Hydroformylation

In organic chemistry, hydroformylation, also known as oxo synthesis or oxo process, is an industrial process for the production of aldehydes (R−CH=O) from alkenes (R2C=CR2). This chemical reaction entails the net addition of a formyl group (−CHO) and a hydrogen atom to a carbon-carbon double bond. This process has undergone continuous growth since its invention: production capacity reached 6.6×106 tons in 1995. It is important because aldehydes are easily converted into many secondary products. For example, the resultant aldehydes are hydrogenated to alcohols that are converted to detergents. Hydroformylation is also used in speciality chemicals, relevant to the organic synthesis of fragrances and pharmaceuticals. The development of hydroformylation is one of the premier achievements of 20th-century industrial chemistry. The process entails treatment of an alkene typically with high pressures (between 10 and 100 atmospheres) of carbon monoxide and hydrogen at temperatures between 40 and 200 °C. In one variation, formaldehyde is used in place of synthesis gas. Transition metal catalysts are required. Invariably, the catalyst dissolves in the reaction medium, i.e. hydroformylation is an example of homogeneous catalysis.

History The process was discovered by the German chemist Otto Roelen in 1938 in the course of investigations of the Fischer–Tropsch process. Aldehydes and diethylketone were obtained when ethylene was added to an F-T reactor. Through these studies, Roelen discovered the utility of cobalt catalysts. HCo(CO)4, which had been isolated only a few years prior to Roelen's work, was shown to be an excellent catalyst. The term oxo synthesis was coined by the Ruhrchemie patent department, who expected the process to be applicable to the preparation of both aldehydes and ketones. Subsequent work demonstrated that the ligand tributylphosphine (PBu3) improved the selectivity of the cobalt-catalysed process. The mechanism of Co-catalyzed hydroformylation was elucidated by Richard F. Heck and David Breslow in the 1960s.

In 1968, highly active rhodium-based catalysts were reported. Since the 1970s, most hydroformylation relies on catalysts based on rhodium. Water-soluble catalysts have been developed. They facilitate the separation of the products from the catalyst.

Mechanism

Selectivity A key consideration of hydroformylation is the "normal" vs. "iso" selectivity. For example, the hydroformylation of propylene can afford two isomeric products, butyraldehyde or isobutyraldehyde:

H2 + CO + CH3CH=CH2 → CH3CH2CH2CHO (normal) H2 + CO + CH3CH=CH2 → (CH3)2CHCHO (iso) These isomers reflect the regiochemistry of the insertion of the alkene into the M–H bond. Since both products are not equally desirable (normal is more stable than iso), much research was dedicated to the quest for catalyst that favored the normal isomer.

Steric effects Markovnikov's rule addition of the cobalt hydride to primary alkenes is disfavored by steric hindrance between the cobalt centre and the secondary alkyl ligand. Bulky ligands exacerbate this steric hindrance. Hence, the mixed carbonyl/phosphine complexes offer a greater selectivity for anti-Markovnikov addition, thus favoring straight chain products (n-) aldehydes. Modern catalysts rely increasingly on chelating ligands, especially diphosphites.

Electronic effects Additionally, electron-rich the hydride complex are less proton-like. Thus, as a result, the electronic effects that normally favour the Markovnikov addition to an alkene are less applicable. Thus, electron-rich hydrides are more selective.

Acyl formation To suppress competing isomerization of the alkene, the rate of migratory insertion of the carbonyl into the carbon-metal bond of the alkyl must be relatively fast. The rate of insertion of the carbonyl carbon into the C-M bond is likely to be greater than the rate of beta-hydride elimination.

Asymmetric hydroformylation Hydroformylation of prochiral alkenes creates new stereocenters. Using chiral phosphine ligands, the hydroformylation can be tailored to favor one enantiomer. Thus, for example, dexibuprofen, the (+)−(S)-enantiomer of ibuprofen, can be produced by enantioselective hydroformylation followed by oxidation.

Processes The industrial processes vary depending on the chain length of the olefin to be hydroformylated, the catalyst metal and ligands, and the recovery of the catalyst. The original Ruhrchemie process produced propanal from ethylene and syngas using cobalt tetracarbonyl hydride as the catalyst. Today, industrial processes based on cobalt catalysts are mainly used for the production of medium- to long-chain olefins, whereas the rhodium-based catalysts are usually used for the hydroformylation of propene. The rhodium catalysts are significantly more expensive than cobalt catalysts. In the hydroformylation of higher molecular weight olefins the separation of the catalyst from the produced aldehydes is difficult.

BASF-oxo process The BASF-oxo process starts mostly with higher olefins and relies on cobalt carbonyl-based catalyst. By conducting the reaction at low temperatures, one observes increased selectivity favoring the linear product. The process is carried out at a pressure of about 30 MPa and in a temperature range of 150 to 170 °C. The cobalt is recovered from the liquid product by oxidation to water-soluble Co2 +, followed by the addition of aqueous formic or acetic acids. This process gives an aqueous phase of cobalt, which can then be recycled. Losses are compensated by the addition of cobalt salts.

Exxon process The Exxon process, also Kuhlmann- or PCUK – oxo process, is used for the hydroformylation of C6–C12 olefins. The process relies on cobalt catalysts. In order to recover the catalyst, an aqueous sodium hydroxide solution or sodium carbonate is added to the organic phase. By extraction with olefin and neutralization by addition of sulfuric acid solution under carbon monoxide pressure the metal carbonyl hydride can recovered. This is stripped out with syngas, absorbed by the olefin, and returned to the reactor. Similar to the BASF process, the Exxon process is carried out at a pressure of about 30 MPa and at a temperature of about 160 to 180 °C.

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