Seeking Improvement To Alkoxylation Synthesis

A SpecialChem Client is seeking to improve their alkoxylation process by replacing their current traditional Bases with a more selective catalyst. Additionally, they are interested in implementing an innovative technology that could lead to new alkoxylation reaction.

This SpecialChem Client is using a range of well-known traditional catalysts for their alkoxylation synthesis route: NaOH, KOH, NaOMe, KOtBu or DMC (Double Metal Cyanide). These catalysts, used in a broad range of application (mostly Ethoxylation and Propoxylation), have a direct impact on the overall efficiency of the reaction.
The SpecialChem Client is interested in expanding their alkoxylation know-how. Any solutions that yield to proven advantage in a production scale for: cost effectiveness, improvement of end-product quality or robustness, is welcome.

The proposed innovative catalyst must improve at least one of the following:

• Minimize side products from rearrangement reactions.
• Be robust (tolerate amount of sodium/potassium > 20ppm).
• Provide a liquid catalyst or a catalyst in an inert solvent.
• Narrow molecular weight distributions.
• Have an acceptable eco-tox profile and cost, allowing that catalyst remains in the product (benchmark: alkaline catalyst).

The SpecialChem Client is also interested in technology that would improve the following:

• Permits alkoxylation of C-H acid molecules and provides high selectivity.
• Reduced amount of unreacted starting material.
• Improvements in allyl rearrangement products in propoxylation reactions, as well as dioxane management during ethoxylation.
• A technology that allows Ethoxylation/Propoxylation (EO/PO) block copolymers - DMC does not.

The identified solution could be implemented as a standard in all (~10) manufacturing sites of SpecialChem Client within the next few years. Their current consumption is more than 100,000 tons of alkylenoxides per year.

Any or all of the following options are acceptable to meet the success criteria:

• A provider of catalysts with the proof of concept. Note that the SpecialChem Client can perform tests in his own lab, as well as scale-up runs.
• A research institute with proven expertise in alkoxylation could also become a privileged partner.
• Technologies which are able to add EO/PO to C-H acid molecules and lead to a new class of products.

The SpecialChem Client would like to have the freedom to operate with the technology
REACH has to be considered.