A process concept that exploits CXLs to intensify hydroformylation reactions was recently demonstrated.[1] When dense CO2 is used to partially replace the excess substrate (1-octene) to create a CO2-expanded liquid (CXL) phase, the 1-octene hydroformylation turnover frequency (~300 h-1) and the selectivity towards the linear aldehyde (~90%) are significantly enhanced relative to the reaction in neat media. Further, these enhancements occur at mild pressures (~40 bar) and temperatures (60°C). Preliminary economic analysis indicates that near-quantitative (>99.8%) recovery of the Rh-based catalysts is essential for commercial viability.[2] Toward this end, soluble polymer supported bidentate phosphite ligands for hydroformylation of higher (> C4) alkenes have been developed and evaluated. The efficient separation and recycle of homogeneous rhodium catalyst complexes from reaction mixtures is attempted by using membrane filtration technology in a high-pressure filtration cell equipped with cross-linked asymmetric polyimide nano- and ultra- filtration membranes. Experiments with the catalyst complex dissolved in pure toluene revealed a Rh loss in the permeate of less than 1% while no P was detectable in the permeate. Similar measurements at actual hydroformylation conditions are ongoing. The effects of dissolved CO2 (in the CXL media) on the solution viscosity and the permeate flux will be discussed. In addition, results on the recyclability and durability of polymer supported rhodium catalyzed 1-octene hydroformylation in CXLs will be presented.
[2]. J. Fang, H. Jin, T. Ruddy, K. Pennybaker, D. Fahey and B. Subramaniam, "Economic and Environmental Impact Analyses of Catalytic Olefin Hydroformylation in CO2-Expanded Liquid (CXL) Media," Industrial and Engineering Chemistry Research, 46, 8687-8692 (2007).