Immobilization of catalyst in a wall-coated micro-structured reactor for gas/liquid oxidation of p-cymene
- Authors: Makgwane, Peter Ramashadi
- Date: 2009
- Subjects: Oxidation , Cymene
- Language: English
- Type: Thesis , Doctoral , DPhil
- Identifier: vital:10389 , http://hdl.handle.net/10948/1182 , Oxidation , Cymene
- Description: The selective, liquid phase oxidation of p-cymene is an important synthetic route for the production of p-cresol via the tertiary cymene hydroperoxide (TCHP). The industrial-scale oxidation process is characterised by slow oxidation rates due to limitations in the mass transfer of oxidant (gaseous oxygen) into the liquid phase. However, like all other autoxidation reactions, the oxidation reaction is exothermic, following the typical free radical autoxidation reaction mechanism, which implies that careful temperature control is critical in order to prevent the further reaction of the initially formed hydroperoxide species. In the presence of metal catalysts, the limiting oxidation rate is the transfer of oxygen from the gas to liquid boundary interface. As a result, low product yields and poor productivity space-time yield are typically experienced. At high substrate conversions, by-products resulting from the decomposition of the formed hydroperoxides predominate. For this reason, the conversion of substrate is restricted to preserve the TCHP selectivity. The slow rates in industrial-scale p-cymene oxidations results in long oxidation times, typically 8-12 h. Substrate conversions are typically between 15-20 percent, and the TCHP selectivity ranges between 65-70 percent. The work described in this thesis concerns the oxidation of p-cymene in a microstructured falling film reactor (FFMSR). These reactor systems facilitate chemical reactors to have high mass and heat transfer rates because of high surface area-to-volume ratios. Due to their small internal volumes, these reactors are inherently safe to operate. These properties were exploited to improve the p-cymene oxidation rate and, consequently, the space-time yield. In order to evaluate the suitability of vanadium phosphate oxide (VPO) catalysts for use as supported catalyst in the FFMSR, different catalysts prepared from VOHPO4∙0.5H2O and VO(H2PO4)2 precursors was first evaluated for the oxidation of p-cymene in a well-stirred batch reactor. The results of the two activated catalysts, (VO)2P2O7 and VO(PO3)2 when used as powders in their pure form, showed a significant improvement in p-cymene oxidation rates with conversions up to 40 percent in 3-4 h reaction time with a TCHP selectivity of 75-80 percent. The (VO)2P2O7 catalyst showed better oxidation rates and selectivity when compared to the VO(PO3)2 catalyst obtained from the VO(H2PO4)2 precursor. The (VO)2P2O7 catalyst was supported on a stainless steel plate and the coated plate used to study the long-term stability and catalytic perfornance of the catalyst during p-cymene oxidations in a batch reactor. Comparable oxidation rates and TCHP selectivity were obtained with the stainless steel coated VPO catalyst when compared to the “free powder” (VO)2P2O7 catalyst. The results also showed that the stainless steel coated catalyst displays a slow, yet significant deactivation over extended reaction periods (250 h onstream). Characterization of the exposed (VO)2P2O7 catalyst to p-cymene oxidation conditions by powder XRD, SEM and TGA-MS showed that (VO)2P2O7 phase undergoes structural transformation back to VOHPO4∙0.5H2O phase over time. The (VO)2P2O7/-Al2O3 catalyst was used to coat the micro-channel reaction plates of the FFMSR. Both uncoated and coated micro-channel reaction plates were evaluated in the FFMSR for the oxidation of p-cymene. The FFMSR showed effective improvement of oxidation rates in terms of productivity space-time-yield at comparable batch p-cymene conversions. A Typical 10 percent conversion in catalysed batch oxidations at 1-2 h reaction time was achieved in few seconds (19 s) reaction time in FFMSR. The comparison of uncoated (i.e. uncatalysed) and coated (i.e. catalysed) FFMSR oxidations showed slight differences in oxidation rates. No clear explanation could be established with the present results for the observed same behaviour. However, the insufficient contact time between the gas and liquid reactants with the wall-coated solid catalyst is one of the possible causes for the observed behaviour of the coated and uncoated micro-channel plates. A simple developed kinetic model was used to confirm the obtained batch oxidation results using cumene as probe compound due to its similarity to p-cumene oxidation and extensive studied kinetics. With the estimated K values and available rate constants from literature, it was possible to predict the conversions in a batch reactor at the same typical micro-structured reactor residence time (i.e. of 19 s). The predicted conversions in the batch reactor were less than 0.1 percent even at harsh conditions such as 170 oC when compared to about 10 percent achieved in the micro-structured reactor at the same reaction temperature, reactants concentration and reaction time of 19 s. This difference in the reactor systems performance indicates the unique advantages offered by micro-structured reactors (e.g. improved mass transfer, temperature management and high surface-to-volume ratios) to perform typical gas/liquid mass transfer limited reactions such as cumene and p-cymene autoxidations.
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- Date Issued: 2009
The electrochemical synthesis of 3-tert-Butyl-4-Methoxybenzaldehyde
- Authors: Qusheka, Sivuyile Emmanuel
- Date: 2007
- Subjects: Oxidation
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:10410 , http://hdl.handle.net/10948/595 , Oxidation
- Description: This project was concerned with the evaluation of three potential synthetic routes for 3-tert-butyl-4-methoxybenzaldehyde, a useful fine chemical intermediate and ingredient in many sunscreen agents. The three synthetic routes all involved the selective oxidation of the 3-tert-butyl-4-methoxytoluene to the desired benzaldehyde by (a) catalytic air oxidation, (b) direct electrochemical oxidation, and (c) indirect electrochemical oxidation. In order to decide whether catalytic oxidation should precede the alkylation of 4-methoxytoluene, the selective oxidation using the well-known cobalt(II)- bromide catalyst system in acetic acid solutions were investigated with the view to determine whether increased electron density on the aromatic ring improves selectivity to the desired benzaldehyde or not. In addition, the effect of various important reaction variables was also investigated. These studies showed that increased electron density, hence increased substitution, increases the desired benzaldehyde selectivity. In addition, while reaction conditions such as reaction temperature, catalyst concentration, water concentration, etc. may be optimised for maximum 3-tert-butyl-4- methoxybenzaldehyde yields (~80 percent), such yields can only be achieved at relatively low (<40 percent) alkoxytoluene conversions. The direct electrochemical oxidation of 3-tert-butyl-4-methoxytoluene was investigated in methanol solutions containing various supporting electrolytes and using constant current electrolysis with the intention of optimizing the production of 3-tert-butyl-4-methoxybenzyl dimethyl acetal which can later be hydrolyzed using sulfuric acid to the 3-tert-butyl-4-methoxybenzaldehyde. In this study, various parameters such as supporting electrolyte and electrodes were studied. Previous studies showed undoubtedly that methanol as a solvent gave better results amongst the rest of the solvents. Indirect route was also studied as a method of synthesizing 3-tert-butyl-4- methoxybenzaldehyde and compared to the direct electro synthesis.
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- Date Issued: 2007
The oxidative coupling of phenols using stoichiometric metal oxidants
- Authors: Hoffmann, Eric
- Date: 2005
- Subjects: Phenols , Oxidation , Stoichiometry
- Language: English
- Type: Thesis , Doctoral , DTech
- Identifier: vital:10977 , http://hdl.handle.net/10948/180 , Phenols , Oxidation , Stoichiometry
- Description: The oxidative coupling of 2,6-di-t-butylphenol under mild reaction conditions is well documented and the subject of many patents. However, the coupling of other monoand di- substituted phenols is not as well documented and thus there is scope for further investigation for providing a convenient, environmentally friendly and economically viable method for the oxidative coupling of these phenols. In this study, the oxidative coupling of a variety of alkylated phenolic substrates, 2-tbutylphenol, 2,6-di-t-butylphenol, 2,4 -di-t-butylphenol and ,4-dimethylphenol, using a range of different oxidizing agents, were investigated by means of experimental and/or theoretical means. The dibutylated aromatics provided the highest selectivities to their respective coupled products, with results obtained with the dimethyl analogue being only satisfactory, and that for 2 -t-butylphenol being totally inefficient. PM3 Molecular orbital (MO) calculations were used to predict the possible modes of coupling for the substrates 2,6 -di-t-butylphenol and 2,4-di-t-butylphenol, and these results were then compared with those obtained experimentally in the laboratory. Preliminarily, the coupling of unsubstituted phenolics was also assessed by means of MO calculations. Much emphasis was placed on Ce(IV) as the oxidant, and the reaction conditions under which it was used and the results that were obtained have not been reported before and are therefore novel. The oxidation of 2,4-di-t-butylphenol using Ce(IV) in the presence of methanesulphonic acid was optimized to afford high yields and selectivities to the desired ortho C-ortho C coupled product under mild reaction conditions. Various reaction parameters were also investigated in this case, such as varying the MeSO3H concentration, the solvent, the reaction temperature, the reaction time, the substrate loading, the rate of oxidant addition and the substrate to oxidant ratio. Ce(IV) also gave a high selectivity to the para C-para C coupled product when IX using 2,6-di-t-butylphenol as the substrate. However, it was not as effective with 2,4- dimethylphenol, and even less so with 2-t-butylphenol. The oxidation reactions of 2-t-butylphenol and 2,4-dimethylphenol with various coupling agents were also investigated with the intention of obtaining high selectivities to the respective desired coupled products. In these studies, 2-t-butylphenol afforded a large number of products, irrespective of the oxidant used. The dimethyl analogue was more selective, but results were not optimal. It was clear that the number of substituents on the phenol ring, their nature and their position with regards to the hydroxyl moiety was of great importance and made a significant impact on the preferred coupling mode of the substrate. It was observed that steric effects also played a major role in the outcome of these reactions: 2,6-di-t-butylphenol never afforded any C-O coupled products whereas 2-t-butylphenol, 2,4-di-t-butylphenol and 2,4-dimethylphenol all appeared to undergo some C-O coupling. Finally, reaction mechanisms were provided for both the K3Fe(CN)6 and Ce(IV) work, these reacting in basic and acidic media, respectively. It was proposed that both of these mechanisms operate through the initial formation of the phenoxyl radical.
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- Date Issued: 2005
Alkane oxidation using metallophthalocyanine as homogeneous catalysts
- Authors: Grootboom, Natasha Denise
- Date: 2002
- Subjects: Oxidation , Alkanes
- Language: English
- Type: Thesis , Masters , MSc
- Identifier: vital:4449 , http://hdl.handle.net/10962/d1007794
- Description: Iron polychlorophthalocyanine (FePc(Cl)₁₆) and tetrasulfophthalocyanine ([M¹¹TSPc]⁴) complexes of iron, cobalt and manganese are employed as catalysts for the oxidation of cyclohexane using tert-butyl hydroperoxide (TBHP), chloroperoxybenzoic acid (CPBA) and hydrogen peroxide as oxidants. Catalysis using the FePc(Cl)₁₆ was performed in a dimethylformamide:dichloromethane (3 :7) solvent mixture. For the [Fe¹¹TSPc]⁴⁻, [Co¹¹TSPc]⁻ and [Mn¹¹TSPc]⁴⁻catalysts, a water:methanol (1:9) mixture was employed. The products of the catalysis are cyclohexanone, cyclohexanol and cyclohexanediol. The relative percentage yields, percentage selectivity and overall percentage conversion of the products depended on types of oxidant, or catalyst, concentrations of substrate or catalysts and temperature. TBHP was found to be the best oxidant since minimal destruction of the catalyst and higher selectivity in the products were observed when this oxidant was employed. Of the four catalysts investigated [Fe¹¹TSPc]⁴⁻ yielded the highest overall percentage conversion of 20%.The mechanism of the oxidation of cyclohexane in the presence of the FePc(Cl)₁₆ and [M¹¹TSPc]⁴⁻ involves the oxidation of these catalysts, forming an Fe(IlI) phthalocyanine species as an intermediate. Electrocatalysis using [Co¹¹TSPc]⁴⁻ as catalyst, employed an aqueous pH 7 buffer medium for electro-oxidation of 4-pentenoic acid. An enone is suggested as the only oxidation product of 4-pentenoic acid. No degradation of [Co¹¹TSPc]⁴⁻ was observed during the electrocatalytic process. In this process water was used as a source of oxygen therefore eliminating the production of by products from oxidant as in the case of TBHP and CPBA. This system was studied In an attempt to set up conditions for alkane electrocatalytic oxidation.
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- Date Issued: 2002
Biological sulphide oxidation in heterotrophic environments
- Authors: Rein, Neil Berthold
- Date: 2002
- Subjects: Acid mine drainage , Oxidation , Sulfides , Oxidation, Physiological
- Language: English
- Type: Thesis , Masters , MSc
- Identifier: vital:3919 , http://hdl.handle.net/10962/d1003978 , Acid mine drainage , Oxidation , Sulfides , Oxidation, Physiological
- Description: Acid mine drainage is a major environmental pollution concern associated with the mining of sulphide-containing ore bodies. Both physicochemical and biological options have been investigated for the treatment of acid mine drainage with recent interest in biological processes targeting low-cost and passive treatment applications. All acid mine drainage biological treatment processes are based to some extent on the activity of sulphate reducing bacteria, and their ability to reduce sulphate to sulphide in the presence of a range of carbon and electron donor sources. A portion of the sulphide produced may be consumed in the precipitation of heavy metals present in the mine drainage. Residual sulphide must be removed, not only due to its toxicity, but especially to prevent its reoxidation to sulphate where salinity reduction is a target of the treatment process. The partial oxidation of sulphide to elemental sulphur is an option that has received considerable attention and both physicochemical and biological options have been investigated. Biological processes have substantial potential cost advantages and run at ambient temperatures and pressures. However, the oxidation of sulphide to elemental sulphur is poised over a narrow redox range and process control to maintain optimum conditions remains a serious problem. In addition little has been reported in the literature on process control of sulphide oxidation to elemental sulphur, in the heterotrophic conditions prevailing in the reaction environment following sulphate reduction. This study undertook an investigation of biological sulphide oxidation under heterotrophic conditions in order to establish the effect of organic compounds on biological sulphide oxidation, and to determine whether the presence of organics, and associated heterotrophic oxygen consumption, may be manipulated to maintain the defined redox conditions required for the production of elemental sulphur. Biological sulphide oxidation under heterotrophic conditions was investigated in a series of flask experiments. Based on these results three different reactor configurations, a Fixed-Film Trickle Filter Reactor, Submerged Fixed-Film Reactor and a Silicone Tubular Reactor were used to investigate sulphur production. The flask studies indicated that organics, and associated heterotrophic metabolism in the presence of excess oxygen in the sulphide oxidation reaction environment, did contribute to the poising of redox conditions and thereby enabling the production of elemental sulphur. While the Fixed-Film Trickle Filter Reactor was found to be redox unstable, probably due to excess oxygen ingress to the system, a reduced oxygen challenge in the Submerged Fixed-Film Reactor configuration was found to be more successful for production of elemental sulphur. However, due to the production of a predominantly filamentous sulphur producing microbial population, recovery of sulphur from the column was intermittent and unpredictable. Extended residence times for produced sulphur on the column increased the likelihood for its eventual oxidation to sulphate. The Silicone Tubular Reactor was found to support a vigorous sulphide oxidising biofilm and produced elemental sulphur effectively. Electron microscopic studies showed that this occurred as both biologically produced sulphur and, probably mainly, as crystalline sulphur in the ortho-rhomic form. Given the linear extension of the sulphur production reaction environment it is was possible to investigate the sequence of the reaction mechanism in grater detail than is possible in mixed systems. Based on these findings a model explaining sulphur production under heterotrophic conditions has been proposed and is presented. The commercial implications of the development have also been noted.
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- Date Issued: 2002
Strategies for the improvement of the industrial oxidation of cymene
- Authors: Harmse, Nigel
- Date: 2001
- Subjects: Oxidation , Cymene
- Language: English
- Type: Thesis , Masters , MTech (Chemistry)
- Identifier: vital:10958 , http://hdl.handle.net/10948/73 , Oxidation , Cymene
- Description: The oxidation of cymene with dioxygen has been investigated in some detail with the view of establishing the feasibility of improving the efficiency of the oxidation process. Of particular interest were the rate of cymene oxidation and the selectivity of the oxidation process for the tertiary cymene hydroperoxide, especially at conversions above 15%. In order to be able to evaluate the selectivity of oxidation processes, a reliable method for analysis of the individual hydroperoxides had to be established. Two methods were investigated, namely reduction of the hydroperoxides to alcohols using ferrous sulphate and reduction using triphenylphosphine, and analysing the reduction products by gas chromatography. Of these two methods, the triphenylphosphine method proved to be superior to the ferrous sulphate method and was used as the method of choice for this investigation. A number of oxidation systems were evaluated in an initial screening experiment for the oxidation of p-cymene. The results of this screening experiment showed that three-phase oxidation systems, i.e. systems containing an organic phase, an aqueous phase and gas, gave significantly lower activities than two-phase oxidation systems. In addition, the use of a base in the aqueous layer does not improve the overall selectivity of the oxidation process, but improves the selectivity towards the tertiary hydroperoxide to some extent due to the decomposition and extraction of primary hydroperoxide into the basic aqueous phase. Oxidation systems using a non-autoxidation catalyst, i.e. a catalyst that does not catalyse the conventional autoxidation of organic compounds, gave by far the most promising results. These systems gave both a high selectivity as well as high reaction rate. From the initial screening experiment, and using multi-factorial statistical techniques, two catalyst systems were selected for investigation, namely vanadium phosphate and boron phosphate. The results of these investigations showed that these two catalysts are remarkably active and selective for the oxidation of p-cymene, giving the cymene tertiary hydroperoxide in selectivities exceeding 85% and at substrate conversions as high as 25%. These results are a considerable improvement over currently known oxidation systems and may offer opportunities for further commercial exploitation.
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- Date Issued: 2001
The evaluation of autoxidation procedures for the selective oxidation of aliphatic alcohols
- Authors: Bacela, Siyabulela Mawande
- Date: 2001
- Subjects: Oxidation , Aliphatic compounds
- Language: English
- Type: Thesis , Masters , MTech (Chemistry)
- Identifier: vital:10950 , http://hdl.handle.net/10948/59 , Oxidation , Aliphatic compounds
- Description: The homogeneously catalyzed oxidation of 1-propanol by dioxygen in glacial acetic acid using cobalt(II)acetate and sodium bromide as the catalyst system has been investigated with the view of determining the significance of various experimental variables during the oxidation. The results of this investigation show unequivocally that a number of reaction variables have a direct influence upon catalytic activity and hence the reaction products. It is quite evident that the major product of this autoxidation reaction is propionic acid with the respective esters as side-products. This is an indication that the autoxidation mechanism occurs via a two-stage pathway, namely, the oxidation of 1-propanol to propionaldehyde as the primary product and, subsequently, the further oxidation of the propionaldehyde to propionic acid as the major product. Thus the esterification process of the propionic acid with the substrate 1-propanol could be termed as a side-reaction because its not facilitated by the catalyst system and it consumes the formed product. The catalyst activity has been demonstrated to depend on a number of factors, including the bromide concentration, the cobalt(II)acetate concentration, the water concentration, reaction temperature, and the presence of metal acetates as co-catalysts. There is an observed decrease in catalytic activity at high bromide concentration, which may be explained in terms of cobalt bromide complexes that form at these high concentrations. Subsequently, the same trend of catalyst activity reduction at high cobalt(II)acetate concentration may be ascribed to the “inactive” metal complexes that are susceptible to form at high metal ion concentrations. The catalytic activity increases with increase in total concentration and rapidly decreases at very high concentrations. This can be explained in terms of the observations made during the investigation of the effect of cobalt(II)acetate and bromide concentrations. The high increase in catalytic activity with increasing temperature is ascribed to the Arrhenius law, which relates the rate constant for a particular reaction to temperature. However, there is an observed loss of catalyst selectivity at high temperatures which maybe due to two possible factors. The first is simply related to an increased loss of volatile material from the reactor in the oxygen gas stream as the temperature is increased. The second relates to the increasing activity of the catalyst system for the selective decarboxylation of the carboxylic acid product. The addition of water to the reaction system rapidly reduces the catalyst activity. This detrimental effect is an indication that there is an effective competition by water with bromide for coordination sites on cobalt(II), thereby preventing the formation of the active catalyst species. The introduction of metal acetates as co-catalyst reduces the catalyst activity quite dramatically. This inhibition effect is suggested to relate to the redox potential of the respective metal ions. The results of statistical analysis of the experimentally derived response surface during the oxidation of 1-propanol, show no significant lack of fit, and the residuals obtained by applying the response surface to the design settings show that the data is normally distributed. The response surface is therefore reliable, but keeping in mind that the central composite design used is not rotatable so that its predictive power, especially outside the experimental domain investigated, is quite limited. However, several interesting observations were still possible The oxidative dehydrogenation of ethanol over supported noble-metal catalysts has been investigated with the view of identifying the most active supported noble-metal and also to compare this oxidation procedure with the autoxidation procedure. Secondly, the effect of an acidic resin as a co-catalyst was also investigated during the said oxidation. On the basis of results presented in this study during oxidative dehydrogenation of ethanol, catalysts no.2 (10% Pd/C), 8 (2% Pd/Al – Pb-promoted) and 9 (2% Pt/8% Pd/C) appear to be the most active in terms of relative rates, while catalysts 6 (10% Pd/C- Pbpromoted), 7 (5% Pd/C-shell reduced-Pb -promoted) and 10 (5% Pt 5% Pd on C) are more active based on the comparison of average rates. Two other observations are of interest. Firstly, the promotion of the Pd catalysts with lead appears to improve catalyst activity to some extent as shown by the comparisons between catalysts 1 and 5, 4 and 8, 2 and 6 and 3 and 7. Secondly, the introduction of Pt up to equal amounts with palladium seems to produce the most active catalysts. On its own, platinum appears to be a better catalyst than Pd when supported on activated carbon (catalysts 1 and 12). In comparison with the homogeneous, cobalt-bromide catalyzed oxidation of 1- propanol in the liquid-phase, oxidations over noble-metal catalysts in the liquid-phase appear to be significantly less active. The presence of the resin promoted the formation of ethyl acetate to some extent, the improvements are not as dramatic as expected.
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- Date Issued: 2001