PROCESS FOR THE MUTUAL CONDENSATION OF AROMATIC AND CARBONYLIC COMPOUNDS

Abstract: The mutual condensation of aromatic and carbonylic compounds is carried out with zeolitic materials derived from silicalite by replacing a portion of silicon with B and Al, Al and Ti, Ti and Fe, and with ZSM-5, to yield diaryl-alkanes.

Description: A general method of synthesis of diaryl-alkanes is based on the condensation of one mole of a carbonylic compound with 2 moles of aromatic compounds. Catalysts efficacious in this reaction are both organic and inorganic acids, and, sometimes, bases. However, it is necessary to operate under carefully controlled conditions, in order to avoid the formation of large amounts of byproducts. In fact, the carbonylic compounds are very reactive, so that it is difficult to prevent the diaryl-alkane from further reacting yielding higher oligomers and polymeric compounds. In the relevant technical literature (J. Cat. 6 , 237, 1966), also the use of zeolitic catalysts (X, Y, mordenites) in the acidic form, or exchanged with metals belonging to the lanthanide group is described. But they result active at rather high temperatures, and furthermore undergo rather fast deactivation processes, due to the formation in the cages of high-molecular weight compounds. The present Applicant has surprisingly found now that zeolitic materials which can be derived from silicalite by replacing a portion of silicon with B and Al, Al and Ti, Ti and Fe are catalysts efficacious in the synthesis of the diaryl-alkanes. In fact, they show a high catalytic activity in the mutual condensation of the aromatic molecule and the carbonylic molecule, whilst their particular structure (channels of approximately 6 Å of diameter) discourages the further growth of the diaryl-alkane towards higher-molecular weight condensation products. Relatively to the catalysts described in the technical literature (J.Cat. , 6 , 237 (1966), the catalysts used according to this invention are more active and less prone to deactivation. US-A-3 496 239 teaches, for condensing an aromatic compound with a carbonyl compound, a catalyst consisting of a crystalline alumino-silicate having an ordered internal structure. US-A-3 728 408 uses a crystalline alumino-silicate for converting cyclohexene, benzene or toluene by reacting one of these with a substituted or unsubstituted aliphatic alcohol. US-A-4 243 828 teaches the use of ZMS-5 zeolite for dehydrating aliphatic organic oxygenates. EP-A-0 226 257 discloses a zeolite-type material based on Si, Al and Ti and a method for its preparation. This invention, in order to offset the defects of the prior art catalysts discussed above, provides a process for preparing diphenylmethanes having the general formula: wherein: R and R' are independently selected from hydrogen,hydroxyl , alkoxy, or a halogen atom, by condensing, in the liquid phase with an inert solvent, at a temperature of from 50°C to 120°C, an aromatic compound having the general formula: wherein R and R' are as defined above, with a carbonyl compound selected from formaldehyde and trioxane, characterized in that the condensation reaction is conducted in the presence of a catalyst comprising a zeolite selected from: (1) zeolites based on Si, Al and B having, in a calcined and anhydrous form the general formula: pHAlO₂.qB₂O₃.SiO₂ wherein p is from 0,034 to 0,0050 and q is from 0,1 to 0,005, and the H+ of HAlO₂ can be at least partially replaced by cations, said zeolite having an X-ray diffraction spectrum as reported in Table A, and an IR spectrum at least showing the following bands: wn cm⁻¹ I rel 1220-1230 weak 1080-1110 strong 890-920 medium-weak 795-805 medium-weak 550-560 medium 450-470 medium-strong wherein wn is the wave number, and I rel is the relative intensity; (2) zeolites based on Si, Al and Ti having, in a calcined and anhydrous form the general formula: pHAlO₂.qTiO₂.SiO₂ wherein p is greater than zero and not exceeding 0,050 and q is greater than zero and not exceeding 0,025, and the H+ of HAlO₂ can be at least partially replaced by cations, said zeolite having an X-ray diffraction spectrum as reported in Table B, and an IR spectrum at least showing the following bands: wn cm⁻¹ I rel 1220-1230 weak 1080-1110 strong 960-975 medium-weak 795-805 medium-weak 550-560 medium 450-470 medium-strong wherein wn is the wave number, and I rel is the relative intensity; (3) zeolites based on Si, Ti and Fe having, in a calcined and anhydrous form the general formula: pHFeO₂.qTiO₂.SiO₂ wherein p is greater than zero and not exceeding 0,050 and q is greater than zero and not exceeding 0,025, and the H+ of HFeO₂ can be at least partially replaced by cations, said zeolite having an X-ray diffraction spectrum as reported in Table C, aid an IR spectrum at least showing the following bands: wn cm⁻¹ I rel 1220-1230 weak 1080-1110 strong 960-975 medium-weak 795-805 medium-weak 550-560 medium 450-470 medium-strong wherein wn is the wave number, and I rel is the relative intensity, the pore size of each of said (1), (2) and (3) zeolites being in the order of magnitude of 0,6 nm (6 Angstrom units). A polar solvent is preferred , such as water, when formaldehyde and phenol are condesed, whereas benzene is preferred when trioxane and phenol are reacted, for example. As regards the nature of the diphenylmetane which is formed, various isomers can be present, the isomer exhibiting the lowest steric hindrance being predominantly formed. The pressure of the reaction is the one which is spontaneously developed. The zeolites which are used in the process according to the present invention are those which meet the following general formula, expressed as the molar ratios of the oxides (in the calcined and anhydrous form): 1) pHAlO₂.qB₂O₃.SiO₂ wherein p has a value comprised within the range of from 0.034 to 0.0050, and g has a value comprised within the range of from 0.1 to 0.005, and the H⁺ of HAlO₂ can be at least partially replaced by cations, wherein the zeolite of formula (1) has a powder X-ray diffraction spectrum, whose meaningful lines are reported in Table A. nm Å d I rel 1,112 + 0,010 11.12 + 0.10 vs 0,998 + 0,010 9.98 + 0.10 s 0,974 + 0,010 9.74 + 0.10 m 0,634 + 0,007 6.34 + 0.07 mw 0,597 + 0,007 5.97 + 0.07 mw 0,424 + 0,005 4.24 + 0.05 mw 0,384 + 0,004 3.84 + 0.04 s 0,381 + 0,004 3.81 + 0.04 s 0,373 + 0,004 3.73 + 0.04 s 0,371 + 0,004 3.71 + 0.04 s 0,363 + 0,004 3.63 + 0.04 m 0,304 + 0,002 3.04 + 0.02 mw 0,297 + 0,002 2.97 + 0.02 mw wherein d are the interplanar distances, and I rel are the relative intensities, wherein vs means very strong; s = strong; m = medium; mw = medium-weak; w = weak; and an I.R. spectrum at least showing the following bands: wn I rel 1220 - 1230 w 1080 - 1110 s 890 - 920 mw 795 - 805 mw 550 - 560 m 450 - 470 ms wherein wn is the wave number, as cm⁻¹ and I rel are the relative intensities, wherein s means strong; ms = medium-strong; m = medium; mw = medium-weak; w = weak. 2) pHAlO₂ . qTiO₂ . SiO₂ wherein p has a value larger than zero and smaller than, or equal to 0.050, and g has a value larger than zero and smaller than or equal to 0.025; and the H⁺ of HAlO₂ can be at least partially replaceable, or replaced, by cations, wherein the zeolite having the general formula (2) has a X-ray diffraction spectrum of the powders, whose meaningful lines are reported in following Table B. nm Å d I rel 1,114 + 0,010 11.14 + 0.10 vs 0,999 + 0,010 9.99 + 0.10 s 0,974 + 0,010 9.74 + 0.10 m 0,636 + 0,007 6.36 + 0.07 mw 0,599 + 0,007 5.99 + 0.07 mw 0,426 + 0,005 4.26 + 0.05 mw 0,386 + 0,004 3.86 + 0.04 s 0,382 + 0,004 3.82 + 0.04 s 0,375 + 0,004 3.75 + 0.04 s 0,372 + 0,004 3.72 + 0.04 s 0,365 + 0,004 3.65 + 0.04 m 0,305 + 0,002 3.05 + 0.02 mw 0,299 + 0,002 2.99 + 0.02 mw wherein d are the interplanar distances, and I rel are the relative intensities, wherein vs means very strong; s = strong; m = medium; mw = medium-weak; w = weak; and the zeolite having the general formula (2) shows an I.R. spectrum at least showing the following bands: wn I rel 1220 - 1230 w 1080 - 1110 s 960 - 975 mw 795 - 805 mw 550 - 560 m 450 - 470 ms wherein wn is the wave number, as cm⁻¹ and I rel are the relative intensities, wherein s means strong; ms = medium-strong; m = medium; mw = medium-weak; w = weak. 3) pHFeO₂ . qTiO₂ . SiO₂ wherein p has a value larger than zero and smaller than, or equal to 0.050, and g has a value larger than zero and smaller than or equal to 0.025; and the H⁺ of HFeO₂ can be at least partially replaceable, or replaced, by cations, wherein the zeolite having the general formula (3) has an X-ray diffraction spectrum of the powders, whose most meaningful lines are reported in Table C. nm Å d I rel 1,114 + 0,010 11.14 + 0.10 vs 0,999 + 0,010 9.99 + 0.10 s 0,974 + 0,010 9.74 + 0.10 m 0,636 + 0,007 6.36 + 0.07 mw 0,599 + 0,007 5.99 + 0.07 mw 0,426 + 0,005 4.26 + 0.05 mw 0,386 + 0,004 3.86 + 0.04 s 0,382 + 0,004 3.82 + 0.04 s 0,375 + 0,004 3.75 + 0.04 s 0,372 + 0,004 3.72 + 0.04 s 0,365 + 0,004 3.65 + 0.04 m 0,305 + 0,002 3.05 + 0.02 mw 0,299 + 0,002 2.99 + 0.02 mw wherein d are the interplanar distances, and I rel are the relative intensities, wherein vs means very strong; s = strong; m = medium; mw = medium-weak; w = weak, and wherein the zeolite having the general formula (3) shows an I.R. spectrum at least showing the following bands: wn I rel 1220 - 1230 w 1080 - 1110 s 960 - 975 mw 795 - 805 mw 550 - 560 m 450 - 470 ms wherein wn is the wave number, as cm⁻¹ and I rel are the relative intensities, wherein s means strong; ms = medium-strong; m = medium; mw = medium-weak; w = weak . Zeolites 1, 2 and 3 are prepared by means of the following procedures: Zeolite 1 : Under hydrothermal conditions a silicon derivative, a boron derivative, an aluminum derivative and a nitrogenous organic base are reacted, with an SiO₂/Al₂O₃ molar ratio of the reactants larger than 100, preferably comprised within the range of from 300 to 400, an SiO₂/B₂O₃ molar ratio of the reactants comprised within the range of from 5 to 50, an H₂O/SiO₂ molar ratio of the reactants preferably comprised within the range of from 20 to 40, possibly in the presence of one or more alkali-and or alkali-earth-metal salts and/or hydroxides, with a molar M/SiO₂ ratio (wherein M is the alkali- and/or alkali-earth-metal cation) of the reactants smaller than 0.1, preferably smaller than 0.01, or equal to zero. In the empirical formula of the material, aluminum has been shown in HAlO₂ form, to underline that the material is in H⁺ form. When the ratios between the various reactants are discussed, for aluminum the Al₂O₃ form is used, in that it is the most usual. The silicon derivative is selected from silica gel, silica sol and alkyl-silicates, among which tetraethylsilicate is the most preferred; the boron derivative is selected from boric acid and the organic derivatives of boron, such as, e.g., alkyl-borates, preferably triethylborate; the aluminum derivative is selected from its salts, such as, e.g., the halides and the hydroxides, and its organic derivatives, such as, e.g., the alkyl aluminates, preferably isopropyl-aluminate. The nitrogenous organic base can be an alkylammonium hydroxide, preferably tetrapropyl-ammonium hydroxide. In case tetrapropyl-ammonium hydroxide is used, the TPA⁺ /SiO₂ ratio (wherein TPA = tetrapropyl-ammonium) of the reactants is comprised within the range of from 0.1 to 1, preferably of from 0.2 to 0.4. The reactants are reacted by operating at a temperature comprised within the range of from 100 to 200°C, preferably comprised within the range of from 160 to 180°C, at a pH comprised within the range of from 9 to 14, preferably of from 10 to 12, and for a time ranging from 1 hour to 5 days, preferably of from 3 hours to 10 hours. Zeolite 2 : Under hydrothermal conditions a silicon derivative, a titanium derivative, an aluminum derivative and a nitrogenous organic base are reacted, with an SiO₂/Al₂O₃ molar ratio of the reactants larger than 100, preferably comprised within the range of from 300 to 400, an SiO₂/TiO₂ molar ratio of the reactants larger than 5, preferably comprised within the range of from 15 to 25, an H₂O/SiO₂ molar ratio of the reactants preferably comprised within the range of from 10 to 100, more preferably within the range of from 30 to 50, possibly in the presence of one or more alkali- and or alkali-earth-metal salts and/or hydroxides, with a molar M/SiO₂ ratio (wherein M is the alkali- and/or alkali-earth-metal cation) of the reactants smaller than 0.1, preferably smaller than 0.01, or equal to zero. In the empirical formula of the material, aluminum has been shown in the HAlO₂ form, to underline that the material is in H⁺ form. When the ratios between the various reactants are discussed, for aluminum the Al₂O₃ form is used, in that it is the most usual. The silicon derivative is selected from silica gel, silica sol and alkyl-silicates, among which tetraethylsilicate is the most preferred; the titanium derivative is selected from the salts, such as, e.g., the halides, and the organic derivatives of titanium, such as, e.g., alkyl-titanates, preferably tetraethyl-titanate; the aluminum derivative is selected from its salts, such as, e.g., the halides and the hydroxides, and its organic derivatives, such as, e.g., the alkyl aluminates, preferably isopropyl-aluminate. The nitrogenous organic base can be an alkylammonium hydroxide, preferably tetrapropyl-ammonium hydroxide. In case tetrapropyl-ammonium hydroxide is used, the TPA⁺/SiO₂ ratio (wherein TPA = tetrapropyl-ammonium) of the reactants is comprised within the range of from 0.1 to 1, preferably of from 0.2 to 0.4. The reactants are reacted by operating at a temperature comprised within the range of from 100 to 200°C, preferably comprised within the range of from 160 to 180°C, at a pH comprised within the range of from 9 to 14, preferably of from 10 to 12, and for a time ranging from 1 hour to 5 days, preferably of from 3 hours to 10 hours. Zeolite 3 : Under hydrothermal conditions a silicon derivative, a titanium derivative, an iron derivative and a nitrogenous organic base are reacted, with an SiO₂/Fe₂O₃ molar ratio of the reactants larger than 50, preferably comprised within the range of from 150 to 600, an SiO₂/TiO₂ molar ratio of the reactants larger than 5, preferably comprised within the range of from 15 to 25, an H₂O/SiO₂ molar ratio of the reactants preferably comprised within the range of from 10 to 100, more preferably within the range of from 30 to 50, possibly in the presence of one or more alkali- and or alkali-earth-metal salts and/or hydroxides, with a molar M/SiO₂ ratio (wherein M is the alkali- and/or alkali-earth-metal cation) of the reactants smaller than 0.1, preferably smaller than 0.08, or equal to zero. In the empirical formula of the material, iron has been shown in HFeO₂ form, to underline that the material is in H⁺ form. When the ratios between the various reactants are discussed, for iron the Fe₂O₃ form is used, in that it is the most usual. The silicon derivative is selected from silica gel, silica sol and alkyl-silicates, among which tetraethylsilicate is the most preferred; the titanium derivative is selected from the salts, such as, e.g., the halides, and the organic derivatives of titanium, such as, e.g., alkyl-titanates, preferably tetraethyl-titanate; the iron derivative is selected from its salts, such as, e.g., the halides or the nitrates, the hydroxides, and the organic derivatives, such as, e.g., the alkoxides. The nitrogenous organic base can be an alkyl-ammonium hydroxide, preferably tetrapropyl-ammonium hydroxide. In case tetrapropyl-ammonium hydroxide is used, the TPA⁺/SiO₂ ratio (wherein TPA = tetrapropyl-ammonium) of the reactants is comprised within the range of from 0.1 to 1, preferably of from 0.2 to 0.4. The reactants are reacted by operating at a temperature comprised within the range of from 100 to 200°C, preferably comprised within the range of from 160 to 180°C, at a pH comprised within the range of from 9 to 14, preferably of from 10 to 12, and for a time ranging from 1 hour to 5 days, preferably of from 3 hours to 10 hours. According to a second form of practical embodiment of the present invention, the zeolites 1, 2 and 3 can be in the form bonded with amorphous oligomeric silica, wherein the molar ratio of the oligomeric silica to zeolite 1, or zeolite 2, or zeolite 3 is comprised within the range of from 0.05 to 0.12, the crystals of zeolite 1, zeolite 2, zeolite 3 being encaged by Si-O-Si bridges, the mass of crystals of zeolites with silica being in the form of microspheres having a diameter comprised within the range of from 5 to 1000 µm. The process for preparing the zeolites 1, 2 and 3 with the bonding agent consists in dispersing in an aqueous solution of silica and tetraalkyl-ammonium hydroxide, wherein the alkyl radicals preferably have a number of carbon atoms comprised within the range of from 1 to 5, more preferably with tetrapropyl-ammonium, prepared by hydrolysing at a temperature comprised within the range of from room temperature to 200°C, preferably of from 40 to 100°C, in the liquid phase, a tetraalkylorthosilicate, preferably tetraethyl-orthosilicate, in an aqueous solution of tetraalkyl-ammonium hydroxide, for a time comprised within the range of from 0.2 to 10 hours, zeolite 1, or zeolite 2, or zeolite 3, each containing a percentage by weight of organic base comprised within the range of from 7 to 12% and a percentage of water comprised within the range of from 23 to 28%, sumbitting the so-obtained suspension to a fast drying. The following Examples illustrate the specific non-limitative preparations of the zeolites used: Preparation Example 1: Zeolite 1 67.8 g of Al(NO₃)₃.9H₂O is dissolved in 1,275 g of ethyl alcohol and to the so-obtained solution 2,819 g of tetraethyl-silicate is added, with stirring until a homogeneous and clear solution is obtained. To a stainless-steel vessel 1,036 g of deionized water, 8,878 g of an aqueous solution at 15.5% by weight of tetrapropyl-ammonium (TPA⁺) hydroxide and 167.5 g of boric acid powder are charged in the order shown, with stirring. When all the acid has gone into solution, to this latter the previously obtained solution is added, and the mixture is stirred, while being heated at 60°C for approximately 4 hours, and anyway until the hydrolysis of the silicate is complete and the ethyl alcohol present is nearly completely removed. The molar composition of the reaction mixture is the following: SiO₂/Al₂O₃ = 150; SiO₂/B₂O₃ = 10; TPA⁺/SiO₂ = 0.5; H₂O/SiO₂ = 35. The so-obtained solution is charged to an autoclave equipped with stirring means, and is heated, under its autogenous pressure, with stirring, at l70°C, for 4 hours. The discharged product is centrifuged, and the centrifuge cake is carefully dispersed in 70 litres of deionized water; the obtained suspension is centrifuged again, yielding a washed cake. A portion of the washed centrifuge cake is calcined in air for 5 hours at 550°C, and at the end it is shown to be a zeolite having, in the anhydrous form, the following composition: 0.0098 Al₂O₃; 0.0108 B₂O₃; SiO₂. Preparation Example 2: Zeolite 1 with Bonding Agent Zeolite 1 is prepared as disclosed in Example 1, then 219 g of tetraethyl-silicate is added, with vigorous stirring, to 234 g of solution of tetrapropyl-ammonium hydroxide at 12% by weight, and the reaction mixture is stirred for 1 hour; then 958 g of demineralized water is added to it, and stirring is continued for a further hour. A clear solution is thus obtained, inside which 875 g of the centrifuging cake prepared as above said, containing 9% by weight of TPA⁺ , 26% by weight of water and 65% by weight of zeolite 1 are dispersed. The milky suspension resulting from the dispersion is fed to a spray-dryer (NIRO-ATOMIZER disk-atomizer; inlet air temperature 300°C; outlet air temperature 120°C; chamber diameter 1.5 m), compact microspheres being obtained, which have an average diameter close to 20 µm. The atomized product is charged to a muffle under a N₂ atmosphere, and is heated up to 550°C. After a 2-hour stay at that temperature under N₂ , the atmosphere is gradually turned from N₂ to air, and the product is left standing a further two hours at 550°C in air. The obtained catalyst has the following molar composition: 0.0088 Al₂O₃ ; 0.0097 B₂O₃; SiO₂. Preparation Example 3: Zeolite 2 27 g of aluminum isopropoxide is dissolved in 5,400 g of solution at 18.7% by weight of tetrapropyl-ammonium hydroxide. Separately, 230 g of tetraethyl-orthotitanate is dissolved in 4,160 g of tetraethyl-silicate, and this solution is added to the previous one, with stirring. The resulting mixture is heated up to 50-60°C, always with stirring, until a single-phase solution is obtained; then, 10,000 cc of water is added. The so-obtained solution is charged to an autoclave and is heated, under its autogenous pressure, at 170°C, for 4 hours. The product discharged from the autoclave is centrifuged and washed twice by re-dispersion and centrifugation. A portion of the washed centrifuge cake is calcined in air for 5 hours at 550°C, and at the end it shows to be a zeolite having, in the anhydrous form, the following composition: 0.0081 Al₂O₃; 0.0250 TiO₂; SiO₂. Preparation Example 4: Zeolite 2 with Bonding Agent The zeolite is prepared as in Example 3, then 320 g of tetraethyl-silicate is added with vigorous stirring to 340 g of an aqueous solution of tetrapropyl-ammonium hydroxide at 12% by weight, and the resulting mixture is stirred 1 hour; then, 1,400 g of demineralized water is added, and the solution is kept stirred a further hour. A clear solution is so obtained, into which 1,280 g is carefully dispersed of the washed centrifugation cake, prepared as disclosed above, containing 9% by weight of TPA⁺ and 26% by weight of water, and 65% of zeolite 2. The milky suspension resulting from the dispersion is fed to a spray-dryer (NIRO-ATOMIZER disk-atomizer; inlet air temperature 300°C; outlet air temperature 120°C; chamber diameter 1.5 m), compact microspheres being obtained, which have an average diameter close to 20 µm. The atomized product is charged to a muffle under a N₂ atmosphere and is heated up to 550°C. After a 2-hour stay at that temperature under N₂ , the atmosphere is gradually turned from N₂ to air, and the product is left standing a further two hours at 550°C in air. The obtained product has the following molar composition: 0.0073 Al₂O₃ ; 0.0225 TiO₂ ; SiO₂. Preparation Example 5: Zeolite 3 This Example illustrates the preparation of titanium-ferrosilicalite. 20.2 g of Fe(NO₃)₃.9H₂O is dissolved in water, and from the solution the hydroxide is precipitated by means of the addition of ammonium hydrate. The precipitate is filtered off, and is washed by being re-dispersed in cold water and filtered until the filtrate turns to neutral. The damp hydroxide is then dissolved in 2,700 g of solution of tetrapropyl-ammonium hydroxide at 18.7% by weight. Separately, 114 g of tetraethyl-orthotitanate is dissolved in 2,080 g of tetraethyl-orthosilicate, and this solution is added to the previous one, with stirring. The resulting mixture is heated up to 50-60°C, always with stirring, until a single-phase solution is obtained; then, 5,000 cc of water is added. The so-obtained solution is charged to an autoclave and is heated, under its autogenous pressure, at 170°C, for 4 hours. The product discharged from the autoclave is centrifuged and washed twice by re-dispersion and centrifugation. A portion of the washed centrifuge cake is calcined in air for 4 hours at 550°C, and at the end it shows to be a zeolite having, in the anhydrous form, the following composition: 0.0025 Fe₂O; 0.0208 TiO₂; SiO₂. Preparation Example 6: Zeolite 3 with Bonding Agent The zeolite is prepared as in Example 5, then 162 g of tetraethyl-silicate is added with vigorous stirring to 173 g of a solution of tetrapropyl-ammonium hydroxide at 12% by weight, and the resulting mixture is stirred 1 hour; then, 709 g of demineralized water is added, and the solution is kept stirred a further hour. A clear solution is so obtained, into which 720 g is carefully dispersed of the centrifugation cake, prepared as disclosed above, containing 9% by weight of TPA⁺ and 26% by weight of water, and 65% by weight of zeolite 3. The milky suspension resulting from the dispersion is fed to a spray-dryer (NIRO-ATOMIZER disk-atomizer; inlet air temperature 300°C; outlet air temperature 120°C; chamber diameter 1.5 m) compact microspheres being obtained, which have an average diameter close to 20 µm. The atomized product is charged to a muffle under an N₂ atmosphere and is heated up to 550°C. After a 2-hour stay at that temperature under N₂, the atmosphere is gradually turned from N₂ to air, and the product is left standing a further two hours at 550°C in air. The obtained product has the following composition: 0.0025 Fe₂O₃; 0.0188 TiO₂ ; SiO₂. Examples 7-9 2 g of catalyst is suspended in a solution of 8 g of phenol, 3 g of aqueous formaldehyde (at 40%) and 50 cc of water. With stirring, the suspension is heated at boiling temperature for 6 hours, turning gradually reddish. After removing water, the residue is extracted with ethanol, and is quantitatively analysed by gas-chromatography and mass-spectrometry by comparison with pure samples. The results are shown in Table 1. Only trace amounts of higher oligomers are present. Zeolite Catalyst Phenol Conversion Selectivity to dihydroxydiphenylmethane 2,2' 2,4' 4,4' 1 35% 2.5% 27% 70% 2 40% 1.5% 25% 73% 3 18% 3.5% 30% 66% Example 10 3 g of zeolite 2 is suspended in a mixture of 20 g of anisole and 3 cc of aqueous formaldehyde (at 40%) in 50 cc of water/ethanol at 50%. The suspension is heated in an autoclave at 120°C for 4 hours. Anisole conversion: 35%. Selectivity to bis(methoxyphenyl)methane: 2,2′-isomer: 1%; 2,4′-isomer: 15%; 4,4′-isomer: 84%. Only trace amounts of higher oligomers are present. Example 11 To a glass autoclave 12 g of phenol, and 1.5 g of trioxane dissolved in 60 cc of benzene are charged, together with 2 g of zeolite 1. The reaction mixture is heated 5 hours at 120°C with magnetic stirring. After cooling, the solvent is evaporated off, and the residue is extracted with ethanol. The reaction products are analysed and are quantitatively analysed by gas-chromatography and mass-spectrometry. Phenol conversion: 65% 2,2′-dihydroxy-diphenyl-methane: 1.2 g 2,4′-dihydroxy-diphenyl-methane: 2.3 g 4,4′-dihydroxy-diphenyl-methane: 4.1 g Example 12 3.3 g of catalyst zeolite 2 with bonding agent is suspended in a solution of 20 g of anisole and 3 cc of aqueous formaldehyde (at 40%) in 50 cc of water/ethanol at 50%. The suspension is heated in an autoclave at 120°C for 4 hours. Anisole conversion: 35%. Selectivity to bis(methoxyphenyl)methane: 2,2′-isomer: 1%; 2,4′-isomer: 15%; 4,4′-isomer: 84%. Only trace amounts of higher oligomers are present. Example 13 To a glass autoclave 12 g of phenol, 1.5 g of trioxane dissolved in 60 cc of benzene are charged, together with 2.2 g of zeolite 1 with bonding agent as the catalyst. The reaction mixture is heated 5 hours at 120°C with magnetic stirring. The reaction products are analysed and their amounts are determined by gas-chromatography and mass-spectrometry. Phenol conversion: 65% 2,2′-dihydroxy-diphenyl-methane: 1.2 g 2,4′-dihydroxy-diphenyl-methane: 2.3 g 4,4′-dihydroxy-diphenyl-methane: 4.1 g Example 14 2.2 g of catalyst zeolite 3 with bonding agent is suspended in a solution of 8 g of phenol, 3 cc of aqueous formaldehyde (at 40%), and 50 cc of water. With stirring, the suspension is heated at the boiling temperature for 6 hours, gradually turning reddish. After removing water, the residue is extracted with ethanol and is quantitatively analysed by gas-chromatography and mass-spectrometry, by comparison with pure samples. The results are as follows: Phenol conversion: 18%. Selectivity to 2,2′-dihydroxydiphenyl-methane: 3.5% Selectivity to 2,4′-dihydroxydiphenyl-methane: 30 % Selectivity to 4,4′-dihydroxydiphenyl-methane: 66 % Only trace amounts of higher oligomers are present.

Claims: Process for preparing diphenylmethanes having the general formula: wherein: R and R' are independently selected from hydrogen, hydroxyl, alkoxy, or a halogen atom, by condensing, in the liquid phase with an inert solvent, at a temperature of from 50°C to 120°C, an aromatic compound having the general formula: wherein R and R' are as defined above, with a carbonyl compound selected from formaldehyde and trioxane, characterized in that the condensation reaction is conducted in the presence of a catalyst comprising a zeolite selected from: (1) zeolites based on Si, Al and B having, in a calcined and anhydrous form the general formula: pHAlO₂.qB₂O₃.SiO₂ wherein p is from 0,034 to 0,0050 and q is from 0,1 to 0,005, and the H+ of HAlO₂ can be at least partially replaced by cations, said zeolite having an X-ray diffraction spectrum as reported in Table A, and an IR spectrum at least showing the following bands: wn cm⁻¹ I rel 1220-1230 weak 1080-1110 strong 890-920 medium-weak 795-805 medium-weak 550-560 medium 450-470 medium-strong wherein wn is the wave number, and I rel is the relative intensity; (2) zeolites based on Si, Al and Ti having, in a calcined and anhydrous form the general formula: pHAlO₂.qTiO₂.SiO₂ wherein p is greater than zero and not exceeding 0,050 and q is greater than zero and not exceeding 0,025, and the H+ of HAlO₂ can be at least partially replaced by cations, said zeolite having an X-ray diffraction spectrum as reported in Table B, and an IR spectrum at least showing the following bands: wn cm⁻¹ I rel 1220-1230 weak 1080-1110 strong 960-975 medium-weak 795-805 medium-weak 550-560 medium 450-470 medium-strong wherein wn is the wave number, and I rel is the relative intensity; (3) zeolites based on Si, Ti and Fe having, in a calcined and anhydrous form the general formula: pHFeO₂.qTiO₂.SiO₂ wherein p is greater than zero and not exceeding 0,050 and q is greater than zero and not exceeding 0,025, and the H+ of HFeO₂ can be at least partially replaced by cations, said zeolite having an X-ray diffraction spectrum as reported in Table C , and an IR spectrum at least showing the following bands: wn cm⁻¹ I rel 1220-1230 weak 1080-1110 strong 960-975 medium-weak 795-805 medium-weak 550-560 medium 450-470 medium-strong wherein wn is the wave number, and I rel is the relative intensity. the pore size of each of said (1), (2) and (3) zeolites being in the order of magnitude of 0,6 nm (6 Angstrom units). Process according to Claim 1, wherein the zeolite is bonded to oligomeric silica to form microspheres having a diameter of from 5 µm to 1000 µm, with an oligomeric silica/zeolite molar ratio of from 0,05 to 0,12, the zeolite crystals being encaged by Si-O-Si bridges. Process according to Claim 2, wherein the microspheres constituted by oligomeric silica and the zeolite are prepared by dispersing in an aqueous solution of silica and a tetraalkyl-ammonium hydroxide, prepared by hydrolyzing in the liquid phase a tetraalkyl-orthosilicate in an aqueous solution of a tetraalkyl-ammonium hydroxide at a maximum temperature of from room temperature to 200°C and for a time of from 0,2 hours to 10 hours, the zeolite containing a percentage by weight of the organic base of from 7% to 12% and a percentage of water of from 23% to 28%, resulting in a suspension of the zeolite and oligomerlc silica and the suspension being fast dried. Process according to Claim 3, wherein the tetraalkyl-orthosilicate is tetraethyl-orthosilicate. Process according to Claim 3, wherein the hydrolysis is carried out at a temperature of from 40°C to 100°C. Process according to Claim 3, wherein the tetraalkyl-ammonium has alkyl radicals containing 1 to 5 carbon atoms. Process according to Claim 6, wherein the tetraalkyl-ammonium is tetrapropyl-ammonium.

Inventors: BELLUSSI GIUSEPPE, CLERICI MARIO GABRIELE, BELLUSSI, GIUSEPPE, CLERICI, MARIO GABRIELE
Applicants: ENICHEM SINTESI, ENIRICERCHE SPA, SNAM PROGETTI, ENICHEM SYNTHESIS S.P.A., ENIRICERCHE S.P.A., SNAMPROGETTI S.P.A.
Application year: 1987
Main classification: C07C37
IPC codes: C07C27, B01J29, C07C37, C07C41, C07C67, C07B37, C07C1, B01J27, C07C39, C07C15, C07B61, C07B31, C07C2, C07C43