Rodrigo
Amandi
a,
Jason R.
Hyde
a,
Stephen K.
Ross
b,
Tobias J.
Lotz
c and
Martyn
Poliakoff
*a
aSchool of Chemistry, University of Nottingham, University Park, Nottingham, UK NG7 2RD. E-mail: Martyn.poliakoff@Nottingham.ac.uk
bThomas Swan & Co. Ltd., Crookhall, Consett, Co. Durham, UK DH8 7ND
cSchenectady Pratteln GmbH, Kästelliweg 7, Postfach CH-4133 Pratteln 1, Switzerland
First published on 11th April 2005
Continuous fixed-bed catalytic Friedel–Crafts alkylation of m-cresol with different alkylating agents, isopropanol (IPA) and propylene, has been carried out using supercritical CO2, scCO2, as an alternative and more environmentally friendly reaction medium, for the synthesis of the fine chemical thymol. Both a solid Lewis acid catalyst (γ-Al2O3) and a solid Brønsted acid catalyst (Nafion® SAC-13) have been investigated over a range of reaction conditions to optimise yield and selectivity for thymol. The reaction product distribution was found to be related to the type of catalyst employed. This is likely to have been due to the different reaction pathways through which the reaction occurred, a direct Friedel–Crafts alkylation in the case of Brønsted type acids and a Fries rearrangement when employing the Lewis catalyst. The new technique of 2DCOR-GC analysis was employed to establish the order of formation of the different species generated in the reaction over the two catalysts in scCO2.
![]() | Rodrigo Amandi studied chemistry in San-Pablo CEU University in Madrid, Spain, where he obtained his degree in 1999. Later on in the year he joined the research group of Dr Flaviano Garcia-Alvarado where he investigated the synthesis and characterisation of new cathodic materials for rechargeable lithium batteries. In September 2000, he started his PhD in the Clean Technology Group, at the University of Nottingham, UK, under the supervision of Prof. Martyn Poliakoff. His research was developed in collaboration with the fine chemical manufacturer Thomas Swan & Co. and was focused on the application of supercritical fluids as replacement solvents for the synthesis of fine chemicals. After completion of his PhD, in late 2003, he started a post-doc within the Clean Technology Group funded by the chemical manufacturer Schenectady Pratteln. He is currently employed as a post-doc, in the Institute of Process Engineering at the ETH in Zurich, Switzerland, under the supervision of Prof. Philipp Rudolf von Rohr. |
When combined with solid acid catalysts, scCO2 forms the basis of a very efficient process. Friedel–Crafts alkylation of aromatics has been successfully conducted in scCO2 in batch reactors by a number of groups.8,9 Batch reactions in scCO2 are economically difficult to scale-up because of the cost of large high pressure vessels. However, the use of continuous processes reduces the size of the reactor required to generate a given amount of product and increases safety. This type of process10 has been demonstrated with the opening of the world's first industrial-scale, multi-purpose supercritical flow reactor in July 2002. Continuous fixed-bed catalytic flow reactors have been used in a wide range of supercritical reactions including hydrogenation,11 hydroformylation,12 etherification13 and indeed Friedel–Crafts type alkylation of simple aromatics.14
In this work, we describe the successful application of continuous Friedel–Crafts alkylation in the synthesis of the fine chemical thymol (6-isopropyl-3-methyl-phenol) 1. Thymol possesses some important physiological properties, and it is also widely used in perfumery as an important intermediate in the manufacture of menthol, the major component of fragrances with a peppermint odour.15 Industrially, thymol is obtained by the liquid phase isopropylation of m-cresol 2 with propene using activated alumina as catalyst.16 Wimmer et al.17 have described a process for the synthesis of thymol by reacting m-cresol with propene, but using wide and medium pore size (pore diameter of 5–7 Å) zeolites.
![]() | ||
Scheme 1 Products formed in the alkylation of 2 over solid acid catalysts in scCO2. |
In the last few years, other types of solid acid catalysts have been employed in the synthesis of thymol, including calcined Mg–Al hydrotalcites,18 zinc aluminate spinel (ZnAl2O4)15 and mesoporous Al-MCM-41 molecular sieves of different Al∶
Si ratios.19
The most important reaction parameter to be controlled in the synthesis of thymol is selectivity towards the product of interest. This is because the boiling points of all the possible isomers generated during the reaction, 2-isopropyl-3-methyl-phenol3, 4-isopropyl-3-methyl-phenol4 and 5-isopropyl-3-methyl-phenol5 are very similar, making the distillation step needed to separate all the components very difficult indeed; in particular, separation of thymol from 3. For this reason, generation of unwanted isomers is an issue that must be minimised by careful control of the reaction parameters. Also, an excess of the aromatic species is generally used to decrease the amount of dialkylated and polyalkylated derivatives formed during the reaction.
Catalyst | % Yieldd | % Select.e1 | |||||
---|---|---|---|---|---|---|---|
1 | 3 | 4 | 5 | 6 | Dialkyl. | ||
a 200 bar, 3![]() ![]() ![]() ![]() |
|||||||
Nafion® SAC-13b | 52.0 | 2.5 | 21.3 | 4.4 | 0 | 6.6 | 61.2 |
γ-Al2O3c | 54.0 | 9.7 | 1.0 | 0.4 | 0.8 | 2.0 | 78.6 |
It is clear from Table 1 that the major by-product formed during the reaction, when employing Nafion® SAC-13 is 4. Further changes in the reaction pressure (100–400 bar), molar ratio of reactants from 3∶
1 to 10
∶
1 (2
∶
IPA) and concentration of organic material in scCO2
(10–50%w/w) did not have a significant influence on the reaction outcome in terms of yield and selectivity of products. In contrast, when using γ-Al2O3 as a solid acid catalyst, the major by-product observed was 3. Also, a small amount of isopropyl-3-methyl-benzylether 6 was observed when using γ-Al2O3. Increasing the reaction temperature above 275 °C, caused a decrease in the yield and selectivity towards thymol as well as an increase in the yield of 4 and 5. There was a substantial increase in the by-products 3 and 6 when the concentration of organic substrate within scCO2
(see Table 2) was increased with a corresponding decrease in the thymol yield.
The amount of organic substrate pumped into the supercritical flow system per unit of time, is related to the residence time of reactants across the catalyst bed. As seen from Table 2, the amounts of 3 and 6 generated during the reaction decreased with increasing residence time, but also during this same increase in residence time, an increase in the yield of 1 and 4 were observed. This behaviour suggests that 6 is the first species formed in the reaction, and that 1, 3 and 4 are formed through a Fries rearrangement process in which 3 (kinetic product) is formed before 1 and 4 (thermodynamic products) according to Scheme 2. The yield of 5 also increased, albeit moderately, with increasing residence time. Formation of 5 is believed to occur via an isomerisation process from the more stable species generated in the reaction (1, 3 and 4).20
![]() | ||
Scheme 2 The proposed mechanism for the alkylation of 2 with IPA using γ-Al2O3 as the catalyst in scCO2. |
The alkylation of anisole (methyl-phenylether) using IPA and n-propanol as the alkylating agents over γ-Al2O3, was also attempted. No alkylated derivatives whatsoever were observed across the range of temperature from 100 °C to 250 °C, at 200 bar, 3∶
1 molar ratio of reactants (aromatic
:
alkylating agent) and a concentration of organic substrate in scCO2 of 10%w/w. The only products detected, were phenol, o-cresol, m-cresol and p-cresol. Formation of these cresols would come from the Fries rearrangement of the starting material, anisole, under the reaction conditions investigated. The fact that a non-hydroxy aromatic cannot be alkylated by IPA using γ-Al2O3 as catalyst, is consistent with the Fries rearrangement pathway postulated.
2DCOR-GC analysis was carried out in order to investigate further the proposed mechanism for the formation of thymol. 2DCOR-GC is a new technique developed at Nottingham,21 which is particularly applicable to unselective reactions monitored by GC. The technique has previously been described in detail.21 Briefly, 2DCOR-GC uses a set of chromatograms from a system which has been perturbed, for example by changing residence time in a reactor, and uses these chromatograms to generate a 2D map which is rich in information. One of the advantages of 2DCOR-GC is an increase in resolution obtained by stretching chromatograms in a second dimension, which is demonstrated21 by the resolution between the two isomers of thymol, 1 and 3, on this particular chromatographic column. In our experiments the reaction residence time was used as the perturbation in order to distinguish in which order the reaction products are produced. Only the synchronous relationships are shown in Fig. 1, because these are sufficient to show that the mechanisms of the two catalysts are clearly very different. One advantage of 2DCOR-GC is that, even at this level of analysis, it is possible to see significant differences between a series of apparently similar chromatograms. Fig. 1a shows the synchronous map produced by the reaction performed with Nafion® SAC-13. A detailed analysis of this correlation map can be found elsewhere.21 However, it is clear that many products are produced from this reaction. The correlations and their strengths indicate that the reaction is most likely a direct alkylation. A more detailed analysis shows that 6 is formed first, with 3 being produced more rapidly than 1 and 4. 5 is produced at the slowest rate. By comparison Fig. 1b is the synchronous correlation map obtained from the reaction performed over γ-Al2O3 catalyst. It can be seen that this is a cleaner reaction producing fewer products and intermediates. The relationships between 3 and 1 and 4 indicate that all three products most probably originate from 6; this is consistent with the postulated Fries rearrangement. Again, 3 is produced more rapidly than 1 but in smaller quantities. Since the reaction residence time is the same during the perturbation for both experiments, the lack of 5 production over the γ-Al2O3 catalyst indicates that this reaction is not a direct alkylation, and that transalkylation reactions do not occur within the residence time in the reactor. The 2DCOR-GC analysis presented here supports the proposed routes for production of 1 over the two catalysts.
![]() | ||
Fig. 1 2DCOR-GC synchronous map produced from the chromatograms recorded using the residence-time perturbed reaction of 2 with IPA over (a) Nafion® SAC-13 catalyst and (b) γ-Al2O3 catalyst. 2DCOR-GC can produce two types of correlation maps, synchronous and asynchronous. Only the synchronous maps are shown here. If the mechanisms were related, then, under the same perturbation and level of contouring, the maps would appear identical. Clearly, the maps are different so the mechanisms cannot be identical. The maps are symmetrical about the diagonal axis. Signals along this diagonal, referred to as ‘autopeaks’, reflect the change in a particular GC signal during the course of the perturbation; a strong autopeak reflects a strong change in signal. The autopeaks are labelled 1, 2, etc according to Scheme 1 (note that the autopeaks of 1 and 3 almost overlap). Off-diagonal peaks indicate correlations between two signals centred about ν1 and ν2 positions. Thus, the point X indicates that the correlation between 2 and 6 is weaker in (a) than in (b), because the contour plot for X is larger in (b). In addition there are more peaks to the right of X along the bottom of (a) than in equivalent positions in (b). This indicates that 2 is correlated to more products in (a) than in (b), precisely reflecting the greater selectivity of the Lewis acid catalyst in (b). It can be seen that in both cases, 1, 4 and 3 are synchronously related, but only in (a) is there an autopeak for 5. In both (a) and (b) it can be seen that 1 and 3 are formed, and can be correlated to 6, as indicated by the direction of the cross-correlation peaks; this indicates that both species have a common relationship. Both the synchronous and asynchronous maps are available in colour as ESI‡ and a full analysis of the correlation map (a) is given in ref. 18. |
Further studies focused on increasing the yield and selectivity for 1 using γ-Al2O3 as heterogeneous catalyst. To maximise the yield and selectivity for 1, the residence time across the catalyst bed had to be maximised by increasing the volume of the reactor tube used in the experiments, by increasing its length, as well as by decreasing the bulk flow of CO2 through the system. Alternatively, a further increase in pressure would have increased the residence time, but as stated before, pressure did not have a major impact on the reaction outcome. Table 3 and Table 4 show the effects of increasing the reactor volume to double its original value and of decreasing the bulk flow of scCO2 respectively.
Reactor volume/mL | % Yield | % Select. 1 | |||||
---|---|---|---|---|---|---|---|
1 | 3 | 4 | 5 | 6 | Dialkyl. | ||
a 200 bar, 275 °C, 5%w/w of organic in scCO2 and 1![]() ![]() ![]() ![]() |
|||||||
10 | 55.0 | 1.5 | 1.1 | 0.3 | 0.3 | 2.9 | 90.5 |
20 | 69.5 | 1.2 | 1.0 | 0.3 | 0.3 | 4.2 | 91.0 |
Bulk flow/L min−1 | % Yield | % Select. 1 | |||||
---|---|---|---|---|---|---|---|
1 | 3 | 4 | 5 | 6 | Dialkyl. | ||
a 200 bar, 275 °C, 10%w/w of organic in scCO2 and 1![]() ![]() ![]() ![]() |
|||||||
0.65 | 48.5 | 5.8 | 0.7 | 0.2 | 0.5 | 3.5 | 82.3 |
0.32 | 46.5 | 6.5 | 0.7 | 0.2 | 0.5 | 3.7 | 80.6 |
As expected, by increasing the reactor volume to 20 mL, the yield and selectivity for 1 was increased while decreasing the amount of 3 generated. In contrast, when the flow of CO2 through the system was decreased to half the initial rate, the reaction outcome was almost unaffected. This was unexpected, because, as explained before, a decrease in the bulk flow of CO2 should have increased the yield of 1. Phase measurements (Fig. 2) were carried out to determine if a phase transition was occurring upon decreasing the amount of organic within scCO2.
![]() | ||
Fig. 2
p
vs.
T phase diagram for the alkylation of 2 with IPA at 1![]() ![]() ![]() ![]() |
Under the conditions studied (200 bar, 275 °C), the reaction proceeded in a single phase for both of the concentrations of organic substrate investigated. Thus, a phase transition cannot explain why the reaction outcome did not vary when the bulk flow of CO2 was decreased. Nevertheless, a possible explanation could be that the water generated when the reaction was conducted at 5%w/w is sufficiently removed by the scCO2 from the catalyst surface. In contrast, at 10%w/w, the water generated in the reaction is too much, and consequently the water removal from the catalyst surface is not sufficient, therefore decreasing the catalyst activity to some extent. To investigate the effect of water on the catalyst performance, water was deliberately added to the mixture of reactants in a 1∶
0.8
∶
0.8 molar ratio (2
∶
IPA
∶
H2O). The results are shown in Table 5.
Table 5 clearly shows that water has an effect on the performance of the catalyst by decreasing the yield and selectivity for 1. The water generated in the reaction, in addition to the water added to the reactants, was not sufficiently removed by the scCO2, hence a deactivation of the catalyst occurred.
Maximum yield in conjunction with very high selectivity for 1 was achieved at 275 °C. The amount of 3 generated decreased upon increasing the reaction temperature. The yield of 3 at 275 °C, was rather low compared to the amount generated using IPA as the alkylating agent as it was shown in Table 4. In contrast, the yield of polyalkylated species increased by a large amount and the yield of 4 was also significantly higher.
Further investigations focused on whether an increase in the concentration of organic substrate, 2 and propylene, within scCO2, had the same effect on the catalyst performance as when employing IPA as the alkylating agent (Table 7). However, yield and selectivity for thymol were maintained to similar values even upon increasing the concentration of organic substrate within scCO2 to 40%w/w. This was thought to be related to the higher reactivity of olefins compared to alcohols. Also, the “dry” reaction conditions when employing propylene as the alkylating agent in scCO2, clearly increased the catalytic performance of γ-Al2O3, therefore maximising the reaction throughput.
It appears that scCO2 can effectively remove the small quantities of water that are formed in the reaction. However, increasing the amount of organic substrate pumped into the system led to a decrease in catalyst performance as a result of the larger amount of water generated. Employing propylene as the alkylating agent eliminates the water formed as a by-product, and therefore increases the catalytic performance of γ-Al2O3 significantly.
Ideally, the alkylation reaction could be performed using IPA as alkylating agent instead of propene, which is used in current industrial processes, thus, eliminating the handling hazards associated with the use of propene. A final question relates to the precise role of the CO2 in this reaction. We have performed the reaction of IPA +
2 over the γ-Al2O3 catalyst in the absence of CO2
(1∶
0.8 ratio of 2
∶
IPA, 0.12 mL min−1 flow rate, reactor volume was 10 mL, 200 bar, 272–276 °C). Surprisingly, the overall selectivity (48.2%) for 1 was almost identical to that observed with CO2
(48.5%). Crucially however, the yield of the two isomers 3 and 4 were doubled. This is of great importance because of the problems of separating 3 and 4 from 2. Thus, the effect of CO2 appears to be significant in suppressing the formation of these minor products but the precise mechanism remains unclear.
Continuous flow scCO2 systems have shown a real advantage for the alkylation of aromatic compounds, to produce species of great industrial interest, such as thymol. Further experiments, including catalyst lifetime, need to be carried out to complete full implementation of this process in the chemical industry.
![]() | ||
Fig. 3 Schematic of the supercritical fluid continuous flow apparatus employed in this research, where D represents the SCF pump and B the static mixer where the organic substrate (A) and the CO2 mix before entering the reactor C. |
Two solid acid catalysts were employed in our experiments, Nafion® SAC-13 and γ-Al2O3. Nafion® SAC-13 (supplied by Aldrich) is a highly porous silica network wherein nanometre sized Nafion® resin particles are entrapped. The composite catalyst SAC-13 contained 13 wt% nanosized Nafion® particles in the porous silica matrix. The surface area of this catalyst is 200 m2 g−1 and its exchange capacity23 is 0.15 mequiv. g−1. γ-Al2O3 had a surface area ranging from 140 to 160 m2 g−1. Its composition was as follows: Al2O3: 95%w/w, SiO2: 0.035%w/w, Fe2O3: 0.025%w/w and Na2O: 0.008%w/w.
Footnotes |
† This work was presented in part at the Green Solvents for Synthesis Meeting, held in Bruchsal, Germany, 3–6 October, 2004. |
‡ Electronic supplementary information (ESI) available: Synchronous and asynchronous correlation maps for the 2DCOR-GC data presented in Fig. 1. See http://www.rsc.org/suppdata/gc/b4/b418983c/ |
This journal is © The Royal Society of Chemistry 2005 |