Chemistry of hydrocarbon compounds – Aromatic compound synthesis – By condensation of entire molecules or entire hydrocarbyl...
Reexamination Certificate
2000-01-14
2001-08-28
Yildirim, Bekir L. (Department: 1764)
Chemistry of hydrocarbon compounds
Aromatic compound synthesis
By condensation of entire molecules or entire hydrocarbyl...
C585S458000, C585S462000, C585S668000, C585S669000, C568S322000, C568S323000, C568S485000, C568S768000, C568S798000, C502S159000, C502S402000, C521S028000
Reexamination Certificate
active
06281400
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates to a process for preparing a microcomposite comprising a highly fluorinated ion-exchange polymer containing pendant sulfonate functional groups, said polymer existing as aggregated particles entrapped within and dispersed throughout a silica network. Due to their high surface area and acid functionality, these microcomposites possess utility as improved solid acid catalysts.
A microcomposite comprising perfluorinated ion-exchange polymers (PFIEP) containing pendant sulfonic acid groups and/or pendant carboxylic acid groups entrapped within and highly dispersed throughout a metal oxide network and its preparation are disclosed in WO95/19222. The microcomposites described therein are prepared using PFIEP in water and alcohol.
Alkylation of aromatics is practiced in many segments of the chemical industry. Around 2.5 MM tons of linear alkylbenzene is produced each year which is used for making detergents. The reaction is usually catalyzed by liquid HF and H
2
SO
4
. In addition, approximately 2 MM tons of phenol and 100 MMlb of hydroquinone are produced by the H
2
SO
4
catalyzed decomposition of the corresponding hydroperoxides. The acid reaction medium is highly corrosive and the decomposition processes can become violent and produce by-product black tars. Further, the Friedel-Crafts acylations of aromatics are currently often catalyzed by Lewis acid, such as AlCl
3
, ZnCl
2
and BF
3
, which generates high volume waste streams. It is desirable to find a clean and effective solid acid catalyst for these and other processes.
It is an object of the present invention to provide a microcomposite that possesses high catalytic activity for a variety of applications.
SUMMARY OF THE INVENTION
The present invention provides a process for the preparation of a porous microcomposite which comprises a highly fluorinated ion-exchange polymer containing pendant sulfonate functional groups, said polymer existing as aggregated particles entrapped within and dispersed throughout a network of silica, wherein the weight percentage of the highly fluorinated ion-exchange polymer in the microcomposite is from about 0.1 to about 90 percent, and a first set of pores have an average pore diameter ranging from about 0.5 nm to about 75 nm, said process comprising the steps of:
(a) preparing a liquid composition consisting essentially of water and a highly fluorinated ion-exchange polymer containing pendant sulfonate functional groups;
(b) contacting said liquid composition with a solution consisting essentially of water and a silicate selected from the group consisting of: sodium silicate, ammonium silicate, potassium silicate, and any combinations thereof;
(c) allowing the silicate to form a network of silica; and
(d) recovering the porous microcomposite.
In a separate embodiment, the microcomposite can simultaneously contain a second set of larger pores ranging from about 75 nm to about 1000 nm, wherein these larger pores are formed by introducing acid-extractable filler particles during the formation process.
The present invention also provides a porous microcomposite prepared by the above process.
The present invention further provides an improved process for the following reactions wherein the improvement comprises using a catalytic amount of a microcomposite prepared by the above process: olefin isomerization; decomposition of cumene hydroperoxide; and aromatic substitution, such as aromatic alkylation, and Friedel-Crafts acylation.
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Harmer Mark Andrew
Sun Qun
E. I. Du Pont de Nemours and Company
Yildirim Bekir L.
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