Process for preparing 3,5-dialkyl phenols
United States Patent Norell Apr. 15, 1975 PROCESS FOR PREPARING 3,5-DIALKYL PHENOLS. Primary ExaminerLeon Zitver [75] Inventor: John R. Norell, Bartlesville, Okla. Amsmnt Exammer NormanMorgenstem [73] Assignee: Phillips Petroleum Company,  
 Bartlesville, Okla. ABSTRACT [22] Filed: June 5, 1972 A process for preparing 3,5-dialkyl phenols is provided. In one embodiment an ortho-, para-, or meta- [211 Appl&#39; 259561 monoalkyl phenol is caused to isomerize and/or disproportionate to the 3,5-dialkyl phenol in reaction [52] US. Cl 260/624 R; 260/621 D; 260/624 E medium comprising liquid hydrogen fluoride. In an- [51] Int, Cl... C07c 37/14; (307 37/16; C07 37/13 other embodiment the 3,5-dialkyl phenol is obtained [58 Field of Search 260/621 D, 624 c, 624 E, y contacting Phenol with an alkylafing agent Selected 260/626 R 624 R from tertiary alcohols, tertiary alkyl halides, and olefins in a reaction medium comprising liquid hydrogen [56] References Cited fluoride.  
 UNITED STATES PATENTS 10/1967 Alul et al. 260/624 C X 4 Claims, No Drawings PROCESS FOR PREPARING 3,5-DIALKY PI-IENOLS BACKGROUND OF THE INVENTION In one aspect, this invention relates to a process for isomerizing and/or disproportionating alkyl phenols. In yet another aspect, this invention relates to a process for alkylating phenols.  
  Heretofore, 3,5-dialky1 phenols have not been readily obtained. The prior art procedures normally involve inconvenient, multi-step processes. One such process is described in U.S. Pat. No. 3,308,165. Another such process is described in the Canadian Journal of Chemistry, 41, 1653 (1963).  
 Although it is known in the prior art that phenol can be alkylated directly, no successful alkylation resulting in 3,5-dialkyl phenol has been reported. However, the isomerization and transalkylation of tert-butylphenols on Type Y Zeolite catalysts to a mixture of dialkyl phenols in which the 3,5-dialkyl phenol predominates has been reported by Bolton, et al, in J. Org. Chem., 33. 3415 (1968).  
 SUMMARY OF THE INVENTION It is an object of this invention to provide 3,5-dialkyl phenols by an improved process.  
  In accordance with the object of this invention, it has been found that a 3,5-dialkyl phenol can be obtained by isomerizing and/or disproportionating an ortho-, meta-, or para-substituted monoalkyl phenol in a reaction medium comprising liquid hydrogen fluoride.  
  Further in accordance with this invention, it has been found that a 3,5-dialkyl phenol can be obtained by contacting phenol with an alkylating agent selected from tertiary alcohols, tertiary alkyl halides and olefins in a reaction medium comprising liquid hydrogen fluoride.  
 DESCRIPTION OF THE PREFERRED EMBODIMENT According to one presently preferred embodiment of this invention, 3,5dialkyl phenols can be obtained by contacting a monoalkyl phenol in a reaction medium comprising liquid hydrogen fluoride. The monoalkyl phenol undergoes isomerization and/or disproportionation to the desired 3,5-dialkyl phenol.  
  The monoalkyl phenols suitable for use in this invention can be either the ortho-, meta-, or para-isomers of the alkyl phenol. Best yields are obtained using alkyl phenols having a tertiary carbon atom attached to the aromatic ring. For that reason, tertiary alkyl phenols are preferred.  
  Generally speaking, any tertiary alkyl phenol will be suitable. However, the lower tertiary alkyl phenols of the formula dialkyl phenol according to the following scheme.  
 R(IR d- CR The isomerization-disproportionation&#39; can be carried out by dissolving the monoalkyl phenol in liquid hydrogen fluoride. The amount of hydrogen fluoride relative to the amount of monoalkyl phenol may vary over a wide range. Sufficient hydrogen fluoride should be employed to dissolve the phenol and maintain the reaction mixture in a liquid state until reaction is complete. Normally a mole ratio of hydrogen fluoride to monoalkyl phenol varying over the range 5:1 to 100:1 will be suitable. It is preferred, however, to use a mole ratio varying over the range from 15:1 to 50:1.  
  If desired, a cosolvent can be employed. Normally however, this is not preferred except in those cases when the mole ratio of hydrogen fluoride to monoalkyl phenol is less than about 15:1. Solvents which can be employed in this manner should be stable in the presence of liquid hydrogen fluoride. One such suitable solvent is sulfur dioxide.  
  The reaction may be conducted over a wide temperature range. However, below about 40C reaction rates may be relatively low. Above about 100C the phenol reactant and products are degraded by hydrogen fluoride. Therefore, it is preferred to conduct the reaction at an intermediate temperature range varying from about 0C to C.  
  The reaction should be conducted in a liquid phase. If necessary, the reaction can be run in a pressurized reactor at a pressure sufficient to maintain the reactants in the liquid state. The selection ofa suitable reactor and pressure conditions is considered to be well within the skill of one in the art.  
  The reaction time can vary according to the nature of the reactants, temperature and other reaction variables. Normally, 5 minutes to 24 hours will be suitable. In most cases a reaction time of 15 minutes to 6 hours will insure the desired conversion.  
  In order to demonstrate the&#39;operability of the inven tion, the three tert-butylphenols were treated with liquid hydrogen fluoride. Referring to Table I, there isshown the effect of contacting ortho-, meta-, and paratert-butylphenol with liquid hydrogen fluoride over a wide temperature range.  
 TABLE I tert-BUTYLPHENOL ISOMERIZATION Phenolic Distribution Distribution tert Temp, 7( Recovery Heavies, Monoof Mono-TBP Run Butylphenol C of Phenols 7a Phenol t-Bu Di-t-Bu&#34; ortho meta para 1 ortho 75 90+ 2.4 91.8 5.8 97.4 0 2.4 2 40 90+ 0 2.9 97.1 0 0 0 100 8 meta 75 90+ 0 O 100 0 O 91.0 9.0 9 40 90+ 0 2.6 97.4 0 0 96.7 3.3 10 -5 90+ 0 4.9 86.9 8.1 0 96.7 3.3 11 30 87 tr. 11.5 61.6 26.9 0 98.2 1.8 12 55 81 3 24.8 18.2 57.0 0 86.3 13.7 13 75 77 11 29.9 19.4 42.1 0 83.0 17.0 14 100 51 28 100 tr. 0 0 52.9 47.1 15 para 75 90+ 0 0 100 0 O 0 100 16 40 90+ 0 1.9 97.8 0.2 0 0 100 17 -5 90+ tr. 8.7 77.0 14.2 0 18.3 81.7 18 73 22 25.6 22.1 52.3 0 86.0 14.0 19 55 61 30 36.9 22.1 41.0 1.5 84.1 14.4 20 75 57 45.2 22.4 32.4 2.7 80.4 17.0 21 100 54 22 88.2 11.7 0 74.5 0 25.5  
  All runs were made with 15 grams of tert-butylphcnol in 100 ml HF for 2 hours.  
  If the amount of rnono-tert-BuPhOH is low. the distribution of urtho-mcta-para is probably meaningless.  
 The dialkylatcd phenol is chiefly the 3.5-isomcr.  
 Starting purity of mcta-terbhutylphenol was 91 per cent meta and 9 per cent para.  
  It can be readily seen that all three isomers of tertbutyl phenol can be converted to 3,5-di-tert-butyl phenol according to the process of this invention (see runs 3-7, 10-13 and 17-20). At a temperature of about &#34;C or below, low or no conversion of the starting phenol to 3.5-di-tert-butyl phenol occurs (see runs 1, 2, 8, 9, l5 and 16). At a temperature of about 100C, the recovery of phenolic materials is significantly reduced.  
  From these data it appears that the orthoand paraisomers are first isomerized to the meta-isomer which disproportionates by a transalkylation reaction to form the 3,5-isomer (see runs 4 and 18).  
  In another embodiment of this invention, 3,5-dialkyl phenols are obtained by contacting phenol with an alkylating agent selected from tertiary alcohols, tertiary alkyl halides and olefins in a reaction medium comprising liquid hydrogen fluoride. If an olefin is employed as the alkylating agent, it is preferred that it be capable of forming a tertiary carbonium ion in the presence of hydrogen fluoride.  
 Preferred alkanols and alkyl halides have the formula wherein X can be OH or a halogen selected from F, Cl.  
  bromohexane, 3-isopropyl-3-chloropentane, tert-butyl ene,  
 fluoride, tert-amyl fluoride, and the like.  
 Preferred olefin alkylating agents have the formula wherein R is defined as above.  
  The mole ratio of alkylating agent to phenol can vary over a wide range. Generally, a ratio varying over the range from about 1:1 to 5:1 will be suitable. it is preferred to use a mole ratio varying from about 1.521 to 3:1.  
  The amount of hydrogen fluoride employed in the reaction medium can vary over a wide range. Generally, it will also be used as the reaction solvent. A mole ratio of hydrogen fluoride to phenol varying over the range 5:1 to :1 will normally be suitable. it is preferred to use a mole ratio varying over the range to 50:1.  
  At low ratios of hydrogen fluoride to phenol, cosolvents not reactive towards hydrogen fluoride can be employed. One such solvent is sulfur dioxide. However, it is preferred to use hydrogen fluoride as the only solvent.  
  The reaction can be conducted over a wide temperature range. Suitable temperatures may vary from 80C to +80C. Below about 40C, reaction rates are relatively low, but alkylation does occur. The mixture can then be warmed to a temperature where the disproportionation can occur. When the temperature is above about 100C, degradation of the phenolic mate- &#39;rials occurs and for that reason it is preferred not to exceed about 80C. When the alkylating agent is an olefin, it is preferred to admix the reactants below 0C and allow them to warm above 0C. This minimizes the formation of heavy side products resulting from the olefin Eundergoing polymerization.  
 When the reaction temperature is to be maintained.  
  at a temperature above the atmospheric boiling point of hydrogen fluoride, the reaction should be conducted &#39;in a suitable pressurized vessel in order to maintain the reactants in the liquid phase.  
 The reaction can be conducted for any period of time 25C. When alkylation is complete there will be normally a mixture of orthoand para-substituted alkyl phenols. The temperature is then lowered (to about 78C) and additional hydrogen fluoride added to effect the isomerization and/or disproportionation. The additional hydrogen fluoride will be an amount sufficient to bring it into the range where isomerization and disproportionation occurs. From this point the reaction is run just as in the prior description of this embodiment.  
  In yet another alternative method, a metasubstituted alkyl phenol can be contacted with an alkylating agent in the presence of the hydrogen fluoride solvent. Utilizationof meta-alkyl phenol feedstock has the advantage of minimizing olefin polymerization during the course of the conversion to the 3,5-dialkyl phenol.  
  Referring now to Table II, there is provided a summary of reaction runs involving the alkylation of phenol in the presence of hydrogen fluoride in order to obtain the 3,5-dialkyl phenol.  
  The runs in Table II were conducted by varying a variety of reaction parameters. It can be seen from the Table that the reactants may be admixed in any convenient order (see runs 7 and l l By comparing runs 6 and 7 the effect of temperature can be seen. In run number 6 wherein the contacting occurred at 78C, alkylation occurred but no 3,5-di-tert-butyl phenol was formed. However, in run number 7 wherein the temperature was allowed to increase from 78C to 55C an appreciable amount of 3.5-di-tert-butyl phenol was TABLE IL-ALKYLATION OF PHENOLS 2. Iso- Product distribution a 1 Phenol butylene 3. HF Run Order of Temp., Time, Crude Meta- Para- 3, 5 2, 4- Percent No. G. Mole G. Mole G. Mole addition 0. hr Wt. Phenol TB P TB P Di-TB P Di-TBP heayies 1 18. 8 0. 26. 0 0. 23 100 5. 0 1, 3, 2 0 2 38. 6 4. 1 9. 0 17. 1 2 l2. 0 0. 13 30. 0 0. 54 100 5. 0 1,3, 2 3 32. 7 42. 6 34. 0 3 18. 8 0. 20 33. 0 0. 59 100 5. 0 l, 3, 2 70 2 40. 1 Trace 0 1. 0 4 L 18. 8 0. 20 36. 0 0. 64 100 5. 0 1, 3, 2 70 0. 7 47. 0 0. 6 0 5 B. 15. 0 0. 16 25. 0 0. 100 5. 0 1, 3, 2 70- 25 2 32. l 25. l 12. 0 9. 2 6 18. 8 0. 20 33. 0 0. 59 130 6. 5 3, 2, 1 -78 2 44. 5 3. 4 10. 8 7 18. 8 0. 20 22. 5 0. 40 125 6. 2 3, 2, 1 78 55 2 35. 2 45. 2 17. 5 10. 1 8 9. 4 0. 1 11. 2 0. 2 4 0. 2 1, 2, 3 -75 2 16. 6 Trace 0. 3 2. 2 9 9. 4 0. 1 11. 2 0. 2 4. 0 0. 2 1, 3, 2 55 2 19. 0 Trace Trace 10 9. 4 0. 1 11. 2 0. 2 104 5. 2 1, 3, 2 78 25 2+ 18. 1 27. 1 16. 1 12. 2 11 &#34;L 15. 0 0. 16 11. 2 0. 20 104 5. 2 1, 3, 2 78- 25 3+ 22. 0 17. 6 14. 3 10. 8 19. 8 12 L 18. 8 0. 2 29. 6 0. 42 100 5. 0 1, 3, 2 55 2 34. 0 34. 6 24. 5 8. 8 7. 7  
  (t-butanol) 13 9.4 0.1 18.5 0.2 100 5.0 1,3,2 0 2 17.5 3.0 12.2 53. 1 20.7 11.0 14 23. 0 0. 24 27. 5 0. 49 10 (Zeolon H) 1, 3, 2 150 2 38. 5 29. 7 7. 9 40. 3 22. 0 Trace 15.-. 47.0 0. 5 23.0 0. 5 1. 0 05 61 3 98.2 1. 8 16 47.0 0.5 68.5 1.22 1.0 65 3 10.5 17 15. 0 0. 16 20. 0 0. 36 50. 0 30 1. 25 4. 1 5. 4 18 15. 0 0. 1 6. 0 0. 1 100 0 2 20. 2 0 43. 0  
 (Meta-TB TBP represents tert-butylphenol.  
 b Percent heavies not determined.  
 &#34; Contained 0.7 wt. percent unknown.  
  C4Hs bubbled in over a 2-hour period.  
  B CiHa bubbled in at 25 C. Product was shaken 2 hrs. with 10% NaOH and 30.8 g. of neutrals were obtained. Only 1.3 g. of phenols were recovered.  
 f C4H8 bubbled in over a period of ca. 1 hour.  
 8 Reactants mixed at 78 and allowed to warm to 25 0 t 117 8rgiirture of phenol in HE was added to a mixture of CJHH in HF a f Run as above except warmed to 55 C.  
 1 A mixture of C4HB and HF was added to phenol. Product solidified.  
  S02, 100 ml., was used as a solvent.  
  I lation the temperature can be allowed to warm to about 1 Phenol and 4 ml. HF were mixed at 78 0., GAHB was added and allowed to stand 1 hour, m1. HF was added, stirred 1 hour at 78 C. then warmed to room temperature.  
  In The percent heavies as determined by internal standards. Phenol and 4 ml. HF were mixed at 78&#34; 0., CiHs was added and the reactor was shaken at 25 C. for 1 hr. (Rapid exotherm at 2545 C.) After cooling to 78&#34;, 100 ml. HF was added and the mixture was again warmed to 25 C. for 2 hrs.  
 11 May be additional heavies present.  
 0 May be additional heavies present.  
  Benzene (50 ml.) solvent, pressure at fell from 1525-35 during reaction. The 7.9% ascribed could possibly be orthoIBP.  
 q Catalyst was BFa.  
 ,&#39; Alkylating agent is t-butyl chloride.  
 formed. This is noted in other reaction runs throughout the Table, e.g., runs 5, l0 and ll.  
  Runs 12 and 13 show the effect of using tert-butanol or tert-butyl chloride as the alkylating agent rather than an olefin such as isobutylene. The use of these agents has the advantage that unlike an olefin, they do not polymerize as extensively in liquid hydrogen fluoride.  
  Runs 8 and 9 show the effect of using only a limited amount of hydrogen fluoride. As can be seen, alkylation occurs but no 3,5-dialkyl phenol was detectable in the product mixture. It is to be noted that S was used as the solvent in run 9.  
  Runs and 16 were conducted to demonstrate that prior art methods of alkylating phenol do not result in the 3,5-dialkyl phenol. It is reported by Habibi in U.S. Pat. No. 3,449,444 that dialkyl phenols can be obtained by alkylating phenol in the presence of boron trifluoride and similar catalysts. An examination of this reaction with isobutylene as the alkylating agent shows that a dialkyl phenol is formed but not 3,5-dialkyl phenol. ln this case the dialkyl phenol formed is 2,4-di-tertbutyl phenol (Run 15 When hydrogen fluoride is used in a catalytic amount according to the conditions described in Habibi no dialkyl phenol is detectable (Run 16).  
  Run number l4 represents an attempt to use an acidic clay (Zeolon H) as the acidic component. However, no 3,5-di-tert-butyl phenol is formed although some 2,4-di-tert-butyl phenol was obtained.  
  Runs 10 and ll demonstrate the effect of first contacting isobutylene and phenol with a limited amount of hydrogen fluoride, allowing alkylation to occur and then adding a solvent quantity of hydrogen fluoride for isomerization-disproportionation.  
  Run number 18 demonstrates the effect of contacting meta-tert-butylphenol with isobutylene in the presence of hydrogen fluoride. In this way, the best overall con-- version to the 3,5-dialkyl phenol was obtained.  
 EXPERIMENTAL Apparatus All reactions above 0C.were carried out in a 300 ml Monel vessel equipped with a pressure gauge and Hoke valves. Heating and mixing were supplied by shaking the reactor in an Eberbach thermostated reciprocating shaking water bath. For reactions at or below 0C, a polyethylene vessel was constructed (450 ml capacity) with two openings so that a thermometer could be inserted into the liquid. The reactor was placed in a coolant at the desired temperature and magnetically stirred.  
 General Procedure for Isornen&#39;zation Reactions (Table 1) Standard Procedure for Reactions Above 0C The monoalkyl phenol was placed in a 300 ml Monel reactor cooled in ice under a N flow. Liquid hydrogen fluoride was added, the reactor capped and placed in the shaker bath at the desired temperature. After the allotted time, the reactor was cooled, the valve opened and the HF bled off. The reactor was opened and the reaction mixture was poured on ice water, neutralized with NaHCO and extracted with ether. After drying over MgSO -K CO mixture, the extracts were concentrated to give a crude phenol mixture, which was analyzed by gas chromatographic techniques.  
 Standard Procedure for Reaction Below 0C The 450 ml Marlex polyethylene reactor containing liquid HF was cooled in a suitable coolant until the desired temperature was reached. The monoalkyl phenol was added and stirred magnetically for the allotted time. The entire mixture was poured on ice, neutralized with NaHCO and extracted with ether. After drying, the extracts were concentrated to give a crude phenol mixture which was analyzed by gas chromatography.  
  General Procedure for Alkylation-Disproportionation Reactions (Table ll) The reactants were mixed in the order recorded in column 8 (Order of Addition) of Table II in either the Monel or polyethylene reactor. lsobutylene was usually added slowly through a Gilmont gas flowmeter in the gaseous phase. The reactor was then shaken or stirred for the alloted time at the specified temperature. The 5 contents were poured on ice, ether extracted and the combined ether extracts were neutralized by shaking with saturated NaHCO;, solution. After drying over MgSO the product was concentrated and analyzed by gas chromatographic techniques.  
  The 3,5-dialkyl phenol can be isolated by techniques well known to those skilled in the art. Suitable techniques include distillation, recrystallization, sublimation, solvent extraction, and column chromatography.  
  The 3,5-dialkyl phenols that may be obtained according to this invention are useful in a variety of ways. For example, they are useful as antioxidants in gasolines, lubricating oils and synthetic polymers such as in synthetic rubbers. They are also useful in the preparation of phenol-aldehyde resins.  
 I claim:  
  1. A process for preparing 3,5-dialkyl phenols which comprises:  
 a. forming a reaction mixture comprising phenol, an alkylating agent selected from the group consisting of (l) tertiary alkanols and tertiary alkyl halides having the formula X-C-R v wherein X is selected from the group consisting of OH, Cl, Br or I and each R can be the same or different and is selected from straight or branch chain alkyl groups and a total number of carbon atoms in the alkanol or alkyl halide is from 4-8 and (2) olefins having the formula wherein each R is selected from hydrogen or straight and branch chain alkyl groups and the total number of carbon atoms in the olefin is from 4-8 with the further proviso that at least two R groups on one olefinic carbon must be alkyl, and liquid hydrogen fluoride as the reaction medium at a temperature of 78C with a mole ratio of alkylating agent to phenol ranging from 1:1 to 5:1 and a mole ratio of hydrogen fluoride to phenol in the range 0.1:1 to 2:1,  
 b. warming said reaction mixture to a temperature of about 25C and allowing said phenol and said alkylating agent to react in said HF reaction medium to form a mixture of monoalkyl phenols,  
 c. allowing the alkylation to proceed to completion and then lowering the temperature to about --78C and adding sufficient additional hydrogen fluoride to the reaction mixture to cause isomerization and disproportionation of the mixture of monoalkyl phenols to the 3,5-dialkyl phenols,  
 d. heating the reaction mixture obtained in step (c) to a temperature in the range of about 0C to 80C to obtain said 3,5-dialkyl phenols, and  
 e. recovering 3,5-dialkyl phenols thus produced.  
 2. A process for preparing 3,5-dialkyl phenols which comprises the steps of:  
 a. forming a liquid reaction mixture at a temperature below 0C comprising phenol, an olefin alkylatingl agent having the formula wherein each R is selected from hydrogen or straight and branch chain alkyl groups and the total number of carbon atoms in the olefin is from 4-8 with the further proviso that at least two R groups on one olefinic carbon must be alkyl, and solvent quantities of liquid hydrogen fluoride as the reaction medium with a mole ratio of alkylating agent to phenol ranging from 1:1 to 5:1 and a mole ratio of hydrogen fluoride to phenol ranging from 5:l to 100:1 and b. warming the reaction mixture thus formed to a temperature above 0C and allowing said phenol and said alkylating agent to react in said liquid hydrogen fluoride reaction medium at a temperature in the range of 0C to 80C and form 3.5-dialkyl phenols. 3. A process according to claim 2 wherein the alkylating agent is isobutylene.  
 4. A process for preparing 3,5-di-tert-butyl phenol which comprises:  
 a. forming a reaction mixture comprising phenol, isobutylene, and liquid hydrogen fluoride as the reaction medium at a temperature of 78C with a mole ratio of isobutylene to phenol ranging from 1:1 to 5:1 and a mole ratio of hydrogen fluoride to phenol in the range 0.1:1 to 2:1,  
 . warming said reaction mixture to a temperature of about 25C and allowing said phenol and said alkylating agent to react in said HF reaction medium to form a mixture of monoalkyl phenols,  
 . allowing the alkylation to proceed to completion and then lowering the temperature to about 78C and adding additional hydrogen fluoride to the reaction mixture sufficient to cause isomerization and disproportionation of the mixture of monoalkyl phenols to the 3,5-di-tert-butyl phenol,  
 d. heating the reaction mixture to a temperature in the range of about 0C to 80C to obtain said 3,5-  
 di-tert-butyl phenol,  
 e. recovering 3,5-di-tert-butyl phenol thus produced.