacker reaction) is promoted by the presence of quaternary ammonium salts [14]. For example, using copper(II) chloride and palladium(II) chloride in benzene in the presence of cetyltrimethylammonium bromide, 1-decene is converted into 2-decanone (73%), 1,7-octadiene into 2,7-octadione (77%) and vinylcyclohexane into cyclo-hexylethanone (22%). Benzyltriethylammonium chloride and tetra-n-butylammo-nium hydrogen sulphate are ineffective catalysts. It has been suggested that the process is not micellar, although the catalysts have the characteristics of those which produce micelles. The Wacker reaction is also catalysed by rhodium and ruthenium salts in the presence of a quaternary ammonium salt. Generally, however, the yields are lower than those obtained using the palladium catalyst and, frequently, several oxidation products are obtained from each reaction [15]. 

The electrochemical Wacker-type oxidation of terminal olefins (111) by using palladium chloride or palladium acetate in the presence of a suitable oxidant leading to 2-alkanones (112) has been intensively studied. As recyclable double-mediatory systems (Scheme 43), quinone, ferric chloride, copper acetate, and triphenylamine have been used as co-oxidizing agents for regeneration of the Pd(II) catalyst [151]. The palladium-catalyzed anodic oxidation of... 

The oxidation of olefins to aldehydes using a palladium chloride-copper(II) chloride catalyst, the Wacker Process, is a well-established industrial reaction. The mechanism of this reaction has not been established in detail, but it most probably involves a cr-7r rearrangement... 

Wacker Process The Wacker process is primarily used to produce acetaldehyde from the oxidation of ethylene by palladium(II)Copper(II) chloride solution. 

The invention of the Wacker process was a triumph of common sense. It had been known since 1894 that ethylene is oxidized to acetaldehyde by palladium chloride in a stoichiometric reaction (Figure 27). However, it was not until 1956 that this reaction was combined with the known reoxidation reactions of palladium by copper and, in turn of copper by oxygen. The total process developed by Wacker and Hoechst between 1957 and 1959 can be depicted as an exothermic catalytic direct oxidation to yield acetaldehyde. 

The oxidation of propylene has been chosen as a probe reaction to study the catalytic activity of Cu Pd -TSM. The olefin oxidation in an acidic solution of Cu(II) and Pd(U) chlorides, well known as the Wacker reaction, is achieved when olefins are selectively oxidized to ketones or aldehydes by hydrated Pd, leaving Pd . The Pd is oxidized back to Pd by 2Cu, and the resulting Cu is reoxidized by dissolved oxygen. Because the corrosive nature of the catalyst solution is a serious disadvantage for practical use, supported copper-palladium catalysts have been proposed to operate the reaction in a gas flow reactor (40). 

Oxidations. Various primary and secondary alcohols are oxidized to give aldehydes and ketones by PdfOAcl -O -pyridine in the presence of 3A molecular sieves. Modified Wacker processes which obviate copper and chloride employ the Pd(OAcl -02 system and a water-soluble 1, 10-phenanthroline ligand or polypyrrole as redox-active ligand.- ... 

Heteropolyacids can be very useful in oxidation reactions. In contrast with metal chelate catalysts that usually become oxidized and deactivated eventually, the heteropolyacids are extremely stable to oxidation. Acetaldehyde is produced commercially from ethylene by the Wacker reaction with a palladium(II) chloride catalyst, copper(II) chloride, oxygen, and water. The corrosive conditions are a disadvantage of the process. Catalytica Inc. has devised a process (6.55) that uses only 1% as much palladium and chloride as the usual process. It uses a small amount of palladium (II) chloride with a partial sodium salt of phosphomolybdovanadic acid.287... 

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