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A01 185
A01 185
to produce large-volume chemicals are summa- state. Even if this were possible, contamina-
rized in Table 1, underlining their commercial tion, for example, moisture during application
value. Further examples are given in the rele- to a reaction mixture, is extremely difficult to
vant subchapters. exclude completely. Therefore, under the usual
Friedel – Crafts conditions, the presence of such
impurities as water, oxygen, hydrogen halides,
1.1. Catalysts or organic halides is inevitable. Fortunately,
these compounds are beneficial in trace amounts
Although alkylations can be carried out ther- and in many cases they are even essential cocata-
mally by free-radical pathways, all commercial lysts [14]. These cocatalysts can be proton sup-
alkylation and acylation processes are conducted pliers, such as hydroxy compounds (alcohols,
using acidic, basic, or organometallic com- water) and proton acids (HCl, H2 SO4 , H3 PO4 ,
pounds as promoters. These promoters function RCOOH), leading to very strong conjugated pro-
by increasing either the nucleophilicity of the ton acids:
substrate (basic catalysis) or the electrophilic
character of the reagent (acidic catalysis). HX + AlX3 H+ AlX−
4
Alkylation of aromatics
Benzene and ethylene to give ethylbenzene a) liquid phase, 85 – 95 ◦ C, 1 bar, catalyst: AlCl3 (BASF, Dow), 20
zeolites (Lummus/Unocal/UOP), MCM-22 zeolite (EBMax,
Mobil)
b) vapor phase, 250 – 450 ◦ C, 10 – 80 bar, catalyst: Al2 O3 · SiO2
(Koppers), H3 PO4 – SiO2 (UOP), BF3 – Al2 O3 (UOP, Alkar
process), zeolites ZSM-5 (Mobil/Badger)
Benzene and propene to give cumene a) liquid phase, 35 – 70 ◦ C, 5 – 15 bar, catalyst: solid phosphoric 7.5
acid (UOP), AlCl3 catalyst (Monsanto/Kellog), H2 SO4 (Hock
process), HF (Hüls)
b) zeolite technologies (Mobil, UOP – QMax, CDTech,
Dow/Kellog and Enichem)
Benzene and propene to give liquid phase, 150 – 250 ◦ C, 1 bar, catalyst: Al2 O3 · SiO2 0.1
p-diisopropylbenzene (Shell), zeolites
Benzene and C10 – C18 olefins (or alkyl liquid phase, 10 – 80 ◦ C, 1 bar, catalyst: HF, H2 SO4 , AlCl3 , 0.9
chlorides) to give alkylbenzenes fluorided silica – alumina, UOP-Detal
Alkylation of phenols
Phenol and C6 – C20 olefins to give a) liquid phase, 20 – 100 ◦ C, 1 – 20 bar, catalyst: BF3 , H2 SO4 ,
alkylphenols H3 PO4 – support, cation-exchange resins
b) vapor phase, 300 – 400 ◦ C, 1 – 30 bar, catalyst: BF3 – support, 0.3
H3 PO4 – support, Al2 O3 · SiO2
Phenol and methanol to give o-cresol liquid phase, 300 – 360 ◦ C, 40 – 70 bar, catalyst: Al2 O3 · SiO2 , –
ZnBr2 – HBr
Phenol and acetone to give bisphenol A 50 ◦ C, catalyst: H2 SO4 , HCl, cation-exchange resins 1.1
N-Alkylation
Ammonia and methanol to give methylamines 350 – 400 ◦ C, catalyst: Al2 O3 · SiO2 , H3 PO4 – support 0.6
O-Alkylation
Methanol and isobutene to give methyl <100 ◦ C, catalyst: anion-exchange resins 0.12
tert-butyl ether
Metal alkylation
Na/Pb alloy and RCl to give PbR4 70 ◦ C, no catalyst 0.6
particularly for metal alkoxides, is weakened by Proton Acids. A variety of proton acids can
hyperconjugation effects. Nevertheless, an im- be used in Friedel – Crafts alkylations, the most
portant industrial application is the alkylation important examples being sulfuric acid, anhy-
of phenols, in which aluminum phenoxide is drous hydrogen fluoride, trifluoroacetic acid,
used as the catalyst. Again, a conjugated acid is hydrogen chloride, and phosphoric acids [17].
believed to be the active catalyst: Combinations of Lewis acids and proton acids,
such as HCl – AlCl3 , HCl – GaCl3 , HF – BF3 ,
C6 H5 OH + Al(OC6 H5 )3 H+ Al(OC6 H5 )−
4 H2 SO4 – BF3 , and HF – SbF5 , also can be ap-
plied and these act as conjugate proton su-
Aluminum metal can form aluminum phenox- peracids [18], [19]. Similarly, most Lewis acids
ide in phenolic solution. work under industrial conditions, where traces
of moisture or of other proton donors cannot be
Rare Earth Metal Trifluoromethansul- excluded.
fonates (Triflates). This type of catalyst can be
recycled after use and avoids the stoichiomet- Acidic Oxides and Derivatives. Solid cata-
ric formation of metal salts as is the case with lysts are progressively substituting liquid acid
conventional homogeneous promoters. catalysts in oil refining and synthesis of large
4 Acylation and Alkylation
volume chemicals. This development is due to als with interlayer anions yields porous materi-
novel environmental legislation as well as eco- als similar to zeolites. Although those materials
nomic advantages resulting from superior prod- have been described to be useful for alkylation,
uct qualities of solid catalysts and the possibility especially for larger molecules [26], [27], lit-
to work under noncorrosive conditions (facile tle is known about their industrial application in
construction, handling and disposal). Solid cat- alkylation reactions. Generally, the thermal sta-
alysts are generally classified into different bility and chemical resistance is much smaller
groups, i.e., zeolites, mixed oxides, or solid than that of zeolites.
superacids (e.g., sulfated oxides), clays, het- Heteropolyacids or polyoxoanion com-
eropolyacids or polyoxoanions, supported acids, pounds constitute a large category of
and cation-exchange resins. The latter two will coordination-type salts and free acids with
be discussed in page 4 and page 4 each member containing a complex and high
Zeolites (→ Zeolites) represent a class of molecular mass anion. In these anions, two to
acidic (or basic) microporous materials with a eighteen hexavalent molybdenum (or tungsten)
defined pore structure. The most widely used atoms surround one or more central atoms (het-
systems are based on silica and alumina, how- eroatom). Vanadium, niobium, tantalum, and
ever, a large variety of other elements have been transition metals can replace some of the molyb-
integrated into the zeolite framework. For a com- denum (or tungsten) atoms in the heteropoly
prehensive review on zeolite types see [20]. structure. Typical examples are [PMo12 O40 ]3− ,
Acidity in zeolites is generated by Brønsted and [SiW12 O40 ]4− , [PMo10 V2 O40 ]5− . An excel-
Lewis acid sites. The former are attributed to lent review was given in [28]. As with clays,
protons compensating for the negative lattice little is known about the commercialization of
charge of an oxygen atom in vicinity to an alu- these materials in alkylation reactions.
minum atom, the latter are believed to result
from lattice defect sites and/or extra-framework Supported Acids. A variety of fixed-bed
aluminum species. Zeolites are thermally stable processes have been commercialized in which
up to 800 ◦ C allowing high-temperature reac- Lewis or Brønsted acids are supported on alu-
tions and the thermal regeneration of spent cat- mina, silica, or various other supports (e.g., car-
alysts by burning the carbonaceous residues in bon, graphite). A widely used catalyst of this
oxygen-containing gas streams. Zeolites can be type is “solid phosphoric acid” (phosporic acid
synthesized in a wide variety of pore sizes. Num- adsorbed on kieselguhr), used for the alkyla-
ber and strength of Brønsted acid sites as well tion of benzene with ethylene, butenes, and cy-
as crystal sizes may be tuned. The versatility of clohexene, but especially with propene. Dur-
these materials lead, thus, to a broad field of in- ing use, the catalyst loses water which controls
dustrial applications, e.g., fluid catalytic crack- the equilibrium between ortho, meta, and poly
ing (FCC), alkylation, aromatization, isomeriza- phosphoric acid and hence catalytic activity.
tion, and oligomerization [21]. Small amounts (0.1 % of feed) of water or of
Mixed oxides represent probably the largest the corresponding alcohol (e.g., isopropyl alco-
group of solid acid catalysts. Various mix- hol for the production of cumene) therefore are
tures of (doped) metal oxides have been in- added to the reaction mixture in order to regen-
vestigated in acid catalyzed reactions. Excel- erate the catalyst and thus maintain activity [29].
lent reviews were provided by Arata [22] and Other examples of supported acids are boron
Tanabe [23–25]. As with zeolites, acidity is trifluoride – alumina and solid superacids, such
generated by the incorporation of heteroatoms as SbF5 , TaF5 , and NbF5 , supported on fluori-
(different valence) in a crystal-lattice structure. nated alumina or graphite. Graphite-intercalated
Some of these materials are quoted superacids AlCl3 (i.e., AlCl3 embedded in graphite) also
due to the presence of acid sites stronger than is an effective solid Friedel – Crafts catalyst but
100 % H2 SO4 (H0 < − 12) [H0 = Hammelt acid- loses activity by partial hydrolysis or leaching of
ity function, where H0 = pk a (indicator) + log the Lewis acid halide from the graphite [30]. Fur-
(cindicator /cH[indicator]+ )]. thermore, Lewis-acidic metal halides supported
Clays. Natural clays have attracted relatively on layered clays have attracted attention as het-
low attention, however, pillaring those materi- erogeneous catalysts.
Acylation and Alkylation 5
Cation-Exchange Resins. Solid Brønsted most common reactions of this type described
acids, such as sulfonated styrene – divinylben- in literature. A review on basic zeolites was pro-
zene cross-linked polymers, are used as an acidic vided in [39].
catalyst in a variety of organic reactions. Cation-
exchange resins, such as Permutit Q, Lewatit,
and Dowex 50, are effective catalysts for the 1.1.3. Organometallic Catalysts [40], [41]
alkylation of phenols with olefins, alkyl halides, A variety of catalysts based on transition-metal
and alcohols [31]. Catalysts of this type also compounds are known in alkylation and acyla-
have been applied in the acylation of thiophene tion, as in the following examples (R,R = alkyl,
with acetyl chloride or acetic anhydride [32]. L = (C6 H5 )3 P):
Perfluorinated resin sulfonic acids, such as the
acid form of DuPont’s Nafion, catalyze many
alkylations of aromatic hydrocarbons very ef-
ficiently [33], [34]. New developments in this
field are DuPont’s Nafion – silica nanocompos-
ite [35] and Degussa’s Deloxan materials [36].
those of the last group, may present a health Under the acidic conditions used, both the alky-
hazard. lating agent and the alkylated aromatic com-
The acylating agents most frequently used are pound isomerize. This leads in many cases to
acyl halides, carboxylic acids, and anhydrides. a situation in which neither the structure of the
Less frequently used are ketenes, esters, lac- alkyl substituent nor the orientation in the nu-
tones, etc. Amides [42] and phosgene also can cleus can be predicted.
function as acylating agents. Friedel – Crafts reactions do not necessarily
require free carbenium ions as intermediates; the
reaction can proceed also via formation of a po-
1.3. Mechanism larized complex between the Lewis acid and the
alkylating agent followed by attack of the aro-
The majority of industrial alkylations and acyla- matic substrate [44]. However, carbocationic in-
tions are acid catalyzed (Friedel – Crafts type). termediates as postulated in Friedel – Crafts re-
Therefore only these processes are considered actions were observed in superacidic media and
here. Both alkylation and acylation can pro- were studied by spectroscopic methods [45].
ceed via similar reaction intermediates, involv-
ing similar reaction mechanisms. Alkylation on Solid Acids. The mechanism
of alkylation of aromatics on solid acid cata-
1.3.1. Alkylation lysts (especially on zeolites) has been reviewed
by Venuto [46]. Briefly, alkylation involves an
Friedel – Crafts alkylation is induced by inter- electrophilic addition of a carbocation (formed
action of the acidic catalyst with the alkylating through protonation of or hydride abstraction
agent, as exemplified below for AlCl3 , leading from the alkylating agent) to the aromatic ring.
to the formation of a highly polarized complex However, depending on the basicity of the aro-
containing a carbocation: matic ring compared to that of the alkylating
agent and depending on temperature either the
R-CH=CH2 + HX + AlX3 [R-HC⊕ -CH3 ][AlX4 ]− aromatic ring or the olefin is preferentially ad-
RX + AlX3 [R]+ [AlX4 ]− sorbed on the acid sites and thus, forms the car-
bocation [47]. Although many different hetero-
ROH + AlX3 [R]+ [AlX3 OH]−
geneous catalysts may be used, a major bene-
R = alkyl fit of microporous materials is offered by their
In the case of alkyl halides, carbocations are shape selectivity. Three different types of shape
formed in the complete absence of moisture or selective effects have been postulated, i.e., (1)
any proton acid, whereas in the case of olefins reactant selectivity, (2) transition state selectiv-
a proton donor is needed. The carbocation then ity, and (3) product selectivity. Since the pore
attacks the aromatic substrate, forming the inter- size of zeolites and the kinetic diameter of the
mediate (1), which is transformed into the prod- reacting molecules are in the same order of
uct by loss of a proton [43]: magnitude, bulky isomers/molecules are selec-
tively prevented to (1) enter the zeolite chan-
nels, (2) to be produced in the transition state,
or (3) to leave the zeolite pores. Commercial-
ized processes using this concept are, e.g., Mo-
bil’s Selective Toluene Disproportionation Pro-
cess (MSTDP) or Mobil’s xylene isomerization,
both using ZSM-5 zeolites. In the former pro-
cess, toluene is disproportionated to p-xylene
and benzene; m- and o-xylene are produced in
minor amounts due to diffusion limitations in
the zeolite channels. Mobil/Badger’s gas-phase
Acylation and Alkylation 7
2.1. Alkylation
Depending on the acidity of the catalyst, the product yield markedly, and hence the catalytic
alkyl moiety is more or less completely isomer- activity of Lewis acids depends on the method
ized, and the addition follows the Markovnikov of their preparation.
rule.
Catalysts for Friedel – Crafts alkylation must Isomerization of the Alkylating Agents.
be acidic. Depending on reaction conditions, Because of the acidic reaction conditions, the
alkylating agents, and aromatic substrates, alkylating reagents often undergo rearrange-
Lewis as well as Brønsted acids are active. Ta- ments and are generally transformed into the
ble 2 lists frequently used catalysts and classifies most highly branched isomer possible. For in-
them on the basis of chemical constitutions. stance, the reaction of benzene with propyl
Although acidic halides, such as AlCl3 or chloride leads mainly to isopropylbenzene, and
AlBr3 , and proton acids, such as HCl, HF, or that with n-butyl chloride to the formation of
H2 SO4 , or H3 PO4 supported on diatomaceous sec-butylbenzene. Under Friedel – Crafts con-
earth are widely used, those catalysts are being ditions, isomerization of the alkylating agent
progressively substituted by zeolites and inor- is initiated by migration of a hydrogen atom
ganic oxides because the latter are environmen- and not by direct carbon rearrangements. The
tally benign, easy to handle and to dispose, thus driving force is the formation of the most sta-
implying less expensive process design. ble carbocation, following the usual trend: pri-
All types of bases reduce the acidity of the mary < secondary < tertiary. For example, the
catalyst and hence its efficiency. This is es- alkylation of benzene with long-chain linear
pecially true for organic nitrogen compounds. 1-olefins leads not only to the 2-alkylbenzene
Heavy resinous materials are formed on the cat- but in most cases also to a random distribu-
alyst if oxygen is present even at concentrations tion of the phenyl substituent along the alkyl
as low as 20 ppm [50]. Dienes, such as buta- chain. This effect could result also from the
diene in a butene feed, also cause the forma- isomerization of the alkylated reaction prod-
tion of resinous or tarry materials on the cat- ucts, because n-butylbenzene is transformed
alyst. Traces of moisture or other proton sup- into sec-butylbenzene in the presence of a
pliers in many cases enhance catalytic activity, Friedel – Crafts catalyst, such as AlCl3 [51].
especially of Lewis acids. Higher amounts of Depending on the reaction conditions, alky-
these compounds are detrimental to the catalyst. lation of benzene with tertiary alkyl halides of-
Therefore, it is not surprising that when alco- ten leads to the formation of secondary alkyl-
hols are used, for example, for the alkylation benzenes rather than to the tertiary alkylben-
of benzene, 0.5 – 1.0 mol AlCl3 per mole of al- zenes. For example, alkylation of benzene with
cohol is necessary because the water produced 2-chloro-2,3-dimethylbutane gives mainly 2,2-
reacts with the Lewis acid. In some cases, mild dimethyl-3-phenylbutane via isomerization of
catalyst poisons are used deliberately in order to the primary product tert-hexylbenzene:
lower catalyst acidity and to prevent side reac-
tions, such as isomerization. Typical examples
are organic nitro compounds, which form stoi-
chiometric complexes with Lewis acids. Com-
pounds such as AlCl3 · RNO2 , AlBr3 · RNO2 ,
GaCl3 · RNO2 , or SbF5 catalyze the benzyla-
tion of benzene or toluene cleanly, giving mod-
erate yields, without causing the excessive side
reactions that occur with the uncomplexed Lewis
acids [13]. Similarly, such adducts as BF3 · OEt2
or BF3 · C6 H5 OH act as mild Friedel – Crafts
catalysts.
Impurities in the catalysts can alter both the
yield and the course of the reaction catalyzed by
Lewis acids. For example, the presence of fer-
ric chloride in aluminum chloride can decrease
Acylation and Alkylation 9
Table 2. Catalysts for the Friedel – Crafts alkylation of aromatic compounds
The primary product, tert-hexylbenzene, can be in most cases subsequent isomerization leads to
isolated only if less active catalysts, such as fer- an equilibrium mixture rich in the meta product.
ric chloride, are chosen [52]. Only if the ortho position is sterically hindered
is para substitution favored. For example, the
Reactivity of Aromatic Substrates. The reaction of benzene and 4-methylcyclohexene,
Friedel – Crafts alkylation of aromatic com- catalyzed by HF, gives 75 % monoalkyl deriva-
pounds, as an electrophilic substitution, is influ- tive and 25 % dialkyl derivative, of which 75 %
enced by substituents present on the aromatic is the para isomer and only 25 % the meta iso-
substrate. For example, electron-donating sub- mer [55]. Similarly, alkylation of cumene by
stituents, such as alkyl, NR2 , or OR (R = alkyl), 2-butene over BF3 – H3 PO4 yields 91 % para
lead to enhanced reactivity, and the new sub- product [56], and the dialkylation of benzene
stituent enters preferentially in the ortho or para with propene over silica – alumina gives pref-
position. Therefore the alkylation of benzene erentially p-diisopropylbenzene, which can be
with olefins leads to the monosubstituted ben- used for the synthesis of terephthalic acid and
zene, which in turn reacts faster with a further hydroquinone [57]. Substitution of benzene by
olefin molecule than benzene itself does, result- halides leads to deactivation, as is evident from
ing in a complex product mixture of mono- and Table 5.
polyalkylated benzenes [53]:
Table 4. Initial distributions (mass fraction in %) in the alkylation
of toluene [53]
Alkylating % Product distribution
agent o m p
C2 H4 48 30 22
C3 H6 42 21.5 36.5
of the acid sites as well as on the geometry of [61]. The reverse reaction, the disproportiona-
the zeolite pores (see page 6). Generally, higher tion of monoalkylbenzenes, leads almost exclu-
temperatures are required for the alkylation pro- sively to the meta isomer in the presence of an
cess using solid catalysts, exceptions from this excess of BF3 – HF [62]:
rule being only observed with very strong solid
acids, i.e., solid superacids. An excellent review 2 C6 H5 (C2 H5 ) C6 H6 + C6 H4 (C2 H5 )2 (99 % meta)
on mechanisms and product distributions of or-
ganic reactions on zeolites is given in [46]. This is attributed to the high stability of the
complex [m-Et2 C6 H5 ]+ [BF4 ]− . A similar type
Dealkylation and Transalkylation. Many of complex is used commercially by Japan Gas
of the catalysts used to alkylate aromatic com- to extract m-xylene selectively with HF – BF3
pounds can be used, especially at higher temper- from mixtures of C8 aromatic compounds [63].
atures, to reverse the alkylation reaction [59]. The alkylation – dealkylation equilibria men-
For example, alkylbenzene heated with AlCl3 tioned above also explain product distribution
form mixtures of benzene and polyalkylated in the alkylation of substituted aromatic com-
benzenes: pounds. The ortho and para isomers formed ini-
tially, which can be isolated after short reac-
tion times (kinetic control), isomerize with pro-
longed reaction times to the more stable meta
isomers (thermodynamic control).
Dealkylation is used commercially to convert
The tendency of alkylaromatic compounds to toluene to benzene, to isomerize m-xylene to the
disproportionate depends also on the structure of desired ortho and para derivatives, and to dispro-
the alkyl substituent. The following order is ob- portionate toluene to benzene and xylenes.
served [60]:
tert-C4 H9 > iso-C3 H7 > n-C3 H7 > C2 H5 > CH3
2.1.1. Alkylation of Benzene
For example, disproportionation and transalky-
lation of methylbenzenes takes place at There are three major commercial uses of the
300 – 450 ◦ C in the presence of solid acid cata- alkylation of benzene:
lysts such as SiO2 – Al2 O3 , whereas dispropor-
tionation and transalkylation of ethylbenzenes 1) Alkylation with ethylene to ethylbenzene as
and isopropylbenzenes occur below 100 ◦ C with an intermediate for styrene production. The
typical Friedel – Crafts catalysts [53]. production capacity for ethylbenzene was ca.
This intermolecular alkyl group transfer finds 20 × 106 t/a in 1991, where the USA, West-
different applications in industrial processes. ern Europe, and Japan held 5.3, 4.8, and
For example, in the synthesis of ethylbenzene, 3.3 × 106 t/a, respectively. More than 95 %
the undesired dialkylation product, which is of the ethylbenzene produced worldwide is
formed in considerable amounts, reacts with an converted to styrene, minor amounts are used
excess of fresh benzene: as solvents.
2) Alkylation with propene to cumene as an in-
C6 H4 (C2 H5 )2 + C6 H6 2 C6 H5 (C2 H5 ) termediate for phenol production, with ace-
tone as the byproduct. The production ca-
By this transalkylation process a high conver- pacity for cumene was ca. 7.5 × 106 t/a in
sion of ethylene to ethylbenzene is achieved
Acylation and Alkylation 11
1992, where the USA, Western Europe and since 1966. The catalyst is the noncorrosive
Japan held 2, 1.7 and 0.7 × 106 t/a, respec- boron trifluoride supported on a modified anhy-
tively. The largest fraction of the world’s drous alumina, which is also active for de- and
cumene production is converted to phenol in transalkylation [67]. An unusually wide range
the Hock process, minor quantities are used of ethylene concentration (5 – 95 %) in the feed
admixed with other alkylbenzenes as octane gas can be used, such as that in the off-gas from
enhancers. catalytic cracking, or that from a demethanizer
3) Alkylation with long-chain olefins (with overhead; alternatively, high-purity ethylene can
10 – 18 carbon atoms) to alkylbenzenes, be used. For example, the Alkar process can
which are sulfonated to give surface-active be adapted readily for use in the refinery. Pre-
compounds. The production capacity for lin- ferred process conditions are temperatures of
ear alkylbenzenesulfonates (LAB) in 1992 in about 300 ◦ C and pressures of about 60 bar, lead-
the USA, Western Europe, and Japan was ing to quantitative conversion of ethylene [68].
180 000, 485 000 and 197 000 t/a, respec- For further details, see → Ethylbenzene.
tively. The isomer distribution (mass fraction in %)
obtained by alkylation of benzene with ethylene
Alkylation of benzene with ethylene gives using the Alkar catalyst is as follows:
ethylbenzene [100-41-4] in a fast, exothermic
Diethylbenzenes:
reaction:
1,2- (26);
1,3- (49); and
1,4- (25)
Triethylbenzenes:
1,2,3- (3);
1,2,4- (35); and
Considerable amounts of polyethylbenzenes are 1,3,5- (62)
formed as side products in this process, which A variety of other metal halide
can be carried out in the liquid phase or in Friedel – Crafts-type catalysts and mineral acids
the vapor phase. 1,4-Diethylbenzene [105-05-5] have been used on the laboratory scale for ben-
(→ Hydrocarbons) is of commercial inter- zene ethylation [69], [70]. Of special interest
est because its dehydrogenation product, 1,4- are zeolite catalysts, which have been studied
divinylbenzene [1321-74-0], is a crosslinking widely for this reaction [71], [72]. A commercial
agent for polyolefins and is used widely in the fixed-bed vapor phase process utilizing Mobil’s
production of ion-exchange resins. proprietary ZSM-5 zeolites was introduced by
In the liquid-phase processes, AlCl3 is the Mobil Oil and Badger [73]. The reaction is car-
most widely used catalyst, but other catalysts, ried out at 420 – 430 ◦ C and 15 – 20 bar. Pure
such as BF3 , FeCl3 , ZrCl4 , SnCl4 , H3 PO4 , or or diluted ethylene can be used as the feed-
alkaline-earth phosphates, also are used com- stock after purification from sulfur, water, and
monly [63]. The reaction is carried out at at- propene. Polyalkylbenzenes can be recycled for
mospheric pressure at 85 – 95 ◦ C [64], [65]. For transalkylation, resulting in a final yield of ethyl-
process details, see → Ethylbenzene. benzene of 98 – 99 mol %. The catalyst is regen-
The vapor-phase ethylation of benzene is erated periodically using oxygen-containing gas
common practice, especially in the United streams.
States, and typically is carried out at about More recently, Raytheon Eng.& Constr. Inc.
300 ◦ C and 40 – 65 bar over acidic heteroge- licensed Mobil/Badger’s EBMax Process us-
neous catalysts such as Al2 O3 · SiO2 (Koppers ing Mobil’s proprietary MCM-22 zeolite cata-
Co.) or H3 PO4 – SiO2 (Universal Oil Products). lyst [74]. This process operates in liquid phase,
The selectivity to monoalkylation is improved contrary to Mobil/Badger’s ZSM5-zeolite based
by use of a low ethylene-benzene (0.2 : 1.0) ra- gas-phase technology [46]. Another fixed-bed,
tio [65], [66]. liquid-phase alkylation technology is licensed
Universal Oil Products developed the Alkar by Lummus/Unocal/UOP employing a unique
process, used commercially in several plants
12 Acylation and Alkylation
zeolite-based catalyst developed by Unocal. The pressure and temperature enhances conversion
catalyst is based on a Y-type zeolite [75]. rather than yields of cumene [78].
The latest zeolite alkylation technology Beside the SPA catalyst, sulfuric acid
yields ethylbenzene of 99.5 – 99.9 % purity. Cat- and AlCl3 are used for the production of
alyst lifetime is indicated to range between 1 and cumene. For further information, see [79] and
3 years. Catalyst regeneration is easily achieved → Hydrocarbons., Chap. 3.7.
by thermal treatment in oxygen containing gas Novel, zeolite-based cumene produc-
streams. tion technologies were developed by Mo-
Zeolite catalysts offer the advantage of be- bil/Raytheon, UOP, CDTech, Dow/Kellogg and
ing noncorrosive and environmentally benign Enichem [80–83]. Mobil is using its own MCM-
compared to liquid Brønsted or Lewis acid cat- 22 zeolite, UOP utilizes a proprietary zeolite
alysts. This renders construction requirements, in its QMax process. Dow is using a highly
handling, and disposal much easier, thus, yield- dealuminated mordenite zeolite and Enichem
ing economic benefits. employs a BEA-zeolite catalyst [75].
Amorphous aluminum silicates similar to Common to most of the novel processes are
those utilized in catalytic cracking also have two reactors and a distillation unit. In the first re-
been studied [76]. Although these catalysts give actor the alkylation takes places, while in the sec-
low conversions per pass, they are regener- ond reactor heavy ends (tri- and polyisopropyl-
ated easily. Also, polyethylbenzene production benzenes) are transalkylated with fresh benzene.
is moderate and recycling by transalkylation is CDTech is using a slightly different reactor con-
possible [76]. cept, i.e., a reactive distillation (→ Reactive Dis-
tillation) unit employing a Y-type zeolite. For
Alkylation of benzene with propene leads references see also [84–86]. Mobil’s technology
in an exothermic reaction to cumene [98-82-8]: is easy to retrofit to existing plants and by mid-
1998 six revamps with a total capacity of about
3 × 106 t/a were in operation [81].
Alkylation of cumene with propene, over
a pretreated aluminum silicate catalyst
and in the liquid phase under pressure at
150 – 250 ◦ C, leads to a mixture of mainly
p-diisopropylbenzene [100-18-5] and m-
The first cumene processes were developed be- diisopropylbenzene [99-62-7] with only traces
tween 1939 and 1945 to meet the demand for of the ortho isomer.
high-octane aviation gasoline. Today, almost all p-Diisopropylbenzene (bp 210.4 ◦ C at
of the cumene produced as a pure compound 101.3 kPa) can be separated by distillation
is used for the synthesis of phenol (→ Phenol); from the mixture of m-diisopropylbenzene
acetone is also recovered from the process. The (bp 203.2 ◦ C) and o-diisopropylbenzene (bp
remainder is utilized for the production of α- 203.8 ◦ C), which is isomerized in a second
methylstyrene [65], [77]. reactor at 240 – 320 ◦ C over the same alu-
Both liquid- and vapor-phase processes are minum silicate catalyst. In this second reactor,
used for the commercial synthesis of cumene. polyalkylbenzenes are transalkylated with ben-
The most widely used is the liquid-phase process zene to give further p-diisopropylbenzene [87].
of Universal Oil Products, which operates with a m-Diisopropylbenzene can be produced in a
solid phosphoric acid catalyst (SPA, H3 PO4 sup- similar manner, with only slight modifications.
ported on diatomaceous earth). The conversion The diisopropylbenzenes are also important in-
is carried out at 15 – 35 bar and temperatures of termediates for the production of hydroquinone
200 – 250 ◦ C. A 5 : 1 molar ratio of benzene to (or resorcinol) (→ Hydroquinone).
propene is necessary to prevent polyalkylation
and to achieve a high conversion (ca. 94 %) of Alkylation of Benzene with Higher Olefins.
propene. The conversion is lowered to 70 % if a Monoalkylbenzenes with 10 – 14 carbon atoms
4 : 1 benzene – propene feed is used. Increase of in the alkyl chain, such as dodecylben-
zene [123-01-3], are important intermediates
Acylation and Alkylation 13
for alkylbenzenesulfonates, which are widely of branching of the alkyl side chain – three to five
used in anionic commercial detergent products methyl groups in dodecylbenzene are optimum,
(→ Surfactants). whereas the highly branched butene oligomers
Until about 1965, the most important olefin were not suitable as starting material [64] – but
for this reaction was propene tetramer. However, depend also on the position of the phenyl group
the resistance of detergents based on propene on the alkyl chain [90]. Irrespective of the po-
tetramer to biodegradation led to environmental sition of the olefin double bond, Friedel – Crafts
problems and hence to the introduction of lin- alkylation leads to an equilibrium product mix-
ear alkylbenzenesulfonates. The feedstock for ture with a random distribution of the phenyl
the production of alkylbenzenesulfonates there- over the alkyl chain. The product composition,
fore consists of linear olefins with 10 – 14 carbon however, is affected by the nature of the catalyst,
atoms. The catalysts generally used for this re- as shown in Table 6, where the product distribu-
action are liquid HF, H2 SO4 , or AlCl3 and the tions obtained from the reaction of benzene with
following conditions are suitable [50]: 1-dodecene [112-41-4] utilizing AlCl3 , HF, and
1) HF: 0 – 10 ◦ C, 4 – 10 mol of benzene to 1 mol H2 SO4 as catalyst are listed [54].
alkene, 2 – 3 kg of alkene per kilogram of HF Table 6. Isomer distribution of dodecylbenzenes obtained
2) H2 SO4 : 10 – 30 ◦ C, 4 – 5 mol of benzene to from 1-dodecene and benzene
1 mol alkene, 2 volumes of alkene per vol- Phenyldodecane, Catalyst, temperature
ume of 96 – 98 % H2 SO4 Mass fraction in %
◦
HF, 16 C AlCl3 , 30 ◦ C H2 SO4 , 0 ◦ C
3) AlCl3 : 55 – 60 ◦ C, 3 – 4 mol of benzene to
1 mol olefin, 25 mol of alkene per mole of 1- 0 0 0
2- 20 32 41
AlCl3 3- 17 22 20
4- 16 16 13
The HF process is reported to be the most eco- 5- 23 15 13
nomical with respect to catalyst consumption. 6- 24 15 13
The process is carried out in the liquid phase at
atmospheric pressure and 10 ◦ C. Effective stir- As expected, no terminal phenyldodecanes
ring and cooling is necessary to remove the heat are observed. With AlCl3 and H2 SO4 as the
of the exothermic reaction. This determines the catalyst, the 2-phenyl isomer is formed prefer-
reaction times. The acid strength is maintained entially, and the 3- to 6-phenyl isomers occur
at 79 % HF, and a high benzene to olefin ra- in lesser amounts. In contrast, with HF, the 3-
tio is needed to insure complete conversion of to 6-phenyl isomer formation is enhanced. This
olefins and a high selectivity to monoalkylates. can be explained by the ability of Lewis acids,
The products are separated from the acid in a set- such as AlCl3 , to isomerize the phenylalkanes
tler, washed, and distilled at atmospheric pres- formed, whereas the proton acids isomerize only
sure to recover benzene and at reduced pressure the olefins prior to the final alkylation of the ben-
to isolate the alkylbenzenes [65], [88]. zene.
More recently, many solid alkylation cata-
lysts for the production of linear alkyl ben- Alkylation of benzene with alkyl chlorides
zenes have been described in the literature, also is used commercially for the production of
however, since a slow-down in LAB demand detergent alkylates. The alkyl chloride obtained
has taken place in the industrialized regions, from the chlorination of paraffins contains about
only UOP (Detal process) has commercialized a 70 % paraffin. This mixture then reacts with a
new technology using a noncorrosive catalyst large excess of benzene in an enameled alkylat-
to replace HF. UOP has patented a fluorided ing tower at 80 ◦ C using AlCl3 as the catalyst.
silica – alumina catalyst [89] which is operated The hydrogen chloride, which is formed in stoi-
in liquid phase at about 130 ◦ C. The process chiometric amounts, insures thorough mixing of
achieves 92 % linearity (i.e., unbranched alkyl the reactants and is separated at the top of the re-
chain, see Table 6) at 100 % conversion and a actor. The products are separated from the cata-
selectivity of 90 %. lyst in a settler, neutralized, washed, and distilled
The detergent properties of the alkylbenzene- to recover benzene and paraffin, which are recy-
sulfonates are not only influenced by the degree
14 Acylation and Alkylation
cled; they are then distilled under reduced pres- some diphenylmethane) from dichloromethane
sure to isolate the alkylates [91] (→ Surfactants). and benzene:
Considerable amounts of indane and tetralin
derivatives are formed as byproducts because of
the dichloroalkane impurities in the alkyl chlo-
ride:
Anthracene derivatives also are formed in this
reaction [93].
Intramolecular cycloalkylation is possible
for alkylated aromatic compounds carrying a
double bond or a functional group, such as a
halogen or hydroxy group, in the side chain. For
example, 3-phenyl-1-propene [300-57-2] is iso-
merized to give indane [496-11-7] in the pres-
ence of AlCl3 [94]:
As pointed out in Section 2.1.1, the alkylation Alkylation of higher aromatic compounds,
of benzene rarely leads to the monoalkylated such as biphenyl, indane, and tetralin, or of
product only, but to a complex mixture with di- polynuclear aromatic compounds, such as naph-
and polysubstituted compounds. The reactivity thalene, acenaphthene, anthracene, fluorene, and
as well as the orientation in the second substi- phenanthrene, also has been reported [101].
tution step depends on the electronic and steric The alkylation of naphthalene [91-20-3] with
properties of the first substituent and on the bulk- higher olefins has found commercial applica-
iness of the alkylating agent. tion for the production of fluorescent agents
Some dialkylated benzenes are of consider- used in lubricating oils. The reaction is carried
able commercial importance [65], [73]. For ex- out in the liquid phase using AlCl3 as the cat-
ample, diethylbenzenes are useful for improving alyst at temperatures up to 180 ◦ C [102]. An-
the octane ratings of motor fuels and are obtained other application of naphthalene alkylation is
as side products in ethylbenzene production pro- the production of detergents of the “Nekal” type
cesses. Dialkylbenzenes can be dehydrogenated (BASF), which are alkylnaphthalenesulfonates.
to give divinylbenzenes that are used for cross- These compounds were among the first synthetic
linking detergents and are still used in the textile indus-
of polyolefins, such as polystyrene in the try as surfactants:
production of ion-exchange resins. Similarly,
ethylmethylbenzene, obtained by ethylation of
toluene, is of industrial interest as a starting ma-
terial for styrenes that are methyl substituted in
the aromatic ring. Another example is the pro-
duction of diisopropylbenzene by reaction of
propene with cumene (see page 12).
16 Acylation and Alkylation
They are prepared in a “one-pot” process by found in significant amounts, whereas at higher
reaction of naphthalene with butanol or hex- temperatures, catalyst concentration, and acid
anol or mixtures of propanol – butanol in the strength, the alkylphenols are formed predomi-
presence of 96 % sulfuric acid at 50 ◦ C. Af- nantly [106]. Olefins, alcohols, and alkyl halides
ter the alkylation is complete, 25 % oleum are the alkylating agents. For industrial phenol
is added for sulfonation. The oxidation of 2- alkylation, three main types of processes have
isopropylnaphthalene, according to the Hock been developed:
process, leads to 2-naphthol [135-19-3]. 2-
1) Liquid-phase alkylation, in which the alky-
Isopropylnaphthalene can be obtained together
lating agent is added to a solution or suspen-
with small amounts of the 1-isopropyl isomer
sion of the catalyst in the phenol. The cata-
by reaction of naphthalene with propene using
lyst must be separated after the reaction, and
ZnCl2 or aluminum silicates as the catalyst at
the last traces of the catalyst decomposed by
150 – 200 ◦ C [103].
neutralization.
2,6-Dialkylnaphthalenes have attracted
2) Fixed-bed liquid-phase processes, in which
much interest. They are oxidized to 2,6-
the reactants pass over the catalyst at ele-
naphthalenedicarboxylic acid which is used for
vated pressures in tubular reactors, which are
the production of the high-performance plas-
cooled externally.
tic poly(ethylene-2,6-naphthalene dicarboxy-
3) Vapor-phase alkylation, in which the phenol
late) (polyethylenenaphthenate, PEN). Various
and the alkylating agent, such as methanol or
shape-selective catalysts have been described to
an olefin, are sent to a fixed-bed reactor op-
alkylate naphthalenes, among which mordenite
erating at 300 – 400 ◦ C. The heat of reaction
seems to be the most effective [104]. How-
must be removed efficiently.
ever, another route to 2,6-dimethylnaphthalene
was commercialized by Amoco in 1995 at a The product is recovered in all cases by dis-
capacity of about 40 000 t/a. Amoco alkylates tillation. The unconverted phenols and alkylat-
o-xylene with butadiene over a strongly basic ing agents are recycled and the various mono-,
catalyst yielding o-tolylpentene, which further di-, and trialkylated phenols separated. In order
undergoes cyclization, dehydrogenation, and to prevent side reactions, such as isomerization,
isomerization [105]. transalkylation, and disproportionation, during
distillation, it is essential to remove all traces of
the acidic catalyst.
2.1.4. Alkylation of Phenols Catalysts. In the liquid-phase processes,
Lewis acid catalysts, such as AlCl3 , BF3 , or
The alkylation of phenols is a very important Al(C6 H5 O)3 ; proton acids, such as HF, H2 SO4 ,
reaction industrially, and the alkylphenols are H3 PO4 , or p-tolylsulfonic acid; or acidic ion-
used widely in a variety of applications, such as exchange resins, such as Nafion resins or sul-
antioxidants, herbicides, insecticides, or poly- fonated polystyrenes, are applied. Catalysts suit-
mers. The nucleophilicity of the hydroxyl group able for the vapor-phase processes must be of
is associated with increased electron density in high thermal stability. Typical examples are
the aromatic ring, which facilitates electrophilic montmorillonites (Al2 O3 · 4 SiO2 · H2 O), zeo-
substitution. Therefore alkylation occurs under lites, such as faujasite, and metal oxides, such as
conditions milder than those needed with aro- γ-Al2 O3 , MgO, CaO, and Fe2 O3 – CrO3 [107–
matic hydrocarbons [101]. 109].
Depending on the reaction conditions, cat- Alkylation with alcohols, especially
alysts and alkylating agents, predominantly methanol, usually is carried out over metal ox-
ortho- or para-monoalkylated, 2,4- or 2,6- ides, preferably MgO. For olefins, the acidic
dialkylated, and 2,4,6-trialkylated phenols are catalysts and γ-Al2 O3 are used. The heteroge-
formed. neous catalysts, such as ion-exchange resins or
Thermodynamically more stable meta iso- zeolites, gradually are replacing the liquid acids
mers are formed at higher temperatures by sec- because of easier product separation and lower
ondary reactions. At low temperatures and low catalyst consumption [107–110].
catalyst concentrations, alkyl aryl ethers also are
Acylation and Alkylation 17
Regioselectivity can be controlled using a va- If different alkyl substituents are to be intro-
riety of catalysts. If HF, BF3 , Al2 O3 · SiO2 , or duced into a phenol, the most sensitive tertiary
acidic ion-exchange resins are used, the alky- alkyl is added last.
lation of phenols with olefins leads predomi- In industry, alkylphenols often are produced
nantly to the p-substituted product. In contrast, in batch operations, which offer higher flex-
Al(C6 H5 O)3 , which is formed from phenol and ibility. However, for compounds produced in
metallic aluminum, especially in the presence of large amounts, such as cresols, 2,6-xylenol
traces of mercury salts, leads almost exclusively (→ Cresols and Xylenols), 2-sec-butylphenol,
to the 2-alkylated and 2,6-dialkylated products. 4-tert-butylphenol, octylphenol, nonylphenol,
The high selectivity for ortho alkylation is ex- dodecylphenol, thymol, or 2,6-di-tert-butyl-4-
plained by a six-membered transition state in- methylphenol (→ Phenol Derivatives), continu-
volving aluminum phenolate and an olefin [111]. ous processes have been introduced with capac-
Other metal salts of phenol, including those of ities of up to 25 000 t/a each. A survey of com-
zinc, magnesium, and calcium, are active. This mercially important alkylphenols and their end
reaction is not restricted to phenol; 2-naphthol, uses is given in Table 7 [115–117].
2-cresol, or 4-cresol also can be alkylated by
ethylene, propene, the butenes, cyclohexene, or Alkylation of phenol with methanol at el-
other olefins. The highest reactivity is observed evated temperatures over a catalyst yields 2-
for isobutene, the lowest for ethylene [112], cresol [95-48-7] (60 – 70 % at 50 % phenol con-
[113]. version and 300 ◦ C) and 2,6-xylenol [576-26-1],
High selectivity to monoalkylated o-phenols together with some 4-cresols, 2,4-, and 2,3-
by reaction of olefins with phenols is achieved xylenols, and a little 3-cresol.
with γ-Al2 O3 as the catalyst. The reaction is car- The reaction can be carried out in the liquid
ried out at elevated temperatures of 200 – 350 ◦ C phase or in the vapor phase. In the vapor-phase
in the liquid phase at pressures of 20 – 200 bar. processes, the reactants are fed at atmospheric
This process is well suited to continuous fixed- or slightly elevated pressure at 300 – 450 ◦ C
bed operation. into a tubular reactor containing the fixed-
Heating alkylphenols, especially in the pres- bed catalyst [118]. A high selectivity to 2-
ence of acidic catalysts, leads to dealkyla- cresol and 2,6-xylenol is observed with acti-
tion, transalkylation, and isomerization [114]. vated Al2 O3 at 300 ◦ C [119] and with MgO
The tendency of the alkylphenols to undergo and CeO2 at 540 and 450 ◦ C, respectively [120].
these reactions depends on the nature of the Use of highly acidic aluminum oxide, alu-
alkyl substituent and increases in the order pri- minum silicates, zeolites, and aluminum phos-
mary < secondary < tertiary alkyl; methyl sub- phate, especially at higher temperatures, leads
stituents are rather inert. Isomerization leads to to transalkylation-isomerization and thus to in-
an equilibrium where the thermodynamically creased formation of 3-cresol and 4-cresol. In
more stable 3 or 3,5 isomers prevail, and dealky- liquid-phase processes, catalysts such as Al2 O3 ,
lation occurs more easily in the ortho or para Al(OMe)3 , Al(OC6 H5 )3 , or ZnCl2 – HCl are
position than in the meta position. The regios- used at elevated pressures [121], [122]. In all
electivity of transalkylations is influenced also cases, the xylenol : cresol ratio increases with the
by the nature of the catalyst, and, therefore, in methanol : phenol ratio, with temperature, and
the presence of aluminum phenolate the ortho with pressure.
products prevail: 2,3,6-Trimethyphenol [2416-94-6] is pro-
duced by a continuous liquid-phase process from
2,6-xylenol and methanol, using a fixed-bed
Al2 O3 catalyst at 280 – 380 ◦ C in a tubular reac-
tor [123].
whereas the alkylation of phenol with propene A most important process commercially is
to 2-isopropylphenol [88-69-7] can be carried the alkylation of phenol with linear or branched
out at 280 – 300 ◦ C using γ-Al2 O3 as the cata- olefins containing 6 – 20 carbon atoms to give
lyst [108], [124]. The propylation of cresols to alkylphenols, which after ethoxylating and sul-
give thymol [89-83-8] or carvacol [499-75-2] is fating, are used widely as anionic detergents.
achieved in continuous liquid-phase processes Diisobutene, tripropene, and tetrapropene are
using γ-Al2 O3 , aluminum silicates, or zeo- preferred as alkylating agents, and the reaction
lites [115]. Under similar conditions, 2-sec- is catalyzed under mild conditions (50 – 85 ◦ C)
butylphenol [89-72-5] can be produced from by BF3 in continuous-batch or tubular reac-
phenol and n-butenes [124]. tors. Acidic cation-exchange resins, such as
Because of the high reactivity of isobutene, macroreticular sulfonated polystyrene, also are
the production of 2-tert-butylphenol [88-18-6] excellent catalysts that overcome the problem
and 2,6-di-tert-butylphenol [128-39-2] can be of catalyst separation. To achieve better temper-
carried out at 100 ◦ C at pressures up to ature control, the reaction may be carried out in
20 bar in the presence of Al(C6 H5 O)3 . 4-tert- two stages, using a catalyst of reduced acidity in
Butylphenol [98-54-4] is prepared at atmo- the first stage. A process of this type is utilized by
spheric pressure at 80 – 140 ◦ C in the presence Chemische Werke Hüls (now Degussa-Hüls) in
of H2 SO4 , H3 PO4 , BF3 , or preferably acidic Germany to produce nonylphenol [107], [110],
cation-exchange resins [125]. [115]. In the first stage of this fixed-bed process,
The production of the important antioxidant the temperature increases from 80 to 120 ◦ C and
2,6-di-tert-butyl-4-methylphenol [128-37-0] in the second stage from 110 to 130 ◦ C. Acti-
from 4-cresol and isobutene is carried out at vated aluminum silicates also are used as cat-
70 ◦ C using H2 SO4 as the catalyst [126]. The alysts but require higher reaction temperatures
alkylation of phenol with 2-methylbutenes at and longer reaction times.
100 – 120 ◦ C in the presence of BF3 or H3 PO4 A great variety of alkylphenols,
yields 4-tert-amylphenol [80-46-6], in the pres- haloalkylphenols, and related compounds are
ence of an excess of 2-methylbutenes also 2,4- produced industrially and are used as oxida-
di-tert-amylphenol [127]. tion inhibitors, detergents, bactericides, fungi-
cides, insecticides, and disinfectants. This field
Acylation and Alkylation 19
has been reviewed extensively (→ Cresols and 2,6-Dialkylanilines, for example, 2-ethyl-6-
Xylenols; → Phenol Derivatives) [101], [107], methylaniline [24549-06-2], are produced in-
[108], [128]. dustrially as intermediates for herbicides and
dyes [115].
and AlCl3 led to side reactions. In all cases, the variety of substrates, such as methanol, ethyl,
thiophene substituted in the 2 position was ob- isopropyl, butyl, and benzyl halides, 1,2-di-
served, as well as higher-boiling material, such chloroethane, ethylene, propene, and isobutene.
as dialkylated products [57], [132]. The removal The reaction often yields complicated mixtures
of thiophene from cracked gasoline by refining of homoannular and heteroannular (i.e., both
with cold concentrated sulfuric acid is proba- rings are alkylated) products, because of the in-
bly an alkylation reaction. The olefins present creased reactivity of the system after the first
in the gasoline act as alkylating agents to give alkylation step [137], [138]. Alkylation of fer-
high-boiling alkylthiophenes, which remain as rocene with olefins seems more favorable; that
residue upon distillation [133]. with isobutene to give tert-butylferrocene oc-
curs even at room temperature. At 100 – 150 ◦ C,
N-Heterocycles can be alkylated in the pres- heteroannular tri-tert-butylferrocene is obtained
ence of aluminum amides. Because heterocyclic in 44 % yield, together with some tetra-tert-
compounds, such as carbazole and indole, react butylferrocene. Steric hindrance prevents the
only slowly with aluminum metal to give the attachment of more than two tert-butyl sub-
amide, aluminum anilide is used as the catalyst. stituents to the same cyclopentadienyl ring
For example, carbazole reacts with ethylene in [139]. A more detailed description of fer-
the presence of aniline and aluminum powder rocene alkylation and of alkylation reactions of
to give 1-ethylcarbazole [19275-57-1]. The re- other nonbenzenoid aromatic compounds can be
action takes place in an autoclave at 280 ◦ C and found in [140], [141].
200 bar.
catalyst most often used; other catalysts include This compound is produced industrially in
acidic halides (ZnCl2 – AlCl3 , SnCl4 , AlCl3 – continuous processes using H2 SO4 (or, in the
ketones, AlCl3 – pyridine) or proton acids (HCl, Hooker process, dry HCl) as the catalyst and
H2 SO4 , H3 PO4 , p-toluenesulfonic acid) [142]. methyl mercaptan as promoter. Almost quanti-
A typical example of this reaction is tative yields are obtained at 50 ◦ C [63]. Also,
the chloromethylation with formaldehyde – HCl cation-exchange resins are being used increas-
(Blanc reaction) [143]: ingly as catalysts, because of the simplified cat-
alyst separation [107]. Bisphenol A is utilized
mainly for the production of epoxy- and poly-
carbonate resins.
Hydroxyalkylations (Table 8) are extremely
versatile; numerous alkyl- and aryl-substituted
aldehydes and ketones react with a variety of
Because this reaction leads to reactive inter- aromatic compounds [144]. For instance, 1,1,1-
mediates, it is of considerable synthetic value. trichloro-2-bis-(4-chlorophenyl)ethane (DDT)
However, great care must be exercised because [50-29-3], once a widely used insecticide, is
the intermediate chloromethyl ethers are ex- formed from chloral and chlorobenzene. The
tremely carcinogenic. reaction of phenol with formaldehyde leads to
hydroxymethylphenols, which condense at ele-
Hydroxyalkylation of aromatic compounds vated temperatures to phenol resins.
with aldehydes and ketones in the presence of If an oxirane is used as the alkylating agent,
acids is industrially very important. The elec- a β-hydroxyalkyl aromatic compound is ob-
trophiles attacking the aromatic nucleus are tained. For example, the reaction of ethylene
formed from the aldehyde-ketone by reaction oxide [75-21-8] with benzene in the presence of
with a Lewis or proton acid (R, R = H, alkyl, a stoichiometric amount of AlCl3 leads to an alu-
aryl): minum alkoxide, which gives β-phenylethanol
[60-12-8] on hydrolysis [145].
nitro substituted aromatic compounds can be of the first acyl group hinders the entry of a
alkylated using N-chloromethylcarboxylic acid second, and disubstitution in the same ring is
amides in the presence of AlCl3 [146]. therefore rare [147]. Examples for the disubsti-
tution are the diacylation of mesitylene [150]
or durene[151] and the diacylation of anisole
2.2. Acylation [100-66-3] with a mixture of glacial acetic acid
and phosphorus pentoxide [152]:
In Friedel – Crafts acylation, an aromatic ketone
is formed by reaction of an aromatic compound
with an acylating agent, such as an acyl halide,
an acid anhydride, an acid, or an ester, in the
presence of an acidic catalyst:
Although acylation has much in common the Lewis acid with the aromatic ketone, from
with Friedel – Crafts alkylation, there are char- which the product is liberated by hydrolysis.
acteristic differences. For example, consump- Thus, in contrast to Friedel – Crafts alkylations,
tion of the acidic catalyst is usually at least stoi- the catalyst must be usually applied in at least
chiometric. However, there are examples in the stoichiometric amounts with respect to the acyl
literature where substoichoimetric amounts of halide. Examples for the unusual use of substoi-
Lewis acids are applied. The course of the re- chiometric (“truely catalytic”) amounts of Lewis
action is more uniform than in Friedel – Crafts acids are ferrous chloride [161–164], zinc or
alkylation, leading to higher regioselectivity. iron oxides [165], cobalt chloride [166], and rare
Also, isomerizations and other side reactions are earth metal triflates [167–170].
rare.
Heterogeneous Catalysts. Even if the clas- Zeolites provide not only active acid sites but
sical Friedel – Crafts Synthesis with homoge- also the possibility to perform shape-selective
neous catalysts is still the most important pro- acylations. The geometry of the micropores can
cess for the preparation of aromatic ketones, it control the regioselectivity of the reaction.
has several disadvantages: Clays. Clay minerals are sheet silicates with
alternating layers of alumina and silica sepa-
1) The use of stoichiometric or even greater
rated by nonbonding sheets. For catalytic pur-
amounts of “catalyst” is often required be-
poses these minerals have to be modified to in-
cause of the formation of stable complexes
crease the number of acid sites. There are two
with the products. Lewis acids like AlCl3 are
types of clay catalysts: acid-treated clays and
rather reagents then catalysts and contribute
ion-exchanged clays. Acid treatment of clays
to a great extent to the production costs. They
by H2 SO4 or HCl removes part of the alu-
must be washed out of the product and can-
mina and also some other naturally occurring
not be recycled.
cations such as Mg2+ or Fe3+ from the layers,
2) The reaction system is very corrosive and
so that negatively charged alumosilicate sheets
requires expensive reactors and also an ex-
are generated, which are electrically neutralized
pensive equipment for the purification of the
by protons. These Brønsted acid catalysts (like
waste gas, which consists not only of HCl,
K10) are commercially used for an number of
but also of chlorinated hydrocarbons.
acid-catalyzed reactions. The other type of cata-
3) The catalyst has to be neutralized and dis-
lysts are supported reagents, which are prepared
posed together with a large amount of
by exchanging these protons with Lewis acid
wastewater.
cations such as Zn2+ or Fe3+ . Commercial cat-
For this reason, much work has been done alysts of this type, like Envirocat, can be used
during the last years to substitute the homo- for the preparation of benzophenones even with
geneous catalysts by heterogeneous catalysts, less active aromatic compounds.
which do not have to be supplied in stoichio- Solid Superacids. According to the defini-
metric amounts and are not corrosive and can tion of Gillespie superacids are acids, that are
be easily separated, without neutralization. They stronger than 100 % sulfuric acids. They have
can also be recycled for several times or used in a Hammett acidity value H0 of < −12. A num-
a continuous fixed-bed process. ber of solids belong to this class of materials:
Heterogeneous acylation catalysts have to be sulfated oxides, supported Lewis acids, and sup-
strong Lewis or Brønsted acids. Only few classes ported liquid superacids. Only a small number
of solid acids are strong enough to catalyze this of oxides produces superacid sites on sulfation,
reaction. The most important classes are: including ZrO2, TiO2 , HfO2 , Fe2 O3 and SnO2 .
Zeolites The acid sites are generated by treating an amor-
Modified clays phous oxihydrate of these elements with H2 SO4
Solid superacids or (NH4 )2 SO4 and calcining the products at tem-
Heteropolyacids peratures of 500 – 650 ◦ C. During the calcina-
Proton or Lewis acids on a support tion step, the oxides are transformed into the
Nafion and Nafion like composites crystalline tetragonal phase, which is covered
by a small number of sulfate groups. Instead of
Zeolites are microporous, crystalline alu- H2 SO4 also H2 MoO4 or H2 WO4 can be used to
mosilicates with strong Brønsted or Lewis activate the oxide.
centers. For the acylation reactions especially Miscellaneous. A number of other classes of
medium-pore systems like H-ZSM-5 or large- catalysts have been descibed for acylation reac-
pore systems like HY zeolite, beta zeolite, tions: Heteropolyacids, surface mounted acids
or mordenite have successfully been used. (proton or Lewis acids on a support), and Nafion.
Nevertheless only electron-rich aromatic com- None of them is in commercial use.
pounds like anisol, alkylbenzenes, furanes, ben-
zofuranes, phenoles or naphthalenes are active Solvents. The aromatic substrate itself, non-
enough to react on zeolites in the liquid phase at polar solvents, such as CCl4 or CS2 , or solvents
temperatures below 150 ◦ C. of medium polarity, such as dichloromethane
Acylation and Alkylation 25
or 1,2-dichloroethane, may be used. If AlCl3 is strate can be varied systematically and through
used as the catalyst, heterogeneous systems are a wide range. The reactivity of acylating agents
formed with these solvents. However, in such follows roughly the following order:
solvents as nitromethane or nitrobenzene, ho-
[RCO]+ [BF4 ]− ≈ [RCO]+ [ClO4 ]− >
mogeneous solutions are obtained, and at the
RCOO-SO3 H > RCOX >
same time the reactivity is reduced because of
(RCO)2 O > RCO2 R > RCONR2
complex formation. The choice of solvent also
can influence the regioselectivity of the acyla- Whereas the ionic acyl perchlorates and
tion [174]: tetrafluoroborates are powerful agents, acid
esters and amides are almost inactive in
the absence of catalysts. The reactivity
of the acyl halides decreases as follows:
RCOI > RCOBr > RCOCl > RCOF.
However, the reactivity of acyl halides de-
pends also on R, which may be alkyl or aryl and
which can be substituted by halogen as well as by
an alkyl, alkoxy, or a nitro group. The aromatic
substrate and the type of catalyst also affect the
reactivity [178], [179].
Aromatic acyl halides may well contain ni-
tro substituents or be of the pyridine type, as in
the synthesis of 3-benzoylpyridine [5424-19-1]
A hazard of this reaction is that the adducts from benzene and nicotinyl chloride [149]:
of AlCl3 and nitrobenzene tend to decompose
explosively at elevated temperatures.
Acylation using an acyl halide – Lewis acid
catalyst system usually is carried out according
to one of the following procedures:
1) The acylating agent is added to a cooled so- Bifunctional acyl halides also can act as the acy-
lution or suspension of the catalyst in a sol- lating agent. For example, the reaction of oxalyl
vent; the aromatic substrate then is added chloride with a highly activated aromatic sub-
to the preformed acylating complex (Perrier strate, such as anisole, gives the corresponding
method) [175] benzil derivative [180]:
2) All reactants are mixed and cooled, and the
catalyst added slowly (Elbs method) [176]
3) The aromatic substrate is used as the sol-
vent for the catalyst, and the acylating agent
is then added slowly (Bouveault method)
[177].
The Perrier method often is preferred, be-
cause a constant ratio of catalyst to acylating
agent is maintained throughout the reaction.
If sulfuric acid is used as the catalyst, a large
excess of the acid is needed, to which the reac-
tants are added. In order to avoid ring sulfonation
or aldolization reactions, the temperature should A commercially important reaction of phos-
be kept below 100 ◦ C. gene is the reaction with N,N-dimethylaniline,
yielding 4,4 -bis(dimethylamino)benzophenone
Acylating Agents. The great versatility of (Michler’s ketone) [90-94-8], which is used in
Friedel – Crafts acylation is based on the fact that the production of dyes:
both the acylating agent and the aromatic sub-
26 Acylation and Alkylation
2.2.1. Acylation of Benzene and Benzene nols [191], and the ortho to para ratio depends
Derivatives strongly on the choice of catalysts and solvents.
Linear alkylphenols can be obtained via acy-
Acylation of benzene with acetic anhydride lation followed by reduction. An example is the
to give acetophenone [98-86-2] in 85 % yield synthesis of hexylresorcinol [136-77-6], which
was carried out commercially, using AlCl3 as is used commercially as a disinfectant [192]:
catalyst and keeping the temperature at 30 ◦ C
by cooling. Acetophenone is now produced in-
dustrially by the oxidation of ethylbenzene or of
cumene (→ Ketones, Chap. 7.1.).
Benzene can be acylated with benzoic acid
at elevated temperatures in the gas phase to give
benzophenone [187]:
4 position using P2 O5 as catalyst, as is exempli- for fine chemicals. The Friedel – Crafts acyla-
fied by the synthesis of Michler’s ketone [194], tion of ethylbenzene with phthalic anhydride
[195]. yields, in a two-step process, 2-ethylanthra-
quinone [84-51-5], which is utilized in the syn-
Cyclization Reactions. The para-directing thesis of H2 O2 [198].
effect of substituents also is found here. 6-
Methoxy-1-tetralone [1078-19-9] is obtained in
96 % yield from 4-(3-methoxyphenyl)butyric 2.2.2. Acylation of Polynuclear Aromatic
acid [196], [197]: Compounds
electrophilic substitution reactions and thus can out using zeolites in a continuous liquid-
be acylated under mild conditions. phase process, for example the acylation of 2-
methylbenzofuran with acetic anhydride [209]:
Acylation of furan leads to high yields of
the 2-acyl derivative, especially if anhydrides are
used as acylating agents:
The acylation of olefins with acid chlorides cizers, pharmaceuticals, agricultural chemicals,
in the presence of aluminum chloride leads to β- antioxidants, and vulcanization accelerators.
haloketones and β-unsaturated ketones [238]:
4.1. N-Alkylation
Alcohols, alkyl halides, olefins, and carbonyl
compounds react with ammonia or amines to
give alkyl derivatives [64]. Further alkylation of
a tertiary amine leads to formation of quater-
nary ammonium compounds, which have found
broad application in detergents. For instance,
selected amines are alkylated with 1,3-propane
Acylations of olefins have been commercially sulfonate or epichlorohydrin sulfonate, giving
applied only for the synthesis of fine chemi- sulfobetaines:
cals, such as the unsaturated ketone (2), Vertofix
Coeur [80449-58-7], (International Flavors &
Fragrances, Inc., USA), used in perfume:
Another derivative typical of this class is
cetyltrimethylammonium chloride, made by ex-
haustive methylation of the primary amine with
methyl chloride (→ Surfactants, Chap. 8.1.).
Among the best known “quats” are ben-
zyldimethylalkylammonium chlorides (alkyl,
e.g., dodecyl). These are made by methylat-
ing the primary amine derived from coconut oil
to give the dimethylalkylamine, which is then
quaternized by addition of benzyl chloride. The
products are marketed as Zephirol, Roccal, Am-
monyx, and Triton K 60. These compounds are
used widely as disinfectants, antiseptics, and
fabric softeners.
phase, Al2 O3 , Al2 O3 · SiO2 , or dehydrogena- diamine is produced from ammonia and 1,2-di-
tion catalysts are applied. The liquid-phase op- chloroethane. No catalyst is required here.
eration is hampered by severe corrosion prob- The reaction of an amine with an alkyl halide
lems. The reaction can be carried out in batch is a versatile method for producing a variety of
or continuous-flow operations. Mixtures of the fine chemicals. Examples are the synthesis of
possible NH-exchange reaction products are ob- sodium N-methylglycinate, which is used in the
tained. Some control is possible by varying the production of compounds (3) employed in the
ratio of reactants and by recycling undesired textile and cosmetic industries or as corrosion
compounds. inhibitors, and that of p-N-methylaminophenol
Methylamine, dimethylamine, and trimethyl- (4), used in the photographic industry.
amine [74-89-5], [124-40-3], [75-50-3] are
made by the reaction of methanol with ammonia
in a continuous-flow system in the presence of a
dehydration catalyst, such as aluminum silicate
or phosphate, at 350 – 400 ◦ C. All three possible
methylamines are formed, but the product distri-
butions can be controlled by reaction conditions
(excess NH3 , addition of H2 O) and by recycling
the trimethylamine (→ Methylamines).
Higher aliphatic amines, ethyl through
pentyl, can be made by processes similar to
that described for methylamines. Furthermore,
such a reaction can be applied to make ethylene-
diamine from ethylene glycol.
Aromatic amines can be produced by this
route using an acid as catalyst. However, start-
ing from a secondary amine, it is not possible to
make monoalkyl derivatives exclusively. 4.1.3. N-Alkylation by Olefins
The alkylation of aromatic amines can
be used for an efficient synthesis of N- Alkylamines can be prepared by the direct addi-
methylaniline [100-61-8], N,N-dimethylaniline tion of an olefin to ammonia or an amine using al-
[121-69-7], N,N-diethylaniline [91-66-7], N- kali metals as catalysts. This method works well
benzyl-N-ethyl-m-toluidine [119-94-8], m- with ethylene. For example, mono- and diethy-
chloro-N-ethylaniline [15258-44-3], N-benzyl- lanilines are prepared industrially from ethylene
aniline [103-32-2], and other aromatic amines, and aniline using alkali metals as catalysts.
many of which function as dye precursors. For Higher olefins also react, but amine yields are
instance, N,N-dimethylaniline [121-69-7] has lower.
been produced on a large scale since 1870 by the
alkylation of aniline with methanol. Dimethyl
ether can be used instead of methanol, as is 4.1.4. N-Alkylation by Carbonyl
known from a BASF process. Compounds (Reductive Alkylation)
N-Acylation to provide a protective group. Reactions in which the hydroxyl group is at-
The primary NH group in aniline derivatives tacked are very wide ranging. However, those
can be masked by acylating the compound prior alkylations or acylations in which the OH group
to chlorination or nitration. For this purpose, is attached to a carbon atom are of greatest indus-
acetanilide, N-acetyl-o/p-toluidine, N-acetyl- trial importance. Table 12 enumerates reactions
38 Acylation and Alkylation
and reaction products involving alkylation and perature is kept below 30 ◦ C. After 5 – 8 h, wa-
acylation of hydroxyl groups attached to carbon. ter is added to the cellulose triacetate. The hy-
drolysis is stopped when the required degree of
Table 12. Products of alkylation and acylation of alcohols and car-
boxylic acids acetylation is reached by running the mixture
into a large volume of water followed by cen-
Alkylation/acylation agents ROH RCOOH
trifuging. For further details, → Cellulose Es-
RCOX ∗, (RCO)2 O esters anhydrides ters, Chap. 2.1.3.
RX ∗ ether esters
Olefin ether esters
∗ X=halide. Direct Esterification Using Olefins or
Acetylene. Esters are formed also by alkylation
Besides acyl halides, anhydrides, alkyl of acids by olefins, but this method often is lim-
halides, and olefins, a variety of other alkyla- ited by low catalyst efficiency. Olefins ranging
tion and acylation agents are utilized. Although from ethylene to octenes and higher olefins can
of minor industrial importance, alkylation with be used, together with such catalysts as BF3 ,
dialkyl sulfates or diazo compounds is a com- BF3 · ROR (R = alkyl, aryl), or BF3 – HF. Poly-
mon laboratory method for preparing ethers and merization of reactive olefins often limits this
esters [243]. The commercial synthesis of N- application. The direct esterification of organic
acylcarbamates is based also on an O-alkylation: acids with olefins has distinct advantages from a
processing standpoint over the two-step process
in which the olefin is first hydrated to an alcohol
with the acid.
Some of these processes are in industrial
use. The reaction of α-pinene with carboxylic
acids yields bornyl esters that are intermediates
in camphor chemistry. Of industrial importance
5.1. Synthesis of Esters are also the vinyl esters of higher carboxylic
acids (fatty acids, Koch acids) which are used as
Esters can be prepared by three routes: acylation comonomers in polymerizations of vinyl chlo-
of alcohols, reaction of acids with alkyl or aryl ride, vinyl acetate, acrylonitrile, styrene, and
halides, and reaction of acids with olefins (see other compounds. The process is based on the
Table 12). The most readily available acylating reaction of the acids with acetylene in the liquid
agents are selected, together with appropriate phase at 150 – 170 ◦ C at 10 – 15 bar pressure.
catalysts where required. For acyl halides, such
bases as pyridine or aqueous alkali are the pre-
ferred catalysts; for anhydrides, sodium acetate,
sulfuric acid, and BF3 are preferred. Many fine
chemicals, such as pharmaceuticals, are made by As catalysts, zinc salts or H2 O – H2 SO4 can
this route. The synthesis of acetylsalicylic acid be used.
(aspirin) using acetic anhydride is an example:
3 SnCl4 + 4 R3 Al −→ 3 R4 Sn + 4 AlCl3
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