The investigation of a side reaction leading to colour formation in a polyurethane production chain

In the industrial synthesis of 4,4’-methylene diphenyl diisocyanate (MDI), an unwanted side reaction between the product and the starting material, 4,4’-methylene dianiline, can lead to the formation of ureas. It has been postulated these ureas undergo further reaction with phosgene to produce a precursor to chlorine radicals, which could then attack the MDI backbone forming conjugated systems that would promote colour in the final products. To investigate this process model compounds including 4-benzylaniline (4-BA) and 1,3-diphenylurea were used as starting materials. The reactions carried out showed the phosgenation of the urea forms a chloroformamidine-N-carbonyl chloride (CCC) which upon heating > 303 K can break down to form an isocyanide dichloride (ID). Conventional synthesis routes were used to gain high yields of p-tolyl and phenyl isocyanide dichlorides in order to analyse the compounds. It was found that upon heating to 453 K or irradiating the isocyanide dichlorides in the process solvent (chlorobenzene) coloured solutions were formed; with the presence of MDI and oxygen increasing the intensity of the colouration. Electron paramagnetic resonance spectroscopy was used to gain information on the use of isocyanide dichlorides as a source of chlorine radicals. Using N-tert-butyl--phenylnitrone (PBN) as a spin trap, an 8 line spectra relating to the chlorine adduct was measured confirming the production of Cl•. Throughout the project side reactions involving the formation of carbodiimide from CCC and a secondary route for the phosgenation of the urea to the isocyanate have been investigated and are presented within a global reaction scheme. It was also found the ureas were only partially soluble in the process solvent leading to research into the structure of three different urea molecules and the proposal of a modified reaction scheme

Structural behaviour of copper chloride catalysts during the chlorination of CO to phosgene

The interaction of CO with an attapulgite-supported Cu(II)Cl2 catalyst has been examined in a micro-reactor arrangement. CO exposure to the dried, as-received catalyst at elevated temperatures leads to the formation of CO2 as the only identifiable product. However, phosgene production can be induced by a catalyst pre-treatment where the supported Cu(II)Cl2 sample is exposed to a diluted stream of chlorine. Subsequent CO exposure at ~ 370°C then leads to phosgene production. In order to investigate the origins of this atypical set of reaction characteristics, a series of x-ray absorption experiments were performed that were supplemented by DFT calculations. XANES measurements establish that at the elevated temperatures connected with phosgene formation, the catalyst is comprised of Cu+ and a small amount of Cu2+. Moreover, the data show that unique to the chlorine pre-treated sample, CO exposure at elevated temperature results in a short-lived oxidation of the copper. On the basis of calculated CO adsorption energies, DFT calculations indicate that a mixed Cu+/Cu2+ catalyst is required to support CO chemisorption

Spectroscopic characterization of model compounds, reactants, and byproducts connected with an isocyanate production chain

Aromatic amines and amine hydrochloride salts play an important part in certain large-scale isocyanate production chains. For the first time, via a combination of periodic-DFT calculations, infrared spectroscopy, and inelastic neutron scattering, this work provides a comprehensive vibrational assignment of 4-benzylaniline (C6H4CH2C6H4NH2), 4,4′-methylenedianiline (H2NC6H4CH2C6H4NH2), and their associated amine hydrochloride salts. Deuterated analogues are additionally utilized to assist vibrational assignments. The heightened awareness of vibrational transitions for these technically relevant reagents and byproducts provides the opportunity to apply infrared spectroscopy as an in-line diagnostic tool within the industrial-scale process operation

Evaluating the activity and stability of perovskite LaMO3-based Pt catalysts in the aqueous phase reforming of glycerol

The aqueous phase reforming of glycerol, to hydrogen, alkanes and liquid phase dehydration/dehydrogenation products, was studied over a series of 1 wt% Pt/LaMO3 (where M = Al, Cr, Mn, Fe, Co, Ni) catalysts and compared to a standard 1 wt% Pt/γ-Al2O3 catalyst. The sol–gel combustion synthesis of lanthanum-based perovskites LaMO3 produced pure phase perovskites with surface areas of 8–18 m2g−1. Glycerol conversions were higher than the Pt/γ-Al2O3 (10%) for several perovskite supported catalysts, with the highest being for Pt/LaNiO3 (19%). Perovskite-based catalysts showed reduced alkane formation and significantly increased lactic acid formation compared to the standard catalyst. However, most of the perovskite materials undergo phase separation to LaCO3OH and respective M site oxides with Pt particle migration. The exception being the LaCrO3 support which was found to remain structurally stable. Catalytic performance remained stable over several cycles, for catalysts M = Al, Cr and Ni, despite phase separation of some of these materials. Materials where M site leaching into solution was observed (M = Mn and Co), were found to be catalytically unstable, which was hypothesised to be due to significant loss in support surface area and uncontrolled migration of Pt to the remaining support surface. In the case of Pt/LaNiO3 alloying between the exsoluted Ni and Pt was observed post reaction

Synergistic ultraviolet and visible light photo-activation enables intensified low-temperature methanol synthesis over copper/zinc oxide/alumina

Although photoexcitation has been employed to unlock the low-temperature equilibrium regimes of thermal catalysis, mechanism underlining potential interplay between electron excitations and surface chemical processes remains elusive. Here, we report an associative zinc oxide band-gap excitation and copper plasmonic excitation that can cooperatively promote methanol-production at the copper-zinc oxide interfacial perimeter of copper/zinc oxide/alumina (CZA) catalyst. Conversely, selective excitation of individual components only leads to the promotion of carbon monoxide production. Accompanied by the variation in surface copper oxidation state and local electronic structure of zinc, electrons originating from the zinc oxide excitation and copper plasmonic excitation serve to activate surface adsorbates, catalysing key elementary processes (namely formate conversion and hydrogen molecule activation), thus providing one explanation for the observed photothermal activity. These observations give valuable insights into the key elementary processes occurring on the surface of the CZA catalyst under light-heat dual activation

The highly surprising behaviour of diphosphine ligands in iron-catalysed Negishi cross-coupling

Iron-catalysed cross-coupling is undergoing explosive development, but mechanistic understanding lags far behind synthetic methodology. Here, we find that the activity of iron–diphosphine pre-catalysts in the Negishi coupling of benzyl halides is strongly dependent on the diphosphine, but the ligand does not appear to be coordinated to the iron during turnover. This was determined using time-resolved in operando X-ray absorption fine structure spectroscopy employing a custom-made flow cell and confirmed by 31P NMR spectroscopy. While the diphosphine ligands tested are all able to coordinate to iron(II), in the presence of excess zinc(II)—as in the catalytic reaction—they coordinate predominantly to the zinc. Furthermore, combined synthetic and kinetic investigations implicate the formation of a putative mixed Fe–Zn(dpbz) species before the rate-limiting step of catalysis. These unexpected findings may not only impact the field of iron-catalysed Negishi cross-coupling, but potentially beyond to reactions catalysed by other transition metal/diphosphine complexes

Operando XAFS investigation on the effect of ash deposition on three-way catalyst used in Gasoline Particulate Filters and the effect of the manufacturing process on the catalytic activity

Platinum group metals (PGM) such as palladium and rhodium based catalysts are currently being implemented in Gasoline Particulate Filter (GPF) autoexhaust aftertreatment systems. However, little is known about how the trapped particulate matter, such as the incombustible ash, interacts with the catalyst and so may affect its performance. This operando study follows the evolution of the Pd found in two different model GPF systems: one containing ash components extracted from a GPF and another from a catalyst washcoat prior to adhesion onto the GPF. We show that the catalytic activity of the two systems vary when compared with a 0 g ash containing GPF. Compared to the 0 g ash sample the 20 g ash containing sample had a higher CO light off temperature, in addition, an oscillation profile for CO, CO2 and O2 was observed, which is speculated to be a combination of CO oxidation, C deposition via a Boudouard Reaction and further partial oxidation of the deposited species to CO. During the ageing procedure the washcoat sample reduces NO at a lower temperature than the 0 g ash sample. However, post ageing the 0 g ash sample recovers and both samples reduce NO at 310 circleC. In comparison, the 20 g ash GPF sample maintains a higher NO reduction temperature of 410 circleC post ageing, implying that the combination of high temperature ageing and presence of ash has an irreversible negative effect on catalyst performance

Adsorption and activation of molecular oxygen over atomic copper(I/II) site on ceria

Supported atomic metal sites have discrete molecular orbitals. Precise control over the energies of these sites is key to achieving novel reaction pathways with superior selectivity. Here, we achieve selective oxygen (O2) activation by utilising a framework of cerium (Ce) cations to reduce the energy of 3d orbitals of isolated copper (Cu) sites. Operando X-ray absorption spectroscopy, electron paramagnetic resonance and density-functional theory simulations are used to demonstrate that a [Cu(I)O2]3− site selectively adsorbs molecular O2, forming a rarely reported electrophilic η2-O2 species at 298 K. Assisted by neighbouring Ce(III) cations, η2-O2 is finally reduced to two O2−, that create two Cu–O–Ce oxo-bridges at 453 K. The isolated Cu(I)/(II) sites are ten times more active in CO oxidation than CuO clusters, showing a turnover frequency of 0.028 ± 0.003 s−1 at 373 K and 0.01 bar PCO. The unique electronic structure of [Cu(I)O2]3− site suggests its potential in selective oxidation