Friedel-Crafts reaction with graphite intercalated Lewis acids
United States Patent Lalancette 1 Apr. 29, 1975 1 1 FRlEDEL-CRAFTS REACTION WITH 3.240.827 3/1966 Lain et al 252/441 GRAPHYTE NTERCALATED LEWIS ACIDS 3,785,999 1/1974 Derleth et a1 252/441 [75] Inventor: Jean-Marc Lalancette, Sherbrooke. Quebec, Canada [73] Assignee: Ventron Corporation, Beverly,  
 Mass.  
 [22] Filed: Nov. 13, 1973 [21] Appl. No.: 415,391  
 [52] US. Cl. 260/671 C; 260/671 R; 260/671 P [51] Int. Cl. C07c 3/56 [58] Field of Search 260/671 R. 671 C, 671 P; 252/441 [56] References Cited UNITED STATES PATENTS 2.919266 12/1959 Laucr 252/441 Primary Examiner-C. Davis Attorney, Agent, or F irm-Cushman, Darby &amp; Cushman [57] ABSTRACT Improved synthesis of hydrocarbons of mixed type by the Friedel-Crafts hydrocarbon synthesis is obtained by using a graphite intercalated Lewis acid selected from aluminum trichloride, aluminum tribromide and ferric chloride whereby a greater proportion of monoand disubstituted hydrocarbon is obtainedthan using the Lewis acid alone.  
 6 Claims, No Drawings FRIEDEL-CRAFTS REACTION WITH GRAPHITE INTERCALATED LEWIS ACIDS The invention relates to an improvement in the synthesis of hydrocarbons of mixed type by the Friedel- Crafts hydrocarbon synthesis.  
 BACKGROUND OF THE INVENTION The Friedel-Crafts reaction for the synthesis of ketones or mixed hydrocarbons by the reaction of hydrocarbons with acyl chlorides or anhydrides or with alkyl halides in the presence of a Lewis acid, especially anhydrous aluminum halides such as the chloride is well known. Normally such reaction are used to react unsaturated aliphatic hydrocarbons or halogenated aliphatic hydrocarbons with aromatic or aliphatic unsaturated hydrocarbons. The preferred Lewis acid used as a catalyst is aluminum trichloride or tribromide.  
  A disadvantage of the Friedel-Crafts hydrocarbon synthesis is that the reaction does not stop at the stage of the monosubstitution but proceeds to the formation of polysubstitution products because the monosubstituted hydrocarbon initially formed will undergo further reaction more readily than the starting hydrocarbon, thus yielding an important amount of di, tri and tetra substituted products in the reaction mixture.  
  A further disadvantage of the Friedel-Crafts hydrocarbon synthesis as carried out heretofore is that the Lewis acids used as catalyst in the reaction are very hygroscopic thus requiring special handling precautions because hydrolysis will occur readily even in the presence of moist air.  
  Another disadvantage of the Friedel-Crafts reaction is that once the reactants are placed together in the reaction vessel, there is no possible control of the reac- -Cl+AlC provide a much desired improvement over the prior art procedures.  
 THE INVENTION In accordance with the present invention, there is now provided an improvement in the Friedel-Craft reaction which comprises carrying out the reaction in the presence of a Lewis acid selected from aluminum trichloride, aluminum tribromide and ferric chloride, intercalated in the lattices of graphite, whereby the importance of polysubstitution is decreased thereby yielding a mixture of predominantly mono and disubstituted hydrocarbons rather than the more highly substituted mixtures obtained by the standard Friedel-Crafts catalyst.  
  The intercalation of metal and metal salts in the lattice of graphite has been described in the literature and most authors appear to have been concerned with the study of the crystal structure of intercalated graphite metal and metal salts or the possible reaction between graphite and metal or metal salts (see for example Advances in Inorganic Chemistry and Radiochemistry, Rudorff, I, 224-265, 1959). However the chemistry of intercalated salts has received very little attention.  
  There are many reasons which would lead one to believe that intercalated Lewis acids in graphite would not be suitable as catalysts for Friedel-Crafts reactions. First due to its intercalation the Lewis acid would not be as readily available to the reactants as it is in the usual Friedel-Crafts reaction where the Lewis acid is mixed directly with the reactants.  
 Furthermore it is known that in a Friedel-Crafts reaction an intermediate complex aluminum compound must be formed before the desired substituted hydrocarbon is obtained. The mechanism of the formation of the complex may be illustrated as follows:  
 :AlCl  
 tion in the sense that the reaction cannot be stopped at any particular level of reaction so that eventually the R x Al x 9 :OzAlCl In a straight alkylation the intermediate complex is formed as follows:  
  In view of the structure of the reactant to the Lewis acid when it is intercalated in graphite, one would be led to believe that the essential complex would not be formed, and thus such intercalated Lewis acids in graphite would present the disadvantage of decreased reactivity.  
  Also the Lewis acids&#34; character of substances such as aluminum chloride or ferric chloride has always been believed to be an essential feature of a Friedel- Crafts reaction. However, some of the Lewis acids such as ferric chloride when imbedded in the electron-rich graphite become very resistant to hydrolysis because water can less readily reach the iron partly neutralized by the graphite electrons. Thus it would be normal to believe that a catalyst which would be intercalated would be completely inert.  
  Accordingly, because of the structure of intercalated Lewis acids in graphite, and because of the nonhygroscopicity or reduced hygroscopicity of the Lewis acid in such a structure, one would be led to believe that the essential intermediate required in Friedel- Crafts reactions would not be formed or the intercalated Lewis acid in graphite would be non-reactive.  
  Surprisingly, it has been found that a Lewis acid intercalated in graphite is in many aspects unexpectedly superior in a Friedel-Crafts reaction to the Lewis acid as used previously.  
  The fact that intercalated Lewis acids in graphite are less hydroscopic, the carrying out of the reaction requires less precautions. It has also been observed that the reaction is slower thus allowing a better control of the reaction as opposed to the prior art procedure with the result that an unexpectedly higher proportion of mono and disubstituted hydrocarbon is obtained.  
  Since the improved process of the present invention provide higher yields of less substituted hydrocarbons, it can readily be appreciated that a great advantage is thus provided in industrial synthesis by providing less of the highly substituted fractions whereby expensive separation procedures are avoided or reduced, and the consumption of the starting materials for production of undesired side products is reduced.  
  A possible explanation of the surprising absence of polysubstitution is that once the monosubstituted hydrocarbon has been formed and because it no longer has a planary structure and is much bulkier, it has more difficulty in diffusing through the intercalated graphite and thus is less available for further reaction to form a disubstituted compound, and any disubstituted compound formed will itself have for the same reasons more difficulty in diffusing through the intercalated graphite catalyst thus allowing for less formation of trisubstituted graphite.  
  The Lewis acid which can be intercalated in graphite are aluminum trichloride, aluminum tribromide, and ferric chloride, with aluminum trichloride being preferred because of its low price and appropriate reactivity. The amount of catalyst which can be intercalated can be as low as 0.1% to the saturation point which is about 35% by weight of the graphite in most cases.  
  The preparation of the catalyst used in accordance with the present invention will now be described.  
  The procedure is similar to that described in Rudorff in Z. Anorg. Chem. 279 182 (1955). In this procedure graphite and the metal chloride to be intercalated are introduced in an atmosphere of helium in an aluminum autoclave. The system is then flushed with chlorine and after a suitable pressure has built in the system, it is closed and the autoclave is heated at 260C. for 24 hours. The non-intercalated metal chloride is removed by breaking the solid mass in a dry atmosphere and heating under vacuum at about 250C.  
 In the synthesis of substituted hydrocarbons an aromatic hydrocarbon is reacted with an aliphatic hydrocarbon or a halogenated aliphatic hydrocarbon.  
  As an example of aromatic or aliphatic hydrocarbons there may be mentioned benzene, toluene, naphthalene, biphenyl, xylenes and the like. As an example of unsaturated hydrocarbons there may be mentioned ethylene, propylene, butylenes, including isobutylene, pentenes, heptenes, octenes, decenes, dodecenes and octadecenes, and the like. As an example of halogenated hydrocarbon there may be mentioned ethyl bromide, propyl bromide, butylbromide, ethyl chloride, pentyl bromide.  
  The synthesis of the substituted hydrocarbons may be carried out in accordance with the present invention under temperature and pressure conditions normally used for alkylation. Nevertheless, an increase control of the reaction product is observed by using the intercalated catalyst provided for in the present process.  
  In order to fully understand the process of the present invention reference will now be made to the following examples.  
 EXAMPLE 1 Preparation of Alcl -graphite The method used was in accordance with the description of Rudorff. A mixture of 20 g of graphite and 40 g of AlCl (Fisher, Reagent) was introduced, in an atmosphere of helium, into an aluminium autoclave. The system was flushed with chlorine and a pressure of 40 psi of chlorine was built in the system. The inlet and outlet were then closed and the autoclave heated at 260 for 24 hrs. Upon heating, the pressure reached 250 psi. After cooling, the autoclave was opened. Some AlClwas condensed on top of the autoclave. The solid mass was broken in a dry atmosphere and heated for 16 hrs. under vacuum, at 250. This treatment removed the non-intercalated AlC1 By standard analytical procedure, this material contained 6.0% Al and 24.0% Cl. The experiment could be easily reproduced and gave a concentration of AlCl in the graphite in the range of 30-35%.  
  By proceeding in the same manner, and substituting aluminum tribromide for aluminum trichloride there is obtained an aluminum tribromide-graphite catalyst. By substituting ferric chloride for aluminum trichloride there is obtained the corresponding ferric chloridegraphite catalyst.  
 EXAMPLES 2-7 In Table I there are reported the results obtained by reacting a hydrocarbon with a halogenated hydrocarbon or a unsaturated hydrocarbon under normal temperature and pressure using the AlCl -graphite catalyst obtained in Example 1. Each experiment was repeated using ordinary aluminum chloride as catalyst.  
 System of sealed tube reaction In a thick wall test tube (1.5 X 12.5 cm) AlCl graphite was introduced with the substrate (S) and the reagent (R). The mixture was frozen in dry ice and the tube sealed under vacuum. After a contact of 44 hours at room temperature, the tube was opened and the reaction mixture was extracted with ether. Using the same amount of substrate, reagent and aluminum chloride without intercalation the experiment was repeated. The extracted mixtures were then analyzed by vapor phase chromatography, the fractions being identified by mass spectrometry.  
 TABLEI Reaction with AlCl graphite Analysis of Products obtained in reaction mixture Molar with with System Substrate Reagent Temperature Duration ratio AICL, AlCl -graphite S R &#34;C hrs R/S 2 Sealed Benzene ethyl 25 48 3 benzene 2 29 tube bromide monoethyll 3 40 diethyl- 27 23 triethyl- 54 8 tctraethyl- 4 traces 3 Sealed Toluene ethyl 25 24 3 toluene l7 tube bromide monocthyltraces 52 diethyl- 41 31 triethyl- 60 traces 4 Atmospheric Toluene ethyl -l0 24 2 toluene 5 bromide monoethyltraces 33 diethyl- 30 52 triethyl- 65 10 5 Sealed Naphthalene ethyl 44 3 naphtalene 26 77 tube bromide monoethyl- 39 21 diethyltetrahydro 2 traces diethyll7 1 triethyl 16 0.5 6 Sealed Biphenyl ethyl 25 48 3 biphenyl 26 8| tube bromide diethyll6 l5 tetra-hexa ethyl- 33 4 oetaethyl- 25 0 7 Atmospheric Benzene ethylene 75 24 benzene 0 3 monoethyltraces I9 diethyl 1.1 47 triethyl- 25 22 tetraethyl- 53 6 pentaethyll 8 2 hexaethyl- 4 1 It will be noted that in all Examples the amount of trisubstitution and higher substituted hydrocarbons is unexpectedly reduced when using aluminum chloride intercalated in graphite as catalyst. In most cases the amount of monosubstituted hydrocarbon is unexpectedly increased, while the amount of disubstituted hydrocarbon is also reduced.  
 EXAM PLES 8-1 1 Reaction at elevated temperatures Table II shows examples wherein the substrate (S) TABLE II FRIEDEL-CRAFT REACTION Product With With System Substrate Reagent Temperature Duration AlCl AlCl /C S R &#34;C hrs 8 Atm. Benzene Propylene 0.5 Benzene 23 44 monoisopropyl 56 54 diisopropyl l 8 2 triisopropyl 3 traces 9 Atm. Toluene Ethylene l 745 Toluene 8 l7 monoethyl 49 51 diethyl 40 26 10 Atm. Toluene Propylene 80 2.50 Toluene traces 4 monoisopropyl traces 33 diisopropyl 42 59 triisopropyl 46 traces l l Atm. Toluene Isobutylene 80 1. l5 Toluene 2O 35 monoisohutyl 66 63 diisobutyl l3 1 43.57/ AIC]; in graphite. 27.0% AlCl in graphite.  
  Some minor components of the reaction mixtures have not been identified.  
 EXAMPLE 12 By proceeding as in Example 1 and using g of AlBr instead of aluminum trichloride and 90 g of graphite there is obtained a 10% aluminum tribromidegraphite intercalate.  
  To a mixture of 0.] mole of toluene and 0.3 mole of ethyl bromide was added 3.0 g of aluminum tribromide. Under identical conditions a similar mixture of toluene and ethyl bromide was treated with 30 g of 10% AlBr graphite intercalate. After a contact of 24 hours at room temperature and atmospheric pressure, the two mixtures were filtered, washed with a 3% sodium bicarbonate solution, dried and analyzed by vapor phase chromatography, the fractions being identified by mass spectrometry. The results obtained are as follows:  
  We claim: 1. In a process for the synthesis of substituted aromatic hydrocarbon by the reaction of an unsaturated aliphatic hydrocarbon or a halogenated aliphatic hydrocarbon with an aromatic hydrocarbon, the improvement which comprises carrying out the reaction in the presence of a graphite intercalated Lewis acid selected 5 from the group consisting of aluminum chloride, aluminum tribromide and ferric chloride thereby to yield a reaction mixture containing a higher percentage of mono and disubstituted aromatic hydrocarbon than is obtained when using the Lewis acid alone.  
  2. The process of claim 1, wherein the reaction is carried out in the presence of aluminum trichloride intercalated in graphite, the amount of aluminum trichloride being up to about 35% by weight of graphite.  
  3. The process of claim 1, wherein the reaction is car ried out in the presence of aluminum tribromide intercalated in graphite, the amount of aluminum tribromide being up to about 35% by weight of graphite.  
  4. The process of claim 1 wherein the aromatic hydrocarbon is reacted with an alkene having two to 18 carbon atoms or an alkyl halide having two to five carbon atoms and wherein the halogen is chlorine or bromine.  
  5. The process of claim 4, wherein the aromatic hydrocarbon is benzene, toluene, xylene, naphthalene or biphenyl.  
  6. The process of claim 5 wherein the alkene is ethylene, propylene or isobutylene and the alkyl halide is