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Acylation and Alkylation 1

Acylation and Alkylation


Michael Röper, BASF Aktiengesellschaft, Ludwigshafen, Germany

Eugen Gehrer, BASF Aktiengesellschaft, Ludwigshafen, Germany

Thomas Narbeshuber, BASF Aktiengesellschaft, Ludwigshafen, Germany

Wolfgang Siegel, BASF Aktiengesellschaft, Ludwigshafen, Germany

1. Introduction . . . . . . . . . . . . . . . 1 2.2.3. Acylation of Heteroaromatic Com-


1.1. Catalysts . . . . . . . . . . . . . . . . . . 2 pounds . . . . . . . . . . . . . . . . . . . 29
1.1.1. Acidic Catalysts . . . . . . . . . . . . . 2 2.2.4. Acylation of Nonbenzenoid Aromatic
1.1.2. Basic Catalysts . . . . . . . . . . . . . . 5 Compounds . . . . . . . . . . . . . . . . 31
1.1.3. Organometallic Catalysts . . . . . . . . 5 2.2.5. Miscellaneous Acylation Reactions . 31
1.2. Alkylating and Acylating Agents . . 5 3. Acylation and Alkylation of
1.3. Mechanism . . . . . . . . . . . . . . . . 6 Aliphatic Hydrocarbons . . . . . . . 33
1.3.1. Alkylation . . . . . . . . . . . . . . . . . 6
4. N-Alkylation and N-Acylation . . . 34
1.3.2. Acylation . . . . . . . . . . . . . . . . . . 7
4.1. N-Alkylation . . . . . . . . . . . . . . . 34
2. Alkylation and Acylation of Aro-
matic Compounds . . . . . . . . . . . . 7 4.1.1. N-Alkylation by Alcohols or Ethers . 34
2.1. Alkylation . . . . . . . . . . . . . . . . . 7 4.1.2. N-Alkylation by Alkyl Halides . . . . 35
2.1.1. Alkylation of Benzene . . . . . . . . . . 10 4.1.3. N-Alkylation by Olefins . . . . . . . . 35
2.1.2. Cycloalkylation . . . . . . . . . . . . . . 14 4.1.4. N-Alkylation by Carbonyl Com-
2.1.3. Alkylation of Substituted Benzenes . 15 pounds (Reductive Alkylation) . . . . 35
2.1.4. Alkylation of Phenols . . . . . . . . . . 16 4.2. N-Acylation . . . . . . . . . . . . . . . . 36
2.1.5. Alkylation of Aromatic Amines . . . . 19 5. O-Alkylation and O-Acylation . . . . 37
2.1.6. Alkylation of Heteroaromatic Com- 5.1. Synthesis of Esters . . . . . . . . . . . 38
pounds and Related Substrates . . . . 19
5.2. Synthesis of Anhydrides . . . . . . . . 38
2.1.7. Miscellaneous Alkylation Reactions . 20
5.3. Synthesis of Ethers . . . . . . . . . . . 39
2.2. Acylation . . . . . . . . . . . . . . . . . 22
2.2.1. Acylation of Benzene and Benzene 6. CH-Alkylation and CH-Acylation of
Derivatives . . . . . . . . . . . . . . . . . 27 Nonaromatic Compounds . . . . . . 39
2.2.2. Acylation of Polynuclear Aromatic 7. Synthesis of Metal Alkyls . . . . . . . 39
Compounds . . . . . . . . . . . . . . . . 28 8. References . . . . . . . . . . . . . . . . . 41

1. Introduction phasis is on industrial significance; reactions are


classified according to substrate type.
Alkylation and acylation can be defined as the Because alkylation and acylation reactions
introduction of an alkyl (R) or an acyl (RCO) are diverse in nature, there is no universal
group, respectively, into a molecule. These two method of carrying them out. The production
types of reaction have many features in common. of each compound must be considered individ-
For instance, essentially the same catalysts can ually, assessing chemical, engineering, and eco-
be applied, leading to related reaction interme- nomic factors.
diates. The definition given above covers a wide
range of reactions. Although alkylations and Industrial Importance. A variety of acyla-
acylations often are referred to as acid-catalyzed tions and alkylations are carried out on a large
Friedel – Crafts-type reactions only, alkylation industrial scale. Some reactions of this type are
can refer also to the preparation of alkylates in used predominantly for the synthesis of fine
refinery operations. In this article, the major em- chemicals, such as pharmaceuticals or agricul-
tural chemicals. Some of the processes used

c 2005 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim


10.1002/14356007.a01 185
2 Acylation and Alkylation

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

Cation-forming compounds, such as alkyl and


1.1.1. Acidic Catalysts acyl halides or oxygen, nitrogen, sulfur, and
halide donors, also are effective promoters.
The acidic catalysts can be divided into five From an environmental point of view, acid
groups: acidic halides, metal alkyls and alkox- halides have the disadvantage to produce waste
ides, proton acids, acidic oxides and sulfides, salts after work-up/neutralization of the prod-
supported acids and cation-exchange resins. uct mixture. In an effort to minimize waste for-
mation, reusable aluminum catalysts have been
Acidic Halides. All Lewis acids, including developed. The catalyst forms a liquid clathrate
the metal halides known as Friedel – Crafts cat- which is insoluble in the Friedel – Crafts reaction
alysts, have an electron-deficient center capable products, is separated, e.g., by phase separation,
of attracting electrons from the basic reagents. and is recycled to the process [15].
Olah has classified the catalytic activity of a
variety of halide Lewis acids for the alkyla- Ionic Liquids. A promising new devel-
tion of benzene or toluene by benzyl chloride opment is the use of ionic liquids as cata-
[13]. Catalysts of the highest activity give rise lysts and solvents for alkylations and acyla-
to intra- and intermolecular isomerization reac- tions. Chloroaluminate(III) liquids, that form
tions as well as the desired alkylation. Therefore, ionic liquids at room temperature, specifically
depending on the alkylating agent, the substrate, 1-butylpyridinium chloride – aluminum(III)
and the reaction conditions, the choice of the cat- chloride and 1-butyl-3-methylimidazolium
alysts has to be a compromise between activity chloride – aluminum(III) chloride, allow sepa-
and product selectivity. The acidic halide cata- ration of products from catalysts and provide
lysts most frequently used are aluminum chlo- access to a clean technology, where forma-
ride and aluminum bromide. Other common cat- tion of large amounts of salts as the byproduct
alysts are BF3 , BCl3 , BBr3 , BeCl2 , CdCl2 , is avoided. The design principles for room-
ZnCl2 , GaCl3 , GaBr3 , FeCl3 , SbCl3 , BiCl3 , temperature ionic liquids, some of their proper-
TiCl4 , ZrCl4 , SnCl4 , UCl4 , and SbCl5 . In in- ties, and the rationale for using these neoteric
dustrial applications, however, aluminum chlo- solvents, are discussed in [16] and an indica-
ride is the catalyst of choice because of its low tion of the scope of these solvents for future
cost and wide availability. industrial processes is given.
In their original work, Friedel and Crafts
described reactions using anhydrous aluminum Metal Alkyls and Alkoxides. Because of
chloride. However, it is rather difficult to ob- their Lewis acidity, metal alkyls and alkoxides
tain aluminum chloride or other Lewis acid- are active catalysts in Friedel – Crafts reactions.
type metal halides in an absolutely anhydrous However, the Lewis acidity in these systems,
Acylation and Alkylation 3
Table 1. Examples of industrial alkylation processes

Reaction type Process description Production, 106 t/a ∗

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

∗ estimated for 1992.

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].

1.1.2. Basic Catalysts

Basic catalysts are preferred for C-alkylations


and C-acylations of CH acidic compounds.
Here, the base increases the nucleophilicity of
the CH acidic compound. The type of catalyst
depends upon the substrate to be alkylated or As yet, these catalysts are of no major indus-
acylated. Often, the compounds are of such low trial importance and therefore are not discussed
acidity that prior formation of a metal derivative further.
is required. Aliphatic compounds with electron-
attracting substituents, for example, CN or CO,
usually are depronated by alkoxide, amide, and 1.2. Alkylating and Acylating Agents
similar ions:
The most widely used alkylating agents are
RCH2 CN + NH− 
2 −→ R CHCN + NH3
olefins and alkyl halides. The most impor-
tant olefins are ethylene, propene, dodecene
RCH2 CN + OH− −→ R CHCN + H2 O (tetrapropene), and linear olefins with 10 – 20
carbon atoms; all are used in large-scale in-
Commonly used bases include sodium alkox- dustrial alkylation processes. Among the alkyl
ides, sodium amide, and sodium hydride. Some- halides, methyl chloride, methyl iodide, ethyl
times the powerful triphenylmethylsodium chloride, isopropyl chloride, tert-butyl chloride,
(tritylsodium) or even alkali metals (for exam- and benzyl chloride often are used.
ple, Na in liquid NH3 [37] or Na supported Alcohols, ethers, esters of inorganic or or-
on γ-Al2 O3 [38]) must be used. For example, ganic acids, epoxides, aldehydes and ketones,
toluene is alkylated with ethylene or propene thiols, and related compounds can be used, but
to give propylbenzene or isobutylbenzene and in these cases more than catalytic amounts of
cumene is alkylated with ethylene to give (1,1- the Lewis acid usually are required because the
dimethyl)propylbenzene. catalyst partly hydrolyzes.
Reactions catalyzed by mild bases were con- Other powerful alkylating agents are
ducted on a wide variety of basic oxides (MgO, dimethyl sulfate, diethyl sulfate, ethyl p-toluene-
ZrO2 , La2 O3 ) and basic microporous materi- sulfonate, trifluoromethanesulfonic acid, its
als. The side-chain alkylation of toluene with methyl or ethyl ester, as well as aliphatic diazo
methanol, aldol condensations, Knoevenagel re- compounds and triethyloxonium tetrafluorobo-
actions, and Michael additions represent the rate [368-39-8]. Alkylating agents, especially
6 Acylation and Alkylation

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

EB process using a ZSM-5 zeolite and UOP’s 2. Alkylation and Acylation of


Q-Max cumene process as well as many other Aromatic Compounds
commercial processes (see below) avoid the for-
mation of polysubstituted aromatics effectively The acid-catalyzed conversion of aromatic com-
due to shape selectivity. A comprehensive re- pounds to their alkylated or acylated derivatives
view on the industrial application of shape selec- was discovered as early as 1877 by Friedel and
tive catalysis was given by Chen and Garwood Crafts. Using anhydrous aluminum trichlo-
[48]. ride as catalyst, they were able to demon-
strate the reactivity of aromatic hydrocarbons
toward organic halides and unsaturated com-
1.3.2. Acylation pounds, organic acid anhydrides, phosgene, car-
bon dioxide, and other compounds. Several im-
The mechanistic features of acylation can be il- portant industrial processes then emerged, in-
lustrated by the reaction of an acyl halide with an cluding the synthesis of ethylbenzene, cumene,
aromatic substrate using AlCl3 as the catalyst. higher alkylbenzenes, alkylphenols, benzophe-
The reaction of the acyl halide with the Lewis none, and anthraquinone. These compounds
acid leads to a more or less polarized complex have found broad application in the production
or even an acylium ion, both of which can act of polymers, detergents, perfumes, pharmaceu-
as the active electrophile as shown below [49] ticals, dyes, and agricultural chemicals.
(R = alkyl, aryl):

2.1. Alkylation

The Friedel – Crafts alkylation of aromatic com-


pounds is an acid-catalyzed electrophilic sub-
stitution of an aromatic hydrogen by an alkyl
group. A variety of alkylating agents can be
used, but typically olefins, alkyl halides, and al-
cohols are applied. All aromatic substrates ac-
cessible to electrophilic substitution can be used,
including heteroaromatic compounds and such
compounds as ferrocene. These fast, exothermic
reactions usually are carried out under mild con-
ditions in the liquid phase, although, for some
substrates, vapor-phase processes with more
stringent conditions are applied. Using olefins,
alkyl halides, and alcohols as alkylating agents,
the following overall reactions occur:

The formation of significant amounts of the


free acylium ion can be expected only in highly
polar solvents, such as nitrobenzene or ni-
tromethane. The acylium ion mechanism is also
favored if steric hindrance occurs either in the
acylating compound or in the aromatic substrate
[49]. Also, if anhydrides, esters, or the carbonic
acids themselves are used as the acylating agents
in the presence of proton acids, a high concen-
tration of acylium ions can be expected.
8 Acylation and 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

Group Examples Type of acid

Acidic halides AlCl3 , AlBr3 , SnCl4 , SbCl5 , FeCl3 Lewis acids


Metal alkyls and alkoxides AlR3 , BR3 , ZnR2 , Al(OPh)3 Lewis acids
Proton acids HCl, HCl – AlCl3 , H2 SO4 , HF, H3 PO4 Brønsted acid
Acidic oxides and derivatives zeolites, mixed oxides and solid superacids, clays, heteropolyacids Brønsted/Lewis acid
Supported acids H3 PO4 – SiO2 , BF3 – Al2 O3 Brønsted/Lewis acid
Cation-exchange resins Permutit Q, Amberlite IR 112, Dowex 50, Nafion – silica, Deloxan Brønsted acid

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

Phenols or phenyl ethers react much faster


than benzene in alkylation because of the con-
siderably enhanced electron density in the ortho
The degree of polysubstitution, however, is and para positions.
influenced by reaction conditions and is low- Table 5. AlCl3 -catalyzed alkylation with propene in CH3 NO2 at
ered by steric hindrance by bulky alkyl groups, 25◦ C [58]
as shown in Table 3. Aromatic k rel Isomer distribution,
Benzene can be monoalkylated in good yields compound mass fraction in %
by bulky olefins, such as cyclohexene or lin- o m p
ear C6 – C18 olefins [54]. In the case of ethy-
Benzene 1.00 – – –
lene or propene monoalkylation is made pos- Fluorobenzene 0.23 41.3 2.1 56.4
sible by recycling the polyalkylated products Chlorobenzene 0.11 53.9 5.1 41.0
and by choosing suitable reaction conditions, Bromobenzene 0.07 55.4 8.6 36.0
as in the industrial synthesis of ethylbenzene
and cumene. In the alkylation of monosubsti- Reactivities as well as product and isomer se-
tuted benzenes, initially the ortho and para iso- lectivities in microporous materials largely de-
mers predominate, as Table 4 shows. However, pend on the type, the number and the strength
10 Acylation and Alkylation
Table 3. Relative rate constants for polysubstitution [53]

Reactants Catalyst Temp., ◦ C k1 k2 k3 k4 k5 k6

C6 H6 + C 2 H4 AlCl3 70 1 0.52 0.23 0.08 0.12 0.15


C6 H6 + C3 H6 AlCl3 70 1 0.85 0.28 0.02 – –
C6 H6 + C3 H6 HF 70 1 2.24 0.06 – – –
C6 H5 CH3 + C3 H6 BF3 – H3 PO4 50 1 0.22 0.06 – – –

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]:

A synthesis for anthraquinone [84-65-1], based


on cycloalkylation, was developed by BASF:

Alkylbenzenes with more than 15 carbon atoms


in the side chain lead to alkylbenzenesulfonates
that are almost insoluble in water but are ex-
tremely soluble in organic media, such as min-
eral oils. Such solutions in mineral oil are used
in the metal-working industry as drilling and
cutting fluids or in the textile industry as spin-
ning or batch fluids. Alkylbenzenesulfonates of
this type are being used increasingly as flooding
agents in the enhanced recovery of petroleum.

Miscellaneous Alkylations of Benzene. Styrene is dimerized in the liquid phase to 1-


Benzene can be alkylated by a variety of other methyl-3-phenylindane, utilizing phosphoric
linear, branched, cyclic, aryl- or otherwise sub- acid as catalyst, followed by catalytic vapor-
stituted olefins, alkyl halides, alcohols, ethers, phase oxidation to anthraquinone [95], [96].
and compounds such as alkynes and dienes. For
a comprehensive review of these reactions, see Arylation of aromatic compounds can be
[92]. Some of these reactions have been com- achieved by reaction with aryl halides, by re-
mercialized, such as the synthesis from benzene action with diazonium halides, and by dehydro-
and isobutene of tert-butylbenzene [98-06-6], genating condensation.
which is used for the production of perfumes. Because of their low reactivity, aryl halides
can be used only under specific conditions as
2.1.2. Cycloalkylation Friedel – Crafts arylating agents. Their reactiv-
ity is F  Cl > Br. Aromatic hydrocarbons can
A typical example of intermolecular cy- be arylated with fluorobenzene to give the cor-
cloalkylations is the formation of 9,10- responding biphenyls [97]. The decomposition
dihydroanthracene [613-31-0] (together with
Acylation and Alkylation 15

of aryldiazonium tetrafluoroborates in aromatic The alkylation of toluene with propene to


solvents gives ring-arylated products as well as give cymene [25155-15-1] is carried out com-
fluorobenzene [98]. mercially, for example, by Sumitomo Chemicals
The Scholl reaction is the dehydrogenating [99]:
condensation of an aromatic compound in the
presence of Friedel – Crafts catalysts. Typi-
cal examples are the formation of perylene
[198-55-0] from naphthalene

The cymene formed is rich in the meta and para


isomers and is oxidized to give acetone and
cresols, which consist of 99.5 % m,p-cresols
and 60 % m-cresol and are used as raw mate-
rials for phenolic resins or for plasticizers.
Polymethylated benzenes obtained by dis-
and the formation of 2,2 -dipyridyl [366-18-7] proportionation, for example, of toluene (see
from pyridine Section 2.1.5), or methylation of benzene or
toluene [100] can be oxidized to the correspond-
ing acids, which are used in such polymers as
polyesters, polyamides, and polyimides.
A vast amount of literature on preparative
High molecular weight polycondensated aro- alkylations of substituted benzenes exists, and
matic compounds also can be formed [92]. this field has been comprehensively reviewed
[101]. Some of these reactions are applied for
the production of fine chemicals, such as dyes
2.1.3. Alkylation of Substituted Benzenes and pharmaceuticals.

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].

Alkylation of Phenols with Olefins. 2-


Ethylphenol [90-00-6] is formed from ethy-
lene and phenol in the presence of 1 – 2 %
Al(C6 H5 O)3 at 320 – 340 ◦ C and 200 bar,
18 Acylation and Alkylation
Table 7. Production and end use of alkylphenols [115], [117]

Alkylating agent Phenol Alkylphenol End use

Methanol phenol 2-, 3-, and 4-cresol insecticides, herbicides, antioxidants,


disinfectants, resins, plasticizers
2,6-xylenol polyphenylene oxide resins
3,5-xylenol vitamin E

Methanol 3,6-xylenol 2,3,6-trimethylphenol vitamin E

Ethylene phenol 2-ethylphenol (2,6-diethylphenol) photochemicals

Propene phenol 2-isopropylphenol (2,6-diisopropylphenol) resins, plasticizers, antioxidants, insecticides,


perfumes

Propene 3-cresol 3-methyl-6-isopropylphenol (thymol) perfumes, disinfectants


2-cresol 2-methyl-6-isopropylphenol (carvacol) disinfectants, perfumes

1-Butene phenol 2-sec-butylphenol (2,6-di-sec-butylphenol) insecticides, herbicides, acaricides, resins


Isobutene phenol 2-tert-butylphenol (2,6-di-tert-butylphenol) antioxidants, insecticides
2,4,6-tri-tert-butylphenol acaricides, perfumes, resins
4-tert-butylphenol alkylphenol resins
Isobutene 4-cresol 2,6-di-tert-butyl-4-methylphenol antioxidant
2-Methylbutene phenol 4-tert-amylphenol resins, antioxidants
Diisobutene phenol 4-tert-octylphenol
resins, detergents, antioxidants, emulsifiers,
Tripropene phenol 4-isododecylphenol surfactants
Tetrapropene phenol 4-isododecylphenol

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].

2.1.5. Alkylation of Aromatic Amines


2.1.6. Alkylation of Heteroaromatic
Because of the basicity of aromatic amines, Compounds and Related Substrates
acidic catalysts are not very suitable for the
alkylation of these substrates. For example, the A variety of heterocyclic aromatic compounds,
reaction of ethylene with aniline in the pres- such as furanes, thiophenes, and N-heterocycles,
ence of the Friedel – Crafts catalyst AlCl3 leads can be alkylated, although little is known
mainly to unidentified resinous products with about commercial application of these re-
small amounts of 2-ethylaniline. However, alu- actions. Cyclopentadienyl derivatives undergo
minum anilide, Al(C6 H5 NH)3 , which is formed Friedel – Crafts alkylation in a similar manner.
in situ with the evolution of hydrogen by heat-
ing aluminum powder in aniline, is an active Furan appears to be much more reactive in
catalyst for this reaction. At 300 – 340 ◦ C and Friedel – Crafts alkylations than benzene. How-
200 bar, 2,6-diethylaniline [579-66-8] is formed ever, resinification of furans in the presence of
after 2 – 3 h, whereas at shorter reaction times acids occurs quite rapidly, which often makes
2-ethylaniline [578-54-1] also is formed [129]. product separation difficult. Using phosphoric
The catalytic activity of aluminum anilide acid on kieselguhr, furan can be alkylated with
is enhanced by addition of Friedel – Crafts cat- isobutene in 3 h at 100 ◦ C to give 85 % yield
alysts, such as AlCl3 , SnCl4 , TiCl4 , SiCl4 , of the alkylates together with small amounts of
BF3 , or ZnCl2 . Mixtures of alkali metals isooctene:
and AlCl3 in aniline are also active sys-
tems, whereas alkali metals alone lead se-
lectively to N-alkylation. The reaction has
been extended to a variety of substituted
anilines, such as 2-, 3-, and 4-toluidine,
2,6-, 2,4-, and 2,5-xylidine, 2-propylaniline, 2-
and 3-chloroaniline, and α-naphthylamine. Di-
amines, such as m-phenylenediamine or 2,4-
toluylenediamine, as well as secondary amines,
such as diphenylamine, also can be alkylated. Whereas substitution in the 2 position is fa-
The reactivity of the olefins de- vored under mild conditions (50 ◦ C, 1 h), the
creases in the order ethylene > propene > 1- formation of products substituted in the 3 po-
butene > isobutene, which is the reverse of sition is enhanced at longer reaction times (7 h),
the order observed in phenol alkylation with higher temperatures (150 ◦ C), and greater cat-
Al(OC6 H5 )3 as the catalyst. However, in the alyst concentrations. The formation of 2,5-di-
case of isobutene, Friedel – Crafts catalysts, such tert-butylfuran [4789-40-6] also was observed
as AlCl3 , BF3 , or montmorillonite, are active [57], [101], [131].
even at 200 – 250 ◦ C, whereas with aluminum
anilide only slow reaction occurs. With mont- Thiophene appears to be substantially more
morillonite, 4-tert-butylaniline [769-92-6] is reactive in Friedel – Crafts reactions than aro-
formed selectively, whereas with BF3 or AlCl3 , matic hydrocarbons and can be alkylated
mixtures of the 2 and 4 isomers are produced with olefins, such as propene, 1-butene, 2-
[129], [130]. methylbutenes, or cyclohexene, and with alco-
The alkylation of anilines with methanol hols, such as isopropyl alcohol and tert-butyl al-
is catalyzed by molecular sieves. A com- cohol. Acidic catalysts, such as phosphoric acid
plex mixture of 2-toluidine, 2,6- and 2,4- at 60 ◦ C or alumina silica at 200 ◦ C, were used
xylidine, and 2,4,6-trimethylaniline is formed. successfully, whereas H2 SO4 , HF, BF3 · OMe2 ,
20 Acylation and Alkylation

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.

2.1.7. Miscellaneous Alkylation Reactions

The alkylation of aromatic compounds with bi-


or polyfunctional reagents leads to a variety of
useful mono-, di-, or polynuclear products of
Propene reacts under similar conditions to commercial interest.
give 1-isopropylcarbazole [1484-09-9], but with
a lower yield [130]. Haloalkylations with bi- or polyfunctional
Alkylations using acidic catalysts also have alkylating agents to yield only primary haloalky-
been reported. For example, the formation of di- lation products can be carried out under suitable
isopropylcarbazole from carbazole and propene reaction conditions. Cycloalkylation or linkage
was observed at 90 – 100 ◦ C in the presence of of two or more nuclei as shown in the second
AlCl3 [134]. The same reaction over an alu- reaction can be avoided.
minum silicate gave tetra- and pentaisopropy-
lcarbazole at 180 – 200 ◦ C [135], and the ethy-
lation of pyrrole was achieved at 200 – 370 ◦ C
over an aluminum silicate [101], [136].

Nonbenzenoid aromatic compounds, such


as ferrocenes, fulvenes, azulenes, pseudoazu-
lenes, indolizines, and cyclazines, resemble
chemically not only the benzenoid systems but
also the olefins. Compared to benzene deriva-
tives, their electrophilic substitution reactions
occur under milder conditions. Because these Typical haloalkylating agents are
systems are often of low stability, both cata- aldehyde – hydrogen halide, haloalkyl ethers,
lysts and reaction conditions have to be selected haloalcohols, and similar compounds [92].
carefully. Halomethylation, haloethylation, higher
Ferrocene [102-54-5] can be alkylated, in the haloalkylation, as well as bis- and polyalky-
presence of Lewis acids, such as AlCl3 , with a lation can be achieved. Zinc chloride is the
Acylation and Alkylation 21

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].

Amidomethylation is possible using the


Tscherniac-Einhorn reaction, where N-
Further reaction proceeds according to the hydroxymethylamides or the corresponding
mechanism outlined in Section 1.3.1 and leads to imides react with an aromatic compound un-
a substituted benzyl alcohol; this, under acidic der mild conditions in sulfuric acid [146].
conditions, reacts with a further molecule of
the aromatic compound to yield a substituted
diarylmethane. This process is exemplified by
the reaction of acetone with phenol, giving 2,2-
bis-(4-hydroxyphenyl)propane (bisphenol A)
(→ Phenol Derivatives):

Less reactive aromatic compounds, such as


benzoic acids, also can be amidoalkylated; even
22 Acylation and Alkylation
Table 8. Alkylation of aromatic compounds by aldehydes and ketones [115]

Alkylating agent Aromatic compound Product End use

H2 CO C6 H5 OH 2 – HO – C6 H4 – CH2 OH salicylaldehyde, salicyl alcohol


H2 CO (C6 H5 O)3 B (2 – HOCH2 – C6 H4 – O)3 B 2-cresol
H2 CO C6 H5 NH2 (4 – H2 N – C6 H4 – )2 CH2 methylenediphenyl diisocyanate, resins, adhesives
H2 CO 2 – Cl – C6 H4 NH2 (3 – Cl – 4 – NH2 – C6 H3 )2 CH2 polyurethanes
CH3 CHO C6 H5 CH3 (4 – CH3 – C6 H4 – )2 CHCH3 heat-exchanger liquid
CCl3 CHO C6 H5 OH (4 – HO – C6 H4 – )2 CHCCl3 polymers
HO2 CCHO C6 H5 OH 4 – HO – C6 H4 – CH(OH) – CO2 H 4-hydroxybenzaldehyde, 4-hydroxyphenylacetic acid

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:

Industrially applied examples of multiple acyla-


tion of aromatics can be taken from [153]. As is
The acylation of aromatic substrates is of con- evident from Table 10, electron-donating sub-
siderable industrial interest for making aromatic stituents facilitate acylation, and the increase of
intermediates used for the production of phar- reactivity by polysubstitution is impressive.
maceuticals, insecticides, plasticizers, dyes, per- Table 10. Relative rate of benzoylation of substituted benzenes [154]
fumes, and other commercial products. These
speciality products usually are produced on a Substrate Relative rate
much smaller scale than alkylation products. Chlorobenzene 0.011
Some examples of industrial interest are given Benzene 1
Toluene 154
in Table 9. m-Xylene 3 910
Acylation is extremely versatile, leading to a Mesitylene 125 000
variety of products that include aromatic alde- Pentamethylbenzene 139 000

hydes, alkyl aryl ketones, symmetric and un-


symmetric diaryl ketones, and cyclization prod- Besides benzene and its derivatives, polynu-
ucts [147–149]. Generally, acylating agents re- clear carbocyclic aromatic compounds, such
act more readily than alkylating agents, and as naphthalene, diphenyl, anthracene, phenan-
therefore acylations can be carried out usually threne, and pyrene, also can act as substrates
under quite mild conditions. Electron-donating in acylation reactions. Electron-rich heterocy-
substituents in the aromatic substrate, such as cles, such as pyrrole, furan, and thiophene, as
alkyl, hydroxyl, or alkoxy groups, lead to en- well as their polycyclic derivatives are espe-
hanced reactivity. cially activated, whereas pyridine and quinoline
On the other hand, aromatic compounds con- do not react unless activated by substituents.
taining electron-withdrawing substituents, such Non-benzenoid aromatic substrates active in
as the nitro, acyl, carboxyl, or nitrile groups, are acylation include azulenes, ferrocenes, and in-
attacked only with great difficulty, even by the dolizines [148].
most active acylating agents. The introduction
Acylation and Alkylation 23
Table 9. Aromatic ketones by Friedel – Crafts acylation [115]

Acylating agent Aromatic compound Product End use

Acetic anhydride benzene acetophenone perfumes, pharmaceuticals, solvent,


plasticizer
Acetic anhydride toluene 4-methylacetophenone perfumes
Acetic anhydride anisole 4-methoxyacetophenone perfumes
Acetic anhydride isobutylbenzene 4-isobutylactophenone pharmaceuticals
Dichloroacetyl chloride 1,2-dichlorobenzene α,α,2,4-tetrachloroacetophenone insecticides
Chlorobutyroyl chloride fluorobenzene chloropropyl 4-fluorophenyl ketone pharmaceuticals
Tetrachloromethane benzene benzophenone pharmaceuticals, insecticides, perfumes
Benzoyl chloride benzene benzophenone
Phosgene N,N-dimethylaniline 4,4 -bis-dimethylaminobenzophenone dyes
Phthalic anhydride benzene 2-benzoylbenzoic acid anthraquinone

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.

Catalysts. Essentially the same catalysts as


discussed for the Friedel – Crafts alkylation can
be used. In most cases, the catalyst of choice
is AlCl3 [7446-70-0] [155], [156]. Impurities in
AlCl3 , such as FeCl3 or traces of water, enhance
yields and the reactivity of systems, which other- At least a twofold amount of catalyst is neces-
wise react only slowly [157–159]. In some cases, sary if carboxylic acids or esters are the acylating
however, the high activity of AlCl3 leads to un- agent, and in the case of anhydrides a threefold
desirable side reactions, for example, the decom- amount (but 1.5 mol per mole of product):
position of reactive heterocycles, such as ben-
zofuran, decomposition of ethers, or rearrange- RCO2 H + 2 AlCl3 −→ RCO-Cl · AlCl3 + AlOCl + HCl
ments of alkyl groups [160]. In these cases, the
RCO2 R + 2 AlCl3 −→ RCO-Cl · AlCl3 + AlOCl + R Cl
activity of AlCl3 can be moderated by complex-
ing solvents such as nitrobenzene, which form
(RCO)2 O + 3 AlCl3 −→ 2 RCO-Cl · AlCl3 + AlOCl
1 : 1 adducts. BF3 and SnCl4 are also suitable
acylating catalysts for sensitive heterocycles. R,R = aryl, alkyl)
If anhydrides, esters, or carboxylic acids are
used as the acylating agents, strong proton acids, A catalyst with industrial importance is hy-
such as sulfuric acid, perchloric acid, orthophos- drogen fluoride [171], [172], sometimes in the
phoric, and polyphosphoric acid also can be ap- combination with boron fluoride [173]. This
plied. Polyphosphoric acid, originally utilized has the advantage of avoiding waste forma-
mainly for intramolecular cyclization reactions, tion due to the possibility to recover the cat-
is also being used increasingly in intermolecular alyst by distillation. This technology is used
acylations. commercially for the acylation of isobutylben-
As already mentioned (Chap. 1), the reaction zene to 4-isobutylacetophenone, an intermediate
of an acyl halide with an aromatic substrate, cat- for ibuprofen, a large volume anti-inflammatory
alyzed by AlCl3 , results in a stable complex of drug.
24 Acylation and Alkylation

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

Essentially the same products are obtained with


the acid anhydrides, such as succinic, glutaric,
or maleic anhydrides, in the presence of 2 mol
of AlCl3 per mole of anhydride [148]. By this
method, 4-aryl-4-oxobutanoic acids can be ob-
tained, which are intermediates in the Haworth
synthesis of polynuclear aromatics [184].
A commercially important synthesis is that
of anthraquinone [84-65-1] from phthalic anhy-
dride and benzene [185] (→ Anthraquinone):
Ketone formation can be avoided if one halogen
of the phosgene is replaced by an amido group
(R=H, alkyl):

The resulting amide can be hydrolyzed to the


acid [181]. This reaction has been considered
for an industrial synthesis of terephthalic acid
[100-21-0] [182]:

Under strongly acidic conditions, 3,3-


diphenylphthalide [596-29-2] also can form.
The synthesis of anthraquinone by this process
is of special importance in the United States.

Isocyanates, isothiocyanates, and CO2 also can


be used as acylating agents in the presence of
AlCl3 to give aromatic carboxylic acids or their
derivatives [92].
If an unsymmetrical bifunctional acylating
agent, such as an acid chloride containing an
ester group, is used, only the more active acyl
With zeolite catalysts, it is also possible to use
group reacts [183]:
nonactivated carboxylic acids. Chiche found
that higher fatty acids react in the liquid phase
with toluene on Y-type zeolites to p-acyltoluenes
with yields up to 96 % [186].
Acylation and Alkylation 27

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]:

Both phenols and phenyl ethers belong to the


most reactive substrates and therefore react un-
der relatively mild conditions. For instance,
Acylation of toluene, for example, us- anisole is acylated conveniently at 40 – 50 ◦ C
ing acetyl chloride and aluminum chlo- in the presence of polyphosphoric acid. Phenyl
ride, leads with 97.6 % selectivity to 4- ethers are acylated almost exclusively in the 4
methylacetophenone [122-00-9], which is used position.
for the production of perfumes [188]. A clean alternative to conventional
Friedel – Craft acylation systems, which avoids
Acylation of Deactivated Substrates. Ben- formation of waste salts and byproducts, uses
zenoid aromatic compounds with nitro, car- mixed anhydrides of trifluoroacetic acid which
boxyl, nitrile, and acyl substituents that hinder are formed in situ by reaction with carboxylic
electrophilic substitution can be acylated only if acids. Low concentrations of H3 PO4 are used as
an activating second substituent, such as a hy- the catalyst and trifluoroacetic acid is recycled
droxy or alkoxy group, is present. Deactivated after dehydration [193].
substrates like chlorobenzene can be acylated to
p-chlorobenzophenones by use of commercial
heterogeneous catalysts like zeolites or sulfated
zirconia as solid superacids [189].

Acylation of activated substrates, such as


phenol, can be carried out using carboxylic Acylation of Aromatic Amines. After N-
acid – ZnCl2 , carboxylic acid – BF3 , or car- acylation, aromatic amines react in a manner
boxylic acid – polyphosphorus acid as catalysts similar to alkylaromatic compounds in acyla-
[190]. Up to 25 % selectivity of ortho sub- tion reactions. Tertiary aromatic amines, such
stitution is observed for the acylation of phe- as N,N-dimethylaniline, can be acylated in the
28 Acylation and Alkylation

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

Acylation of naphthalene usually leads to


mixtures of 1- and 2-acyl derivatives, the ratio
of which depends mainly on the solvent used.
Nonpolar solvents, such as CS2 or CCl4 , favor
acylation in the 1 position; polar solvents, such
Important examples of intermolecular cy- as CH3 NO2 or C6 H5 NO2 , favor the formation
clizations are reactions of phthalic anhydride of 2-acetylnaphthalenes [199].
[85-44-9] with benzene and substituted ben-
zenes to give anthraquinone [84-65-1] and sub- Acylation of substituted naphthalenes of-
stituted anthraquinones respectively (see bot- ten gives complex product mixtures. As a rule,
tom): acylation of the more highly activated ring is
The reaction of phthalic anhydride with more likely to occur. However, it is possible to
toluene or chlorobenzene leads, in a two- control the regioselectivity by the shape selec-
step process, to the 2-substituted anthra- tivity of zeolites. Thus, the acylation of 2-meth-
quinones, whereas the corresponding reaction oxynaphthalene on zeolite HY produces only
with 4-chlorophenol gives 1,4-dihydroxyanthra- 1-acetyl-2-methoxynaphthalene while on beta
quinone [81-64-1] (chinizarine) directly. Oxida- zeolite also 2-acetyl-6-methoxynaphthalene is
tion, nitration, chlorination, or amination leads formed [200].
to products that are important intermediates
Acylation and Alkylation 29

Acylation of Anthracene [120-12-7]. In the


presence of AlCl3 and under mild conditions in
nonpolar solvents (0 ◦ C, benzene), anthracene
1,5-Diacylation is possible only under more is acylated at the most reactive 9 position. Iso-
drastic conditions, as in the synthesis of 1,5-di- merization of the ketone – AlCl3 complex is pre-
benzoylnaphthalene [83-80-7]: vented by precipitation. If polar solvents, such
as nitrobenzene, are used, a mixture, consist-
ing mainly of 1-acylanthracene and some 2-
acylanthracene is formed [204]. Also in this
case, 9-acylanthracene is probably the primary
product, which is then isomerized [148]:

This compound can be fused in sodium alu-


minum chloride to give dibenzopyrenequinone
[128-66-5], a dye commercialized as Indanthren
Goldgelb GK [201].
If naphthalene reacts with diacyl compounds,
the 1,8-diacylated products often form [202]:

Acylation of Phenanthrene. Similarly, acy-


lation of phenanthrene [85-01-8] in nitroben-
zene yields mainly the 2- and 3-acyl isomers,
whereas use of the less polar solvent dichloro-
ethane gives the 9-acyl isomer as the main prod-
uct [147], [204].
Acylation of Biphenyls. If one ring of
a biphenyl is deactivated by an electron-
withdrawing substituent, the other ring can be 2.2.3. Acylation of Heteroaromatic
acylated in the 4 position [203]: Compounds

Because of their high electron density, furan,


thiophene, and pyrrole are highly activated in
30 Acylation and Alkylation

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 high reactivity of furan [110-00-9] allows


the use of benzene as solvent. Zinc chloride,
boron trifluoride, and phosphoric acid also are
suitable catalysts [205]. Acylation also can oc- Acylation of Dibenzofuran [132-64-9],
cur in the 5 position. Dibenzothiophen [132-65-0], etc. Acylation or
diacylation occurs in the 2 or 8 position (3 or 6
Acylation of Thiophene. The reactivity of position in carbazole [86-74-8]) [210], [211]:
thiophene [110-02-1] can be compared with that
of anisole; the compound can be acylated in high
yields utilizing acyl halides in the presence of
SnCl4 or anhydrides in the presence of phospho-
ric acid or ZnCl2 as the acylating agent [206].

Acylation of pyrrole [109-97-7] may occur


even in the absence of catalysts, although ZnCl2 ,
BF3 , and AlCl3 often are used with anhydrides
as acylating agents [207]. Acylation usually oc-
curs in the 2 position but 2,5-diacylation also is
possible. 3-Acylation is observed only if the 2
and 5 positions are blocked.

Acylation of Imidazoles. Highly deacti- Miscellaneous. Substituted 4 H-pyrones


vated heterocycles, which can not be acylated have been acylated in excellent yields using
in homogenous liquid phase like imidazole or trifluoroacetic acid as the catalyst. Even di-
pyrazoles react on Na-Y-zeolites at temperatures acylation is possible [212]:
of more than 500 ◦ C [208]:

A large variety of further heteroaromatic com-


pounds, such as chroman, xanthenes, 1,3-benzo-
Acylation of Benzofurans. With very reac- dioxole, and dibenzodioxins, have been acy-
tive heterocycles acylations can be carried lated; for a review see [147].
Acylation and Alkylation 31

2.2.4. Acylation of Nonbenzenoid Aromatic 2.2.5. Miscellaneous Acylation Reactions


Compounds
Among the various reactions leading to aromatic
Ferrocene [102-54-5] can be acylated read- C-acylation products, the formylation reactions,
ily by acyl halides in the presence of aluminum the Houben – Hoesch synthesis, and the Fries re-
chloride, and its reactivity is comparable to arrangement are of importance.
that of phenols [213]. Besides acyl halides, an-
hydrides may be used as the acylating agent. Formylation of aromatic compounds is sim-
Monoacylation of ferrocene is possible with BF3 ply a special case of acylation and occurs when
as catalyst [214]: a formyl halide or formic anhydride reacts with
an aromatic compound in the presence of a
Friedel – Crafts catalyst, such as AlCl3 . How-
ever, the scope of this reaction is limited because
of the instability of most formylating agents.
Gattermann – Koch Synthesis. A mixture of
hydrogen chloride and carbon monoxide in the
With an excess of acylating agent and of AlCl3 , presence of AlCl3 and copper (I) chloride is used
heteroannular diacetylation occurs almost ex- as formylating agent for aromatic compounds
clusively [215]. [219]:
Other cyclopentadienyl derivatives also can
be acylated and the reactivity of some aromatic
substrates has been found to decrease in the fol-
lowing order [215], [216]:

C6 H5 OH≈(C5 H5 )2 Fe > C6 H5 OCH3 Benzene as well as substituted benzenes or poly-


> CH3 C5 H4 Mn(CO)3
cyclic aromatics react in the Gattermann – Koch
synthesis to give aromatic aldehydes. The para
> C5 H5 Mn(CO)3 > C6 H6
isomers are formed preferentially, and aromatic
compounds with meta-directing substituents do
Azulene [275-51-4] reacts smoothly with not react in this formylation [220].
acetic anhydride in the presence of SnCl4 as A modified Gattermann – Koch synthesis is
catalyst; the cyclopentadienyl part is acylated, being considered by Mitsubishi Gas Chemical
giving 1-acetylazulene. Under more drastic con- for the industrial synthesis of terephthalic acid.
ditions and in the presence of AlCl3 or SnCl4 , Toluene reacts with CO and HF – BF3 to give
1,3-diacetylazulene is formed using acetyl chlo- p-tolualdehyde in 96 % yield, which is then ox-
ride or acetic anhydride as the acylating agent idized to terephthalic acid [221], [222].
[217], [218]. More recent studies suggest that the acylat-
ing agent in these processes is in fact [CHO]+ ,
which is formed by protonation of CO or its com-
plexes. An equimolar CO – HCl mixture as re-
quired for this reaction can be prepared as fol-
lows:

HCOOH + ClSO3 H −→ H2 SO4 + CO + HCl

HCOOH + C6 H5 COCl −→ C6 H5 COOH + CO + HCl

Vilsmeier Aldehyde Synthesis [223]. Aro-


matic and heterocyclic substrates are formylated
by reaction with dialkyl- or arylalkylformamides
in the presence of POCl3 :
32 Acylation and Alkylation

Fries Rearrangement. For the synthesis of


fine chemicals, the Fries rearrangement of aryl
esters, which can be prepared by the acylation of
phenols, is a useful method for making phenolic
ketones:

Besides anthracene, pyrene, acenaphthene,


and other reactive polynuclear aromatic com- The production of pharmaceuticals, such as
pounds, phenol ethers, dialkylamines, and N- adrenalon, synephrin, buphenin, and acebutolol,
heterocycles, such as pyrrole and indole, can be involves Fries rearrangements. Although the re-
formylated. The regioselectivity of formylation action tends to give mixtures of the ortho- and
follows the general rules of Friedel – Crafts re- para-acylated phenol, the selective formation of
actions and leads usually to the 4-substituted each of the isomers is possible by controlling
aromatic compounds. Aromatic substrates also the reaction conditions [227]:
can be formylated by use of dichloromethyl
methyl ether or trialkyl orthoformate in the
presence of TiCl4 or AlCl3 , respectively [224].

Houben – Hoesch Synthesis. This synthe-


sis, which is related to the Gattermann reaction,
uses nitriles to acylate reactive aromatic sub-
strates, such as phenols, phenyl ethers, pyrroles,
thiophenes, and indoles. The reactions are car-
ried out in the presence of HCl and ZnCl2 [225],
[226]:
As a rule, para substitution is favored at low
temperatures and ortho substitution at high tem-
peratures, but regioselectivity also is affected by
solvents and the nature and amount of catalysts.
Numerous substrates that can be substituted
both in the phenol part and the acid part
are reactive in this rearrangement. Even phe-
nol derivatives containing electron-withdrawing
substituents, such as the nitro group, react, as
well as naphthol and hydroxy- or dihydroxy-
phenyl esters [228].
N-Acylanilines also can be rearranged to give
4-acylanilines at elevated temperatures [229]:
The active electrophile is the imminium ion,
formed by addition of HCl to the nitrile and
complexed by the Lewis acid. This bulky inter-
mediate leads almost exclusively to acylation in
the 4 position and not in the 2 position. Com-
pared to the Friedel – Crafts acylation with acyl Similarly, the acid part can be varied and all
halides or anhydrides, the Hoesch synthesis is types of alkyl or aryl acids have been used in-
often more straightforward in the acylation of cluding some diaryl dicarboxyl esters. Sulfonic
activated phenols.
Acylation and Alkylation 33

acid esters also have been rearranged to give


4-hydroxyphenyl sulfones [230].
Usually, AlCl3 is used as the catalyst, but
SnCl4 , TiCl4 , FeCl3 , and ZnCl2 are also ac-
tive and in some cases more convenient. The
rearrangement can be carried out by heating a
mixture of the phenolic esters and the catalyst to
80 – 180 ◦ C. Depending on the reactivity of the
substrate, the reaction is complete within a few
minutes or up to 3 or 4 h. The reaction can be car-
In the presence of very strong acids, such as
ried out also at lower temperatures in a solvent,
HF – TaF5 , alkanes also can be self-alkylated
such as C6 H6 NO2 , (CH2 Cl)2 , CS2 , C6 H5 Cl,
[235]. The reaction between a paraffin and an
or petroleum ether. Fairly long reaction times
olefin [64] to produce a higher paraffin is ther-
must be used in this case. Another possibility
modynamically possible at low temperatures
is to start the rearrangement in CS2 , which is
and is exothermic. However, rate and selectiv-
then separated by distillation, and to complete
ity are low, and side reactions occur. Good re-
the reaction at higher temperatures [231].
sults are obtained if highly branched paraffins
The ortho isomer often can be separated
are introduced. The best known example is the
from the product mixtures by steam distillation.
alkylation of isobutane with olefins using acids
Volatile products can be fractionally distilled.
as the catalyst. This reaction is used on a huge
The para isomer can be separated from non-
scale by the petroleum industry to make highly
volatile product mixtures by crystallization. A
branched paraffinic hydrocarbons, which are ex-
more detailed literature survey can be taken from
cellent antiknock components for motor fuels
[228, 232, 233].
(→ Automotive Fuels, Chap. 4.1.; → Oil Refin-
ing, Chap. 3.7.1.). The industrial processes in
operation today use large quantities of liquid
3. Acylation and Alkylation of Brønstedt acids (HF, sulfuric acid). The han-
Aliphatic Hydrocarbons dling of large quantities of these acids has cre-
ated environmental and safety concerns. As an
Aliphatic hydrocarbons can be both alkylated alternative, a fixed-bed alkylation process with a
and acylated, although industrially, alkylation is supported liquid phase (SLP) catalyst has been
by far the more important reaction. Because of developed to the pilot plant stage [236], [237].
their nucleophilicity, reactions must be base or
acid catalyzed. Base catalysis involves the for- Alkylation and Acylation of Olefins. For-
mation of an organometallic derivative, whereas mally, all oligomerizations and polymerizations
acidic catalysts lead to carbenium ions as active of olefins can be considered as alkylation. Ta-
intermediates. ble 11 summarizes a few of these reactions.
There are some similarities in reaction mecha-
Acylation and Alkylation of Paraffins. Not nism between Ziegler – Natta-type catalysts and
very much work has been done on acylation acylation – alkylation catalysts.
and alkylation of pure paraffins; such reactions Acylation of olefins may be considered a
are known but never have gained much interest Friedel – Crafts reaction. The reaction usually
in industry for synthetic purposes [234]. How- occurs with derivatives of carboxylic acids
ever, the alkylation of toluene with propene to in the presence of an acid catalyst. The
yield isobutylbenzene is carried out commer- Lewis acids, whose activities follow the or-
cially at a multithousand t/a scale. Isobutylben- der AlCl3 > BF3 > SnCl4 > ZnCl2 , require an-
zene [538-93-2] is an intermediate for ibuprofen, hydrous conditions and temperatures ranging
a widely used anti-inflammatory agent: from 0 to 100 ◦ C. At elevated temperatures in-
terfering side reactions can occur.
34 Acylation and Alkylation
Table 11. Alkylation of olefins

Olefin Catalyst Product

α-Olefin (ethylene, propylene) Ziegler-Natta (AlR3 – TiX4 ) polymers


Ethylene Ni chelate α-olefins
1-Decene BF3 lubricants
NiX2 – AlXn Rm dimers (motor fuel, plasticizer, detergents)
Isobutene H+ dimers (motor fuel, solvents)
Propene AlR3 dimers, oligomers (isoprene, detergents)
Ethylene – butadiene Rh complexes 1,4-hexadiene

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.

4. N-Alkylation and N-Acylation 4.1.1. N-Alkylation by Alcohols or Ethers


An alkyl or acyl group can be attached to the ni- Alkylations of amines with alcohols or ethers
trogen atom of an amine in many ways. The par- are of commercial interest. These alkylations are
ticular method chosen depends on the nature of carried out at temperatures up to 300 ◦ C and
the alkyl or acyl group and the amine used. The pressures up to 100 bar. Generally, acidic cat-
products obtained are used mainly as intermedi- alysts, such as HCl, H2 SO4 , BF3 , PCl3 , and
ates in the production of detergents, dyes, plasti- H3 PO4 , are used in the liquid phase. In the gas
Acylation and Alkylation 35

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)

Alkyl derivatives can be obtained by the reaction


4.1.2. N-Alkylation by Alkyl Halides of either ammonia or an amine with a carbonyl
compound, such as an aldehyde or a ketone, in
The reaction of an alkyl halide with ammonia the presence of a suitable hydrogenation catalyst
or an amine has long been used, particularly and hydrogen [239].
in the laboratory, to prepare alkylamines, al-
RCHO + R NH2 + H2 −→ RCH2 NHR + H2 O
though industrial processes also are based on
this route. For example, pentylamines are made Reductive alkylation is used commercially, for
by mixing a solution of ammonia in alcohol with instance, to introduce branched alkyl groups (R ,
pentyl chlorides. By a similar reaction, ethylene- R ).
36 Acylation and Alkylation

Besides amines, many other compounds con-


taining NH groups can be acylated. At high
enough temperatures, even diacylation (for ex-
ample, with primary amines) is possible. How-
Antioxidants, such as N,N’-di-sec-butyl-p- ever, secondary amines react much more slowly
phenylenediamine [101-96-2], are synthesized than primary ones.
by this route [240]: Acylation at the nitrogen atom often pro-
ceeds satisfactorily without a catalyst. This is
especially the case for highly nucleophilic NH
derivatives with electron-releasing substituents.
Common catalytic procedures, if used, involve
alkoxides (with esters as alkylating agents), sul-
furic or phosphoric acid (with anhydrides or car-
boxylic acids), and aqueous alkali (with aroyl
halides, Schotten – Baumann reaction).
A further example of importance to the dye in- Acylation is frequently used in the labora-
dustry is the synthesis of anilinoethanenitrile tory to separate tertiary from primary and sec-
(5), which is an intermediate in the production ondary amines (Hinsberg reaction). After acyla-
of indoxyl (6) [480-93-3]: tion of primary and secondary amines, the ter-
tiary amines, which cannot be acylated, can be
distilled.

Acylating Agents. The use of carboxylic


acids requires the removal of water from the
reaction mixture. This can be done by distil-
lation in the presence of xylene, toluene, or
chlorobenzenes. Sometimes catalysts, such as
PCl3 , P2 O5 , or phosphites, are used.
Acyl halides often are preferred as acylating
agents because they are easily prepared. An inert
solvent often is used to precipitate the products.
4.2. N-Acylation After filtration, the amine salt can be removed
from the solid by washing with water. It is note-
The acylation of NH groups occurs quite read- worthy that in this method half the amine is lost
ily. The most common acylating agents are acyl via salt formation. The HCl can be removed by
halides, esters, anhydrides, and carboxylic acids. Na2 CO3 , alkali (Schotten – Baumann reaction),
or by adding other N bases. Among anhydrides,
acetic anhydride plays an important role, but for
economic reasons, industry prefers to use acids.
Esters also have found wide application. They
are especially suitable if the alcohols formed
boil at lower temperatures than the N derivatives,
thus removing the alcohol from the equilibrium.
Other acylating agents in use include alde-
hydes, ketones, ketenes, thiol esters, silicon
tetraesters, carbamates, trihaloketones and alde-
hydes, acyl azides, amides, imides, and hy-
drazides.

N-Acylated products and intermediates


have found many applications, especially in
pharmaceuticals, agrochemicals, dyes, and
Acylation and Alkylation 37

polymers. N-Acetylsalicylamide [487-48-9] o/p-anisidine, N-acetyl-p-phenetidine, and N-


(7) and p-ethoxyacetanilide (phenacetine) acetyl-p-aminophenol are prepared as interme-
[62-44-2] (8) are two representative examples diates. The acetyl group can be removed by heat-
of pharmaceuticals synthesized by N-acylation ing in NaOH. The following reaction is used in
[241]. the pharmaceutical industry to synthesize sul-
fonamides [241]:

Amides of carboxylic acids with such generic


names as propanil, monalide, chloranocryl, and Protection of amine functions is also impor-
allidochlor are used as herbicides [242]. Their tant in peptide syntheses.
synthesis is based on acylation of amines. N-
Acylcarbamates, which can be synthesized by
NH-acylation, are used as insecticides. 5. O-Alkylation and O-Acylation
Two examples of dye precursors are N-
(2-carboxyphenyl)glycine (9) and so-called The following types of reactions can be consid-
“arylide” compounds (10): ered:

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:

5.2. Synthesis of Anhydrides


The acetylation of a carboxylic acid by RCOX
yields an anhydride. By this route, unsymmet-
rical anhydrides can be prepared. Besides acyl
halides, amides, esters, and acids, ketenes also
Cellulose Acetate. An ester process of great
can be used. The ketene reaction is of importance
industrial importance is the synthesis of cel-
for the commercial synthesis of acetic anhydride
lulose acetate for synthetic fibers. Cellulose is
and a convenient laboratory route to acetic car-
added to equal amounts of acetic anhydride and
boxylic anhydrides:
glacial acetic acid, together with a small amount
of sulfuric acid as catalyst. The acylation tem- RCOOH + CH2 =C=O −→ RCOOCOCH3
Acylation and Alkylation 39

5.3. Synthesis of Ethers special polymers, coatings, and adhesives. Of


industrial interest are methyl, ethyl, isopropyl,
Ethers can be formed by the alkylation of a butyl, isobutyl, and 2-ethylhexyl vinyl ethers
metal salt of an alcohol with an alkyl halide (→ Vinyl Ethers).
(Williamson synthesis). The reaction proceeds
cleanly with active primary halides and of-
ten also with secondary halides. Tertiary alkyl 6. CH-Alkylation and CH-Acylation
halides are subject to an elimination reaction
of Nonaromatic Compounds
and are therefore unsuitable for the preparation
of tertiary alkyl ethers. The alkyl chlorides are Carbon-hydrogen bonds adjacent to electron-
less reactive than the bromides or iodides, but attracting groups such as nitro, carbonyl, cyano,
for economic reasons the chlorides are favored sulfone, or phenyl can be C-alkylated or C-
for large-scale operations. acylated [244–246]. The acidity of the C-H bond
Ethers are produced in industry by the reac- depends on the nature of the activating group.
tion of an olefin with an alcohol. This reaction Procedures that involve the formation and subse-
is catalyzed by such acid catalysts as H2 SO4 , quent reaction of anions derived from active CH
ion-exchange resins, phosphoric acids, or zeo- compounds constitute a very important and syn-
lites. The reactivity of the olefin decreases with thetically useful class of organic reactions. Ex-
increasing molecular weight: Isobutene reacts amples are the Dieckmann reaction, the Stobbe
more readily than 2-methyl-2-butene. Best re- condensation, the Michael addition, the Claisen
sults are obtained with olefins containing ter- condensation, and the Thorpe reaction.
tiary carbon atoms because secondary olefins re- CH-Alkylation and -acylations have been
quire higher temperatures and catalyst concen- used widely in the laboratory and for the syn-
trations. Primary alcohols are more suitable than thesis of many fine chemicals. Generally, a car-
secondary alcohols for this reaction. banion is formed by hydrogen atom exchange
with a base followed by reaction with the alky-
Methyl tert-butyl ether [1634-04-4] lation or acylation agent. Bases used are, e.g.,
(MTBE), an ether of significant commercial sodium alkoxide and sodium amides.
interest, is used as an additive in gasoline. It
is produced by the reaction of isobutene with
methanol, applying an acidic catalyst, such as
an anion-exchange resin. Several processes have
been developed by Chemische Werke Hüls (now
Degussa-Hüls), SNAM Progetti, Atlantic Rich-
field Co. (Arco), and Sun Oil Co. World ca-
pacity is estimated at 12 × 106 t/a for 1992 and
16 × 106 t/a for 2000. The C4 fraction of naph-
tha crackers, which is free from butadiene (raf- 7. Synthesis of Metal Alkyls
finate I), can be used directly as olefin feed.
A liquid-phase system operating at <100 ◦ C is The direct alkylation of elements by alkyl
used (→ Methyl tert-Butyl Ether). halides is frequently the first stage in the synthe-
sis of a variety of organometallic compounds.
Vinyl Ethers. The industrial processes for Especially the main-group metals yield stable
vinyl ether are based on the reaction of alcohols derivatives that have found many industrial ap-
with acetylene: plications.
ROH + HC≡CH −→ ROCH=CH2 In 1900, Grignard discovered that the
reaction of magnesium with alkyl halides
leads to alkyl – magnesium – halogen com-
The reaction is carried out in the liquid phase pounds, RMgX. Today, Grignard compounds
at 120 – 180 ◦ C with alkali hydroxides as cat- are standard laboratory chemicals.
alysts. Low-boiling alcohols require the use of
pressures up to 20 bar. Vinyl ethers are used for RX + Mg −→ RMgX
40 Acylation and Alkylation

Organolithium compounds can be prepared by The most important derivative is Al(C2 H5 )3


the direct reaction of alkyl halides with lithium. [97-93-8], the synthesis of which is based on
Large quantities of butyllithium, which is used the reaction of Al(C2 H5 )3 with aluminum, hy-
primarily as an initiator in the polymerization of drogen, and ethylene. Aluminum alkyls are used
dienes, is produced by this method. for the preparation of Ziegler – Natta-type cata-
The scope of organometallic compounds for lysts, in the polymerization of olefins, and in the
CH-alkylations is broad and has found many ap- alfen and alfol processes for the production of
plications, especially in the laboratory. Exam- α-olefins and alcohols, respectively.
ples are the following well-known reactions: Aluminum alkyls also are used industrially
to synthesize other organometallic compounds,
for instance R4 Sn:

3 SnCl4 + 4 R3 Al −→ 3 R4 Sn + 4 AlCl3

Organic Silicon Compounds. The direct


reaction of silicon with alkyl or aryl halides
(Rochow reaction) is used for the industrial
synthesis of organosilicons:
Organometallic compounds also can be prepared
2 RX + Si −→ R2 SiX2
by reacting metal hydrides with olefins.
The process takes place at high tempera-
AlH3 + 3 H2 C=CH2 −→ AlEt3 ture in the presence of a catalyst, such as
Cu, Ag, or Zn. Of the silicon derivatives pro-
Numerous alkylations by transition metals have
duced, (CH3 )2 SiCl2 [75-78-5] dominates the
become known since the 1960s [40] and are
market. It is made by the reaction of silicon with
gradually becoming accepted in chemical indus-
CH3 Cl at 260 – 320 ◦ C, catalyzed by copper. Be-
try, especially for the synthesis of fine chemicals.
sides (CH3 )2 SiCl2 (70 – 90 % of the products),
Examples of elemental acylation are rather
all other possible (CH3 )x SiCly compounds are
rare and are of no practical importance as yet.
formed in this reaction. The heterogeneous gas-
However, some interest, especially among fine
solid reaction can be carried out in a fixed-bed
chemicals, is developing around the use of R–
or fluidized-bed reactor. For further details, see
CO–M compounds to control regio- and stere-
[249] and → Silicon Compounds, Organic.
oselectivity in acylations [247].
Two other silicon derivatives, (C6 H5 )2 SiCl2
and C6 H5 SiCl3 , have some economic impor-
Aluminum Alkyls [248]. Alkylaluminum tance. Besides the direct synthesis, the addition
derivatives have gained considerable importance of Si-H to olefins is used to make silicon deriva-
since 1953 when Ziegler reported their cat- tives.
alytic activity for polymerization and means
of their preparation. Their consumption in the
Lead Alkyls. Tetraethyllead [78-00-2] and
USA, Western Europe and Japan was estimated
tetramethyllead [75-74-1] are added to motor
at 30 000 t in 1996.
fuels to improve the octane number. However,
The method of preparation depends on the
for environmental reasons their use is now lim-
particular alkyl derivative but generally involves
ited or banned. In 1977, world production was
one of the following alkylation reactions:
ca. 700 000 t, ca. 500 000 t in 1980, and 60 000 t
in 1998 (USA, Western Europe and Japan). The
Al2 Mg3 + 6 RCl −→ 2 AlR3 + 3 MgCl2
sole use is in aviation turbine fuels.
Tetraethyllead is made by the reaction of
AlH3 + 3 olefins −→ Al(alkyl)3
lead – sodium alloy with ethyl chloride.
2 Al + 3 RX −→ RAlX2 + R2 AlX 4 NaPb + 4 C2 H5 Cl −→ Pb(C2 H5 )4 + 3 Pb + 4 NaCl
Acylation and Alkylation 41

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