PROCESS FOR PREPARING 1,3-CYCLOHEXANEDIONE DERIVATIVES AND INTERMEDIATES THEREFOR

Abstract: Process for preparing alpha, beta-unsaturated ketones and 1,3-cyclohexanedione derivatives. The 1,3-cyclohexanedione derivatives are useful as intermediates for pesticides especially herbicides.

Description: PROCESS FOR PREPARING 1,3-CYCLOHEXANEDIONE DERIVATIVES AND INTERMEDIATES THEREFOR BACKGROUND OF THE INVENTION This invention relates to a process for prepar¬ ing alpha, eta-unsaturated ketones and substituted 1,3-cyclohexanediones. The aforementioned compounds are useful as intermediates for medicaments and pesticides, especially herbicides. For example, the alpha,beta-unsaturated ketones are useful for preparing the 2-oximino-5-substituted- cyclohexane-1,3-dione class of herbicides via the following known reaction route RR 1 C = C 0 wherein R is a variety of organic residues, R is hydrogen or organic residue, R a is lower alkyl, R c is lower alkyl, R is alkyl, alkenyl, haloalkenyl, etc.; X is cyano, nitro or -COOR , wherein R b is lower alkyl. Such herbicides are, for example, described in U.S. Patents Nos. 3,950,420; 3,989,737; 4,011,256; 4,249,937; 4,334,913; 4,440,566; 4,422,864; German Patent Applications DE 3219315; DE 3227332; DE 3227389; European Patent Application Publication 046860 and published Japanese Patent Application J51013755 (Derwent Abstract No. 21456X/12). U.S. Patent No. 4,355,184 describes a process for preparing alpha,beta-unsaturated ketones via the reac¬ tion of an aldehyde with an alkali metal salt of aceto- acetic acid in the presence of an aliphatic secondary a ine in a mixed heterogeneous solvent system. Based on the art description given in U.S. Patent No. 4,355,184, the synthesis of alpha, eta-unsatu¬ rated ketones via the aldol condensation of aldehydes and acetone is described in Ber. 40, 4764 (1907). Indian J. Che . Vol. 16B, 970 (1978) describes the condensation of aldehydes with ketones in the presence of a piperidine- acetic acid catalyst system. Ber. Vol. 103 2077 (1970) describes the synthesis of alpha, eta-unsaturated ketones via the reaction of an aldehyde with ittig reagent. Acta. Chem. Scand. v. 17, 2216 (1963) describes the pro- duction of such ketones via the decomposition of alpha,beta-unsaturated-beta'-ketoic esters with heat in the presence of p-toluene sulfonic acid. U.S. Patent No. 2,108,427 describes the synthesis of alpha,beta-unsatu¬ rated ketones via the reaction of an aldehyde with a diketene. German patent 840,090 describes a procedure for preparing unsaturated ketones by dehydrating beta-hydroxy ketones to the corresponding unsaturated ketones, by heat¬ ing in the presence of oxalic acid in aqueous medium. Japanese Patent No. 55-141429, teaches the pre¬ paration of beta hydroxy ketones, by the reaction of an appropriately substituted aldehyde with sodium aceto- acetate in methanol in the presence of a tertiary amine. The resulting product, after acidification, is 2-keto-4- hydroxy-6-ethylthioheptane. SUMMARY OF THE INVENTION The present invention provides an improved pro- cess for preparing alpha,beta-unsaturated ketones, 5-substituted-l,3-cyclohexanediones and 4,5-disubstituted- 1,3-cyclohexanedione. The aforementioned substituted 1,3- cyclohexanediones are the next step intermediates in the production of the 2-oximino cyclohexane-l,3-dione herbicides described above. The present process for preparing an alpha,beta- unsaturated ketone product mixture comprises reacting the appropriate aldehyde (RCHO) or ketone [RC(0)R 1 ] with an acetoacetate salt in the presence of a tertiary amine to yield the corresponding 4-substituted-4-hydroxyalkan-2- one. This product is in turn dehydrated to yield the corresponding alpha,beta-unsaturated ketone product mixture. A further aspect of the invention comprises contacting the alpha,beta-unsaturated ketone crude product of my process with a substituted acetate ester and a metal alkoxide under reactive conditions resulting in the pro¬ duction of high yields of 5-substituted-l,3-hexanedione-4- carboxylate derivatives which can then be optionally decarboxylated to yield the corresponding 5-substituted- 1,3-cyclohexanedione. The invention will be further described herein- below. FURTHER DESCRIPTION OF THE INVENTION AND PREFERRED EMBODIMENTS The present process can be schematically illus¬ trated by the following overall reaction equations: 0 OH 0 ιι I ii RCHO + CH 3 CCH 2 COO " M*- | m) T.A t RCHCH 2 CCH 3 + MHCO3 (A) (B) (C) RCH(OH)CH 2 COCH 3 dehydration ^ RCH=CHC(0)CH 3 + H 2 0 ( 2 ) • (C) (D) wherein R is a substituted or unsubstituted aliphatic or alicylic radical; M is a cation and m is its valence; and T.A. is a tertiary amine. The first step of this process can be effected by contacting aldehyde (A) with acetoacetate salt (B), preferably in an aqueous solution, in the presence of a catalytic amount of a tertiary amine, and optionally in an inert organic solvent, under reactive conditions. Typically, this process is conducted at tempera¬ tures in the range of about from 20 to 65°C, preferably 50 to 55°C, for about from 2 to 8 hours, preferably 2 to 4 hours, using about from 1 to 1.5 moles equivalents, pre- ferably 1 to 1.3 moles equivalents of compound B and 0.01 to 0.1 moles, preferably 0.03 to 0.05 moles, of tertiary amine per mole of compound A. Preferably, the process is conducted at pH's in the range of about from 8 to 10, more preferably about 8.2-8.6. Suitable tertiary amines which can be used include, for example, trialkylamin ' es, e.g., triethyla ine, methyl diethylamine, nitrogen heterocycles, e.g., N-methylpiperidine, pyridine, etc., and the like. Where an inert organic solvent is used, suitable solvents which can be used include, for example, liquid alkanols (e.g., methanol, ethanol, etc.) aromatic hydro¬ carbons, e.g., benzene, toluene, chlorinated hydrocarbons, e.g., methylene chloride, chloroform, alkanes, e.g., hexane, heptane, and the like and compatible mixtures thereof. Also, as before noted an aqueous solution of salt B is preferably used. Typically, the aqueous solu¬ tion has a salt (B) concentration in the range of about 5 to 30, preferably 10 to 15 weight percent. Also, if it is desired to produce an RR 1 C=CHC(0)CH 3 product (D 1 ), wherein R 1 is an organic residue, the corresponding RC(0)R 1 ketone (A 1 ) can be used in the above process in place of aldehyde A. For example, by using acetone, CH 3 (CH 3 )C=CHC(0)CH 3 is produced. However, best results are generally obtained using aldehydes. The aldehyde starting materials (A) and ketones (A' ) are generally known compounds and can in any case be prepared by adapting known procedures using the appropri¬ ately substituted starting materials. As before noted, the R group in compounds A, C, * ] I and D (and also the R group, if a ketone is used) is in effect an organic residue. Typical R and also R ~ ~ groups include for example, alkyl having 1 through 10 carbon atoms, preferably lower alkyl, cycloalkyl having 3 through 7 carbon atoms; (cycloalkyl)alkyl, aryl having 6 through 10 carbon atoms, substituted aryl having 6 through 10 carbon atoms in the aryl moiety and having 1 through 3 substituents independently selected from the group of lower alkyl, lower alkenyl, lower alkoxy, lower alkylthio, halo, haloalkyl having 1 or 2 carbon atoms and 1 through 3 of the same or different halo atoms, and nitro, arylalkyl having 1 through 4 carbon atoms in the alkyl moiety and 6 through 10 carbon atoms; substituted arylalkyl wherein the* alkyl moiety has 1 through 4 carbon atoms and the substi¬ tuted aryl moiety is as defined hereinabove; heterocycle, heterocycle-alkyl having 1 to 4 carbon atoms in the alkyl moiety and wherein the heterocycle moiety has 5- or 6-ring atoms 1 or 2 of which are independently oxygen, sulfur or nitrogen atoms, preferably oxygen or sulfur, and the remainder are carbon atoms; or R is the radical R 5 S(0) n R 4 - wherein R 4 is lower alkylene and R 5 is lower alkyl, lower alkenyl, cycloalkyl as defined hereinabove, or aryl or substituted aryl as defined hereinabove and n is 0, 1 or 2. Where a ketone is used R *** can be independently selected from the group indicated for R or R ~~ and R together with the carbon atom to which they are joined can form a cycloalkylidene having 5- or 6-ring carbon atoms. As above noted with respect to salt B, M is a cation. Preferred M cations are those cations .which yield water soluble salts (B) and include, for example, the cations of alkali metals, e.g., sodium, and potassium, etc. The second step, dehydration, can be effected by contacting compound C with a suitable dehydration catalyst at elevated temperatures, optionally in an inert organic solvent or water. Typically, this process is conducted at tempera¬ tures in the range of about from 60 to 200°C, preferably 80 to 150°C, for about from 1 to 3 hours, preferably 1 to 1.5 hours, using about from 0.03 to 0.15, preferably 0.04 to 0.08 mole equivalents of dehydration catalyst per mole of compound C. The optimum amount of dehydration catalyst can vary with the particular catalyst used but, can be determined by routine experimentation. Typical dehydration catalysts which can be used include, for example, dicarboxylic acids, typically having 3 to 6 carbon atoms, such as for example, oxalic acid, malonic acid, or substituted acetic acids whose pKa values approximate oxalic acid, and the like. I have found that best results are generally obtained using oxalic acid. If desired, this process can be conducted in an inert organic solvent or water. However, very good results are obtained even without a solvent. Where an inert organic solvent is used, suitable solvents which can be used include, for example, aromatic hydrocarbons, for example, toluene, xylene, and the like and compatible mixtures thereof. Best results are generally obtained using no solvent or using toluene or xylene as the solvent. Where the reaction is conducted neat (i.e., without a solvent) , the reaction is preferably conducted at temperatures in the range of about from 100 to 115°C. The process can also be conveniently conducted in toluene- water azeotrope or xylene-water azeotrope in which case the process is preferably conducted at temperatures in the range of about from 85 to 115°C and 90 to 145°C, respectively. The azeotrope is formed by the water which is generated as a byproduct of the dehydration reaction. The present process provides high yields, typically total yields of 90% or better, based on aldehyde A or ketone A 1 , of alpha,beta-unsaturated ketone. Typically, the product is a mix of trans and cis isomer, with the major isomer typically being the trans isomer. The crude reaction product (i.e., the reaction product after removal of solvent) also contains a small amount, generally less than 5 wt. % of ketone adduct, i.e., R O R 1 0 wherein R and R **** are as defined hereinabove. For example, where 6-ethylthiobutrylaldehyde is used, the adduct is 2,6-di(ethylthio)heptan-2-one, The crude reaction product also contains a small amount, typically less than 4 wt. %, of the substituted 4-hydroxybutan-2-one intermediate C. However, neither product detracts from the usefulness of the crude product for the preparation of 1,3-cyclohexanedione derivatives. Because both products in low concentration are converted to the 1,3- cyclohexanedione along with both the cis and trans alpha,beta-unsaturated ketone isomers. It is noted that the 4-hydroxyalkan-2-one intermediate C cannot by itself be used to prepare the cyclohexanedione because the reaction generates byproduct water which would ultimately poison the reaction. However, because of the small amount of intermediate C in the present crude product, the correspondingly small amount of byproduct water generated in the cyclization reaction is easily tolerated by the reaction. Thus, the present process provides an especially useful intermediate for the production of 1,3-cyclohexane- dione derivatives. The 1,3-cyclohexanedione cyclization can be represented by the following overall reaction equation: R 1 0 RC = CHCCH 3 + XCH 2 COOR • a i+ MMi'rO-ιτR*>2 2 > (D) (E) (F) (G) wherein R and R ~ ~ is as defined hereinabove; M' is a cation preferably alkali metal, e.g. sodium; R' and R 2 are independently lower alkyl, X is cyano, nitro or -COOR b , wherein R b is lower alkyl. This process can be effected by contacting prod¬ uct D with compound E and an alkanolate salt (F), prefer¬ ably in an inert organic solvent. Typically, this process is conducted at tempera¬ tures in the range of about from 15 to 70°C, preferably 20 to 40°C, for about from 3 to 10 hours, preferably 3 to 7 hours, using about from 1.0 to 1.5 moles, preferably 1.0 to 1.2 moles of compound E and 1.0 to 1.5 moles, prefer¬ ably 1.0 to 1.2 moles of compound F per mole of compound D mixture. Suitable inert organic solvents which can be used, include, for example, alcohols, e.g., methanol, ethanol, and aromatic hydrocarbons, e.g., benzene and toluene, and the like and compatible mixtures thereof. Suitable substituted acetate ester which can be used, include, for example, dimethylmalonate; methyl cyano- acetate; methyl nitroacetate, and the like. Where it is desired to ultimately produce a product which is unsubsti- tuted at the 4-position, then typically, dimethyl malonate or diethyl malonate is used as they are readily commer¬ cially available, relatively inexpensive, and give good results. Where it is desired to prepare a product which is unsubstituted at the 4-position, it is preferred to prepare the 4-alkoxycarbonyl (i.e., X is -COOR *0 ) compound of formula G. In this case, the 4-substituent can be readily removed by first base hydrolyzing off the alkoxy group, yielding the carboxy group or base carboxy salt, followed by decarboxylation to remove the 4-carboxy group. The base hydrolysis can be conveniently effected by contacting compound G 1 with a base (e.g., sodium hydroxide, potassium hydroxide) typically at a pH of about 12 to 14 and temperatures of 20 to 40°C for about 1 to 3 hours. The resulting product is decarboxylated by contact with an acid (e.g., hydrochloric acid, sulfuric acid, etc.). The reaction is typically conducted at a pH of about from 4 to 4.5 for about from 1 to 4 hours at temperatures in the range of 20 to 100°C. An especially useful and valuable application of this invention is in the production of 2-keto-6-ethylthio- heptene-3 which in turn gives improved yields of 5-substi- tuted- and 4-carboalkoxy-5-substituted cyclohexane-1,3- diones. In some cases, the compounds are also obtained in higher purity. In this aspect, 3-ethylthiobutyraldehyde is reacted with a salt of acetoacetic acid in an inert organic solvent with the pH adjusted within the range of 6 to 9 by the addition of an acid, in the presence of a catalytic amount of a tertiary amine. The resulting crude product is then contacted with a catalytic amount of oxalic acid to produce the desired 2-keto-6-ethylthiohept- 3-ene in high purity and high yield. In a preferred embodiment of this aspect of the invention, the first step of the process is conducted using an aqueous solution of sodium acetoacetate acidified to about pH 8.2-8.6 by the addition of a suitable acid, such as, for example, hydrochloric acid or other mineral acid. An inert organic solvent, for example, methanol or ethanol is added, followed by the addition of a catalytic amount of the tertiary amine. 3-Ethylthiobutyraldehyde is then added slowly while the mixture is stirred at a tem¬ perature in the range of 20 to 25°C. After all the aldehyde has been added and stirred at 20-25°C for about 1/2 to 1-1/2 hours, heating and then heated at 45-55°C for 2 to 4 hours or until analysis shows the reaction to be O 5 90-95% complete. Then a water immiscible solvent, for example, toluene is added followed by concentrated hydro¬ chloric acid to pH of about 4. The aqueous and organic layers are separated. The crude product toluene layer is then mixed with about 5 mole % of oxalic acid based on -~ Q starting aldehyde. The resulting mixture is heated at temperatures ranging from about 85 to 119°C, with azeo- tropic removal of water. The solvent may be optionally codistilled with water so the dehydration is done neat typically with an improved reaction time of less than one - • * 5 hour. This heating is continued until analysis indicates less than 2% of the feed 6-ethylthio-4-hydroxyheptan-2-one remains. Work-up can be effected by dissolution in solvent, e.g., toluene, washing with aqueous sodium bicarbonate followed by azeotropic drying. Finally, the 20 toluene is removed by distillation to leave the crude product. The dehydration step of the instant process can be carried out neat with about 5% of the oxalic acid cata¬ lyst, with no solvent, and at a reaction time of less than 25 one hour. The crude reaction product is a mixture of trans and cis 2-keto-6-ethylthiohept-3-ene. I have found that the crude product after removal of catalyst and drying can be reacted directly with dialkyl malonate, e.g., dimethyl malonate, in the presence of a base, such 0 as sodium methoxide, to give very good yields of 4- carbalkoxy-5-(2-ethylthiopropyl)-cyclohexane-l,3-dione. General Process Conditions In the above-described processes, it is gener¬ ally preferable to separate the respective products before 5 proceeding with the next step in the reaction sequence, except where described as an in situ step or unless other¬ wise expressly stated. These products can be recovered from their respective reaction product mixtures by any suitable separation and purification procedure, such as, 0 for example, extraction, distillation or chromatography. Suitable separation and purification procedures are, for example, illustrated in the Examples set forth hereinbelow. Generally, the reactions described above are conducted as liquid phase reaction and hence pressure is generally not significant except as it affects temperature (boiling point) where reactions are conducted at reflux. Therefore, these reactions are generally conducted at pressures of about from 300 to 3,000 mm of mercury and conveniently are conducted at about atmospheric or ambient pressure. It should also be appreciated that where typical or preferred process conditions (e.g., reaction tempera¬ tures, times, mole ratios of reactants, solvents, etc.) have been given, that other process conditions could also be used. Optimum reaction conditions (e.g., temperature, reaction time, mol ratios, solvents, etc.) may vary with the particular reagents or organic solvents used but can be determined by routine optimization procedures. Definitions As used herein the following terms have the following meanings unless expressly stated to the contrary: The term "lower alkyl" refers to both straight- and branched-chain alkyl groups having a total of from 1 through 6 carbon atoms, preferably 1 through 4 carbon atoms and includes primary, secondary and tertiary alkyl groups. Typical lower alkyls include, for example, methyl, ethyl, n-propyl, isopropyl, n-butyl, t-butyl. The term "lower alkylene" refers to both straight chained and branched chained alkylene groups having 1 through 6 carbon atoms, preferably 1 through 4 carbon atoms and includes, for example, CH 3 -CH 2 - ; -CH 2 -CH 2 -; -CH 2 CH 2 - and the like. The term "lower alkenyl" refers to alkenyl groups having 2 through 6, preferably 2 through 4, carbon atoms and includes, for example, vinyl, 1-propenyl, 2-pro- penyl, 1-methylvinyl, 1-butenyl, 2-methylprop-l-enyl and 05 the like. The term "lower alkoxy" refers to the group -OR 1 wherein R' is lower alkyl. The term "lower alkylthio" refers to the group -SR 1 wherein R' is lower alkyl. ~- -* The term "lower alkoxyalkyl" refers to the group R'OR' '- wherein R' and R 1 ' are independently straight chain or branched chain alkyl groups having 1 through 3 carbon atoms. The term "lower alkylthioalkyl" refers to the * **5 group R'SR 11 - wherein R * and R' ' are independently straight chain or branched chain alkyl groups having 1 through 3 carbon atoms. The term "lower alkoxycarbonylalkyl" refers to the group 20 0 R'OCR' '- wherein R 1 is lower alkyl, preferably having 1 through 4 25 carbon atoms, and R' ' is alkylene having 1 through 4 carbon atoms and can be straight or branched chained. Typical alkoxycarbonylalkyl groups include for example, -CH 2 C(0)OCH 3 ; -CH(CH 3 )C(0)OC 2 H 5 , and the like. The term "halo" refers to the group of fluoro, 30 chloro, bromo and iodo. The term "lower haloalkyl" refers to haloalkyl compounds having 1 through 4 carbon atoms and 1 through 3 halo atoms independently selected from the group of fluoro, chloro, bromo and iodo. Preferably the lower 35 haloalkyl group has 1 or 2 carbon atoms. The term "lower haloalkoxy" refers to "lower alkoxy" groups having 1 through 3 halo atoms independently selected from the group of fluoro, chloro, bromo or iodo. The term "aryl" refers to aryl groups having 6 40 through 10 carbon atoms and includes, for example, phenyl, naphthyl, indenyl. Typically the aryl group will be phenyl or naphthyl as compounds having such groups are more readily available commercially than other aryl com¬ pounds. The term "substituted aryl" refers to aryl groups having 1 through 3 substituents independently selected from the group of lower alkyl, lower alkoxy, halo, nitro, or haloalkyl having 1 through 4 carbon atoms and 1 through 3 halo atoms. Typical substituted aryl groups include, for example, 2-fluorophenyl, 2-chloro- phenyl, 2,6-dimethylphenyl, 4-fluorophenyl, 2-methyl- phenyl, 2-chloro,3-chloromethylphenyl, 2-nitro,5-methyl- phenyl, 2,6-dichlorophenyl, 3-trifluoromethylphenyl, 2- methoxyphenyl, 2-bromonaphth-l-yl, 3-methoxyinden-l-yl, and the like. The term "arylalkylene" refers to the group ArR- 3 - wherein Ar is aryl and R J is alkylene having 1 through 3 carbon atoms and includes both straight-chained and branched-chained alkylenes, for example, methylene, ethyl, 1-meth lethyl, and propyl. The term "(substituted aryl)alkylene" or "ring-substituted arylalkylene" refers to the group Ar'R J - wherein Ar 1 is substituted aryl and R 3 is alkylene as defined with respect to arylalkylene. The term "room temperature" or "ambient tempera¬ ture" refers to about 20-25°C. A further understanding of the invention can be had in the following non-limiting Preparations) and Example(s). Wherein, unless expressly stated to the con¬ trary, all temperatures and temperature ranges refer to the Centigrade system and the term "ambient" or "room temperature" refers to about 20-25°C. The term "percent" or "%" refers to weight percent and the term "mole" or "moles" refers to gram moles. The term "equivalent" refers to a quantity of reagent equal in moles, to the moles of the preceding or succeeding reactant recited in that example in terms of finite moles or finite weight or volume. Where given, proton-magnetic resonance spectrum (p.m.r. or n.m.r.) were determined at 90 mHz, signals are assigned as singlets (s), broad singlets (bis), doublets (d), double doublets (dd), triplets (t), double triplets (dt), quartets (q), and multiplets (m) ; and cps refers to cycles per second. Also where necessary examples are repeated to provide additional starting material for sub¬ sequent examples. Preparation 1 3-Ethylthiobutyraldehyde In this example, 1 mole of ethyl mercaptan was added dropwise to a mixture of 1 mole of crotonaldehyde and 0.005 moles of triethy1amine at room temperature. After about 2 hours the mixture was slightly concentrated by evaporation under vacuum to remove any excess mercaptan and the title compound is afforded as a liquid. Example 1 6-Ethylthio-4-hydroxyheptan-2-one A sodium hydroxide solution containing 50.4 g of sodium hydroxide in 117.6 g.of water was added dropwise to a mixture containing 139.32 g methyl acetoacetate and 168 g of water at room temperature. After addition of the sodium hydroxide solution, the mixture was heated at 35°C for 6 hours affording a solution of sodium acetoacetate. The pH of the sodium acetoacette solution was adjusted to pH 8.3 by the addition of aqueous 9 wt. % hydrochloric acid. 200 ml of methanol was then added followed by the addition of 3 g of triethylamine. The entire 3-ethylthio- butyraldehyde reaction product from Example 1 was then added dropwise and stirred for one hour at room tempera¬ ture. The reaction mixture was heated at 50-55°C over a period of time. During this period, the progress of the reaction was monitored by gas liquid chromatography and recorded in graph area percents. The results of this analysis is recorded in Table 1 hereinbelow. For convenience in recording, the compounds have been assigned the code numbers indicated in Table A. TABLE A Code No, Compound 1 3-ethylthiobutyraldehyde 2 6-ethylthio-4-hydroxyheptan-2-one 3 4,6-di(ethylthio)-heptan-2-one TABLE 1 Gas Liquid Chromatographic Analysis of Reaction Mixture COMPOUND CODE NO. ime o C *l 1 2 3 0 23 100 - - 1 hr. 54 9.3 79.6 1.6 2 hr. 54 4.1 88.8 1.1 2.5 hr. 53 4.3 89.1 1.2 3 hr. 52 3.9 89.9 1.3 3.5 hr. 52 3.2 90.5 1.5 * **■ Temperature of reaction mixture at time sample was taken for gas chromatography analysis. Example 3 6-Ethylthiohept-3-en-2-one In this example, 4.5 g of oxalic acid was added to a solution containing 152.2 g (0.8 mole) of 6-ethyl- thio-4-hydroxyheptan-2-one, prepared according to the procedure of Example 1 in 100 ml of toluene and then refluxed. The progress of the reaction mixture was moni¬ tored by gas chromatography. After reaction was complete, toluene was added and the solution washed with 200 ml of aqueous 2.5 wt. % sodium bicarbonate solution and separated. The toluene solution was azeotropically dried and found to contain 0.784 moles of alpha,beta-unsaturated ketone corresponding to a 98% yield based on the 6-ethylthio.heptan-2-one start¬ ing material. On a solvent-free base the crude product was analyzed by gas-liquid chromatography using external standards as containing 87.3 wt. % 6-ethylthiohept-3-en-2- one (trans and cis isomers); 4.28 wt. % 4,δ-di(ethylthio)- heptan-2-one; 2.02 wt. % 4-hydroxy-6-ethylthioheptan-2- one. Similarly, by applying the procedures of Examples 1 and 2 using the corresponding aldehyde or ketone starting material in Example 1 the following com- pounds can be prepared: 2-keto-6-ethylsulfonylhept-3-ene; 2-keto-6-ethylsulfinylhept-3-ene; 2-keto-3-hexane; 2-keto-4-cyclohexylbut-3-ene; 2-keto-5-cyclopentylpent-3-ene; 2-keto-4-phenylbut-3-ene; 2-keto-4-(2-methylphenyl)but-3-ene; 2-keto-4-(3,5-dichloropheny1)but-3-ene; 2-keto-4-(3-trifluoromethylphenyl)but-3-ene; 2-keto-4-(4-nitrophenyl)but-3-ene; 2-keto-6-ethoxyhept-3-ene; 2-keto-5-(2-methoxyphenyl) ent-3-ene; 2-keto-5-(3-methylthiophenyl)pent-3-ene; 2-keto-5-(4-allylphenyl)pent-3-ene; 2-keto-6-(3-trifluoromethylphenyl)hex-3-ene; 2-keto-5-tetrahydropyran-4-yl)pent-3-ene; 2-keto-5-(1,3-dioxan-2-yl)pent-3-ene; 2-keto-5-(l,3-dithiolan-2-yl)pent-3-ene; 2-keto-5-(thien-2-yl)pent-3-ene; 2-keto-7-(1,3-dioxan-2-yl)hept-3-ene; 2-keto-4-methylpent-3-ene; and 2-keto-3-cyclohexylidene-propane. Example 3 5-( 2-Ethylthiopropyl)-1,3-cyclohexanedione The title compound can be prepared by the following procedure. In this example 124.17 g of dimethyl malonate (0.94 moles) are added to 228.5 g of 25 wt. % sodium methoxide (1.06 moles) in methanol. Crude 6-ethyl- thiohept-3-en-2-one, prepared according to the procedure of Example 2, containing 0.784 moles of active ingredients, is added portionwise to the sodium methoxide solution at 20 to 30°C, over a period of one-half hour. The mixture was stirred at room temperature for 7 hours. During this period conversion to 4-methoxycarbonyl-5-(2- ethylthiopropyl)-l,3-cyclohexanedione is monitored by NMR. 225 ml of water is then added and the mixture then divided into two portions. (a) One portion is acidified to pH 3 with dilute aqueous hydrochloric acid and extracted with methylene chloride. The methylene chloride extracts are combined, dried with magnesium sulfate and evaporated to afford 4- methoxycarbonyl-5-(2-ethylthiopropyl)-1,3-cyclohexanedione as the residue. (b) The other portion of the watered reaction prod¬ uct mixture is treated with an equivalent amount of IN aqueous sodium hydroxide solution at room to hydrolyze off the methoxy group. After hydrolysis is complete, the mix¬ ture is heated to 50-60°C and acidified with aqueous 18 wt. % hydrochloric acid to decarboxylate the 4-position thereby affording the title compound. Similarly, by applying this procedure to the compounds listed in Example 2, the corresponding 5-substi- tuted-4-methoxycarbonyl-l,3-cyclohexanediones can be pre¬ pared. Obviously, many modifications and variations of the invention described hereinabove and below can be made without departing from the essence and scope thereof.

Claims: WHAT IS CLAIMED IS: 05 1. A process for preparing an alpha,beta- unsaturated ketone having the formula: RR 1 C = CHCCH 3 10 (D) wherein R is an optionally substituted aliphatic or alicyclic radical and R 1 is hydrogen or an • j ^ optionally substituted aliphatic or alicyclic radical which comprises the steps of: (a) contacting the corresponding aldehyde or ketone of having the formula RR *** C=0 with an acetoacetate salt in the presence of a catalytic amount of a tertiary amine 20 under reactive conditions thereby yielding the corresponding product having the formula: OH RR 1 C-CH 2 CCH 3 25 (C) wherein R and R are as defined hereinabove, and (b) contacting the product of step (a) with a dehydration catalyst at temperatures in the range of about 0 from 60 to 200°C thereby producing the alpha,beta-unsatu- rated ketone of Formula D. 2. The process of Claim 1 wherein R ~ ~ is hydrogen. 5 3. The process of Claim 1 wherein R is lower alkyl, cycloalkyl having 3 through 7 carbon atoms, lower alkoxy, haloalkyl having 1 or 2 carbon atoms and 1 through 3 of the same or different carbon atoms, aryl having 6 through 10 carbon atoms, substituted aryl having 6 through 10 0 carbon atoms in the aryl moiety and having 1 through 3 substituents independently selected from the group of lower alkyl, lower alkenyl, lower alkoxy, lower alkylthio halo, haloalkyl having 1 or 2 carbon atoms and 1 through 3 of the same or different halo atoms and nitro; arylalkyl having 1 through 4 carbon atoms in alkyl moiety and 6 through 10 carbon atoms in the aryl moiety; substituted arylalkyl wherein said alkyl moiety has 1 through 4 carbon atoms and the substituted aryl moiety is as defined here¬ inabove; monocyclic heterocycle having 5- or 6-ring atoms, 1 or 2 of which are independently oxygen, sulfur and the remainder are carbon atoms; or heterocycle-alkyl wherein the alkyl moiety has 1 through 4 carbon atoms and the heterocycle moiety is as defined above or R is the radical R S(0) n R -, wherein n is 0, 1 or 2, R is lower alkylene; R 5 is lower alkyl, lower alkenyl or cycloalkyl, aryl, substituted aryl, arylalkyl or substituted arylalkyl as defined hereinabove; R 1 is hydrogen or selected from the group of substituents defined for R or R ** - together with R and the carbon atom to which they are joined form a cycloalkylidene group having 5 through 7 carbon atoms. 4. The process of Claim 3 wherein R ~ ~ is hydrogen. 5. The process of Claim 4 wherein R is the radical R S(0) n R - wherein R 4 , R 5 and n are as defined herein¬ above. ° ,6. The process of Claim 5 wherein R ~~ is lower alkyl. 7. The process of Claim 6 wherein R has the formula wherein n is 0, 1 or 2 and R^ is lower alkyl. 8. The process of Claim 7 wherein R is 2-ethylthio- propyl. 9. The process of Claim 1 wherein step (a) is con¬ ducted at temperatures in the range of about from 20 to 65°C using about from 1 to 1.5 moles of said acetoacetate salt per mole of said aldehyde or said ketone. 10. The process of Claim 1 wherein said acetoacetate salt is a water soluble salt and said step (a) is con- ducted in water. 11. The process of Claim 1 which step (a) is conducted in water and a liquid alkanol. 12. The process of Claim 11 wherein said liquid alkanol is methanol. 13. The process of Claim 1 wherein step (b) is con¬ ducted neat at temperatures in the range of about 80°C to 150°C using oxalic acid as said dehydration catalyst. 14. The process of Claim 13 wherein about from 0.04 to 0.08 moles of oxalic acid are used be mole of the reac¬ tion product mixture of step (a). 15. The process of Claim 1 wherein step b is con¬ ducted using oxalic acid as the dehydration catalyst in a toluene-water azeotrope or xylene-water azeotrope at tem¬ peratures in the range 85-115°C and 90 to 145°C, respec- tively. 16. A process for preparing 6-ethylthiohept-2-en-3- one which comprises contacting 3-ethylthiobutyraldehyde with an alkali metal acetoacetate under reaction condi- tions at temperatures in the range of about from 45 to 55°C for about from 2 to 4 hours using about from 1.0 to 1.5 moles of said alkali metal acetoacetate per mole of said 2-ethylthiobutyraldehyde thereby yielding 4-hydroxy- 6-ethylthioheptan-2-one; and (b) contacting the reaction product of step (a) with a catalytic amount of oxalic acid under reactive conditions at temperatures in the range of 80 to 150°C thereby yielding said 6-ethylthiohept-2-en-3- one. 17. The process of Claim 16 wherein step (a) is conducted in water and liquid alkanol. 18. The process of Claim 17 wherein said alkali metal acetoacetate is sodium acetoacetate or potassium acetoacetate. 19. The process of Claim 18 wherein step (b) is conducted using a catalytic amount of oxalic acid in the range of about from 0.04 to 0.08 moles of oxalic acid per mole of 4-hydroxy-6-ethylthioheptane-2-one. 20. A process for preparing a compound having the formula: (G) wherein R is independently lower alkyl, cyclo¬ alkyl having 3 through 7 carbon atoms, lower alkoxy, haloalkyl having 1 or 2 carbon atoms and 1 through 3 of the same or different carbon atoms, aryl having 6 through 10 carbon atoms, substituted aryl having 6 through 10 carbon atoms in the aryl moiety and having 1 through 3 substituents independently selected from the group of lower alkyl, lower alkenyl, lower alkoxy,, lower alkylthio halo, haloalkyl having 1 or 2 carbon atoms and 1 through 3 of the same or different halo atoms and nitro; arylalkyl having 1 through 4 carbon atoms in alkyl moiety and 6 through 10 carbon atoms in the aryl moiety; substituted aryl¬ alkyl wherein said alkyl moiety has 1 through 4 carbon atoms and the substituted aryl moiety is as defined hereinabove; monocyclic heterocycle having 5- or 6-ring atoms, 1 or 2 of which are independently oxygen, sulfur and the remainder are carbon atoms; or heterocycle-alkyl wherein the alkyl moiety has 1 through 4 carbon atoms and the heterocycle moiety is as defined above or the radical R-S(0) n R 4 - for mono¬ cyclic heterocycle, wherein n is 0, 1 or 2, R 4 is lower alkyl; R~~ is lower alkyl, lower alkenyl or cycloalkyl, aryl, substituted aryl, arylalkyl or substituted arylalkyl as defined hereinabove; R ~ ~ is hydrogen or selected from the group of substituents defined for R; or R 1 together with R and the carbon atom to which they are joined form a cycloalkylidene group having 5 through 7 carbon atoms; and X is cyano, nitro or -COOR *0 wherein R **** is lower alkyl; which comprises the step of: (a) contacting the corresponding compound having the formula 0 II RCR 1 wherein R and R 1 are as defined hereinabove with an aceto¬ acetate salt under reactive conditions thereby yielding the corresponding hydroxyketone having the formula RR 1 C(OH)CH 2 C(0)CH 3 wherein R and R~~ are as defined hereinabove. (b) contacting the reaction product of step (a) with a catalytic amount of a dehydrating agent under reactive conditions at temperatures in the range of about from 60 to 200°C thereby yielding a crude reaction product mixture comprising as a major product the corresponding alpha,beta-unsaturated ketone; and (c) contacting the crude reaction product mixture of step (b) with the desired substituted acetate ester and an alkali metal lower alkoxide under reactive conditions at temperatures in the range of about from 20 to 40°C thereby yielding the desired compound of Formula G. 21. The process of Claim 20 wherein R 1 is hydrogen. 22. The process of Claim 20 wherein R is the radical R S(0) n R - wherein R 4 , R 5 and n are as defined in Claim 19 and R 1 is hydrogen. 23. The process of Claim 22 wherein R is 2-ethyl- thiopropyl. 24. The process of Claim 20 wherein step (a) is conducted at temperatures in the range of about from 20 to 65°C using about from 1 to 1.5 moles of said acetoacetate salt per mole of said aldehyde or said ketone. 25. The process of Claim 24 wherein said aceto¬ acetate salt is a water soluble salt and said step (a) is conducted in water and a liquid alkanol. 26. The process of Claim 21 wherein step (b) is conducted neat at temperatures in the range of about 80°C to 150°C using oxalic acid as said dehydration catalyst. 27. The process of Claim 25 wherein about from 0.04 to 0.08 moles of oxalic acid are used be mole of the reac¬ tion product mixture of step (a). 28. The process of Claim 20 wherein said substituted acetate ester is lower alkyl cyanoacetate. 29. The process of Claim 20 wherein said substituted acetate of step (a) is lower alkyl nitroacetate. 30. The process of Claim 20 wherein said substituted acetate of step (a) is lower dialkyl malonate. 05 31. The process of Claim 30 wherein said lower alkyl malonate is dimethyl malonate or diethyl malonate. 32. A process for preparing compounds having the 10 formula: wherein X is cyano, nitro or -COOR" wherein Rr 20 is lower alkyl; which comprises the steps of: (a) contacting 3-ethylthiobutyraldehyde with an alkali metal acetoacetate under reaction conditions at temperatures in the range of about from 20 to 60°C for 2 about from 2 to 8 hours using about from 1 to 1.5 moles of said alkali metal acetoacetate per mole of said 2-ethyl- thiobutyraldehyde thereby yielding 4-hydroxy-6-ethyl- thioheptan-2-one; and (b) contacting the reaction product of step (a) with a catalytic amount of oxalic acid under ~ Ω reactive conditions at temperatures in the range of 60 to 200°C thereby affording a crude 6-ethylthiohept-3-en-2- one. (c) contacting the crude product of step (b) with a di(lower alkyl) malonate and an alkali metal lower ..,- alkoxide under reactive conditions at temperatures in the range of about from 15 to 70°C thereby yielding the com¬ pound of Formula G'. 33. The process of Claim 32 wherein step (a) is 40 conducted in water and liquid alkanol. 34. The process of Claim 33 wherein said alkali metal acetoacetate is sodium acetoacetate. 35. The process of Claim 34 wherein step (b) is conducted using a catalytic amount of oxalic acid in the range of about from 0.04 to 0.08 moles of oxalic acid per mole of 4-hydroxy-6-ethylthioheptan-2-one. 36. A process for preparing a compound having the formula: which comprises the steps of * (a) contacting 3-ethylthiobutrylaldehyde with an alkali metal acetoacetate under reaction conditions at temperatures in the range of about from 20 to 60°C for about from 2 to 8 hours using about from 1 to 1.5 moles of said alkali metal acetoacetate per mole of said 2-ethyl- thiobutrylaldehyde thereby yielding 4-hydroxy-2-6-ethyl- thioheptan-2-one; and (b) contacting the reaction product of step (a) with a catalytic amount of oxalic acid under reactive condi¬ tions at temperatures in the range of 60 to 200°C thereby affording crude 6-ethylthiohept-3-en-2-one. (c) contacting the crude product of step (b) with a di(lower alkyl) malonate and an alkali metal lower alkoxide under reactive conditions at temperatures in the range of about from 15 to 70°C thereby yielding 4-lower alkoxycarbonyl-5-(2-ethylthiopropyl)-l,3-cyclohexanedione; (d) contacting the product of step (c) with a base under reactive conditions thereby cleaving the lower alkoxy group affording the corresponding salt of 4- carboxy-5-(2-ethylthiopropyl)-1,3-cyclohexanedione; and (e) contacting the product of step (d) with an acid under reactive conditions thereby decarboxylating the 4-position to yield said 5-(2-ethylthiopropyl-l,3- cyclohexanedione.

Inventors: CLEVELAND JAMES D, CLEVELAND, JAMES, D.
Applicants: CHEVRON RES, CHEVRON RESEARCH COMPANY
Application year: 1985
Main classification: C07C45
IPC codes: B01J31, C07B35, C07B61, C07C45, C07C49, C07C67, C07C69, C07C201, C07C205, C07C253, C07C255, C07C313, C07C317, C07C319, C07C323