PROCESS FOR PREPARING 3,5,5-TRIMETHYLCYCLOHEXA-2-EN-1,4-DIONE

Abstract: 3,3,5-Trimethylcyclohexa-2-en-1,4-dione is prepared by oxidizing 3,5,5-trimethylcyclohexa-3-en-1-one with molecular oxygen or a molecular oxygen-containing gas in the presence of an organic base and an organometallic complex catalyst comprising manganese, iron, cobalt or copper atom and at least four nitrogen atoms coordination-bonded thereto.

Description: The present invention relates to a process for preparing 3,5,5-trimethylcyclohexa-2-en-1,4-dione which per se is highly valued as a perfume for foods, fragrances and tobaccos and is useful as an intermediate for the production of drugs and perfumes, e.g. carotnoids and vitamin E. Heretofore, various processes have been proposed for preparing 3,5,5-trimethylcyclohexa-2-en-1,4-dione. According to the process disclosed in West German Patent No. 2,356,546, 3,5,5-trimethylcyclohexa-2-en-1-one (hereinafter referred to as "α-isophorone") is oxidized with chromium oxide in a mixed solvent of acetic acid and acetic anhydride to thereby prepare 3,5,5-trimethylcyclohexa-2-en-1,4-dione in a yield of about 50% relative to α-isophorone. This process is disadvantageous in that the percentage conversion and yield are low; it is required to use a large excess of chromium oxide relative to α-isophorone, thus causing the danger of explosion; the production cost is high; and much labor is required for the disposal of chromium waste. According to West German Patent No. 2,457,158, α-isophorone is oxidized in vapor phase in the presence of a vanadium catalyst to thereby prepare 3,5,5-trimethylcyclohexa-2-en-1,4-dione in a yield of about 30% relative to isophorone. This process is disadvantageous in that the percentage conversion and yield are low and 5,5-dimethyl-3-formylcyclohexa-2-en-1,4-dione is byproduced in about the same amount as 3,3,5-trimethylcyclohexa-2-en-1,4-dione. According to West German Patent No. 2,459,148, α-isophorone is oxidized in liquid phase in the presence of an acetyl acetonato iron or cobalt catalyst or a rhodium (I) tristriphenylphosphine chloride catalyst to thereby prepare 3,5,5-trimethylcyclohexa-2-en-1,4-dione in an yield of about 30% relative to α-isophorone. This process is disadvantageous in that selectivity and yield are poor. In Japanese Patent Laid-Open No. 191645/1986, 3,5,5-trimethylcyclohexa-2-en-1,4-dione is prepared in a yield of about 50% by oxidized α-isophorone in the presence of an alkali metal or an aromatic amine and phosphomolybdic acid or silicomolybdic acid. This process is disadvantageous in that the percentage conversion and yield are low and α-isophorone, which is difficult to be separated from 3,5,5-trimethylcyclohexa-2-en-1,4-dione, is contained in about the same amount in the reaction product. In French Patent No. 2,253,730, 3,5,5-trimethylcyclohexa-3-en-1-one (hereinafter referred to as "β-isophorone") is oxidized in an alcohol solvent in the presence of a tertiary amine and copper (II) salt of pyridine to thereby prepare 3,5,5-trimethylcyclohexa-2-en-1,4-dione in a yield of about 30% relative to β-isophorone. This process is disadvantageous in that the yield is low and a polymer of β-isophorone is byproduced in a fairly large amount. Further, in West German Patent No. 2,457,157, α-isophorone is oxidized over a period of about 35 hours in the presence of an acetylacetonato complex catalyst which is derived from a transition metal such as vanadium, chromium, copper, manganese, iron, cobalt, or nickel to thereby prepare 3,3,5-trimethylcyclohexa-2-en-1,4-dione in a maximum yield of 55% relative to β-isophorone. This process is disadvantageous in that the reaction time is long and yield is low. It is the object to the present invention to provide a process for preparing 3,5,5-trimethylcyclohexa-2-en-1,4-dione industrially advantageously which process is free of the above-mentioned disadvantages or drawbacks of the prior art Research Disclosure No. 240, April 1984, page 172, Abstract no. 24038, Havant, Hampshire, GB discloses the catalytic oxidation of 3,5,5-trimethylcyclohexa-3-ene-1-one to 3,5,5-trimethyl cyclohexa-2-ene-1,4-dione in the presence of a heterocyclic base and a copper catalyst such as copper phthalocyanine disodium sulphonate or copper phthalocyanine dicalcium tetrasulphonate. FR-A-2303785 discloses the preparation of 3,5,5-trimethylcyclohexa-2-ene-1,4 dione from 3,5,5-trimethylcyclohexa-3-ene-1-one in the presence of a nitrogen containing base and a metal chelate compound which is a complex of cobalt or manganese having two nitrogen and two oxygen atoms co-ordinated to the metal. US-A-4028423 discloses a process for the oxidation of unsubstituted saturated or mono-unsaturated hydrocarbons having 3 to 16 carbon atoms, for example cycloalkenes, with oxygen or air in the presence of a copper polyphthalocyanine catalyst. SUMMARY OF THE INVENTION The present invention resides in the process for preparing 3,5,5-trimethylcyclohexa-2-en-1,4-dione in which process 3,5,5-trimethylcyclohexa-3-en-1-one is oxidized with molecular oxygen or a molecular oxygen-containing gas in the presence of an organic base and an organometallic complex catalyst comprising a porphyrin complex of manganese, iron, cobalt or copper. According to such process of the present invention, the polymerization and side reaction of β-isophorone are suppressed as compared with the conventional processes and 3,5,5-trimethylcyclohexa-2-en-1,4-dione can be prepared industrially advantageously and in high yield without formation of any by-product difficult to be separated from the desired product. DETAILED DESCRIPTION OF THE INVENTION The β-isophorone used in the present invention can be prepared, for example, by a process (U.S. Patent No. 3,385,902) wherein α-isophorone is distilled in the presence of p-toluenesulfonic acid. As well known, porphyrin complex has a basic structure represented by the following formula (I): wherein M represents a metal atom. Used in the present invention is one wherein M is manganese, cobalt, iron or copper. In the porphyrin complexes of the formula (I) electron transfer between the metal ions and tetrapyrrole is presumed to be easy because the tetrapyrrole has a large electron system exhibiting aromatic properties. As long as there is the basic structure shown in the formula (I), substantially any substituent groups may be bonded thereto, which can be suitably selected, for example, taking into account whether the porphyrin material for forming a complex with metal M is easily available or not. For explanation on substituent groups of high utility, there is given the following general formula (I') showing a porphyrin complex with substituent groups in the formula (I): Preferably, in the above formula, X¹, X², X³ and X⁴, which may be the same or different, are each hydrogen, C₁-C₄ alkyl, C₁-C₄ alkoxy, or phenyl, which phenyl may be substituted with one to five halogen atoms, C₁-C₄ alkyl, C₁-C₄ alkoxy, or phenyl; R¹, R², R³, R⁴, R⁵, R⁶, R⁷ and R⁸ are each hydrogen atom, C₁-C₄ alkyl, C₁-C₄ alkoxy, halogen atom, C₁-C₄ alkylamino, or nitro; and M is manganese, cobalt, iron, or copper. In these porphyrin complexes, it is presumed that the four nitrogen atoms are coordination bonded to the metal in the form of a quadrilateral in plane or in a form similar thereto. Where required, as the fifth and sixth ligands there may be used various compounds having coordination ability. Examples are gases such as oxygen molecule, oxygen atom, carbon monoxide and nitrogen monoxide; halogen ions such as chlorine bromine, fluorine and iodine; nucleophiles such as methylate, ethylate, phenolate, isothiocyanate, azide, hydroxide, cyanide, perfluorate, methane thiolate and acetate; organic bases such as pyridine and imidazole; ethers such as tetrahydrofuran and 1,4-dioxane; and acetonitrile. Examples of X¹, X², X³, X⁴, R¹, R², R³, R⁴, R⁵, R⁶, R⁷, R⁸ and M in the general formula (I') are shown in Table-1 together with compound names. Most of them are available easily. The porphyrin metal complex catalyst can be prepared easily, for example, by a process (J. Am. Chem. Coc., 81, 5111, 1959 ) wherein an organic acid is refluxed in the presence of porphyrin and a metal salt; a process (J. Inorg. Nucl. Chem., 32, 2443, 1970 ) wherein dimethyl formamide is reflexed in the presence of porphyrin and a metal salt; or a process (Justus Liebigs Ann. Chem., 745, 135, 1971 ) wherein an organic solvent such as benzene, chloroform or phenyl is refluxed in the presence of porphyrin and metal acetyl acetonate. As known well, porphyrin can be prepared easily by the reaction of pyrroles and aldehydes (e.g. X₁CHO). The amount of the organometallic complex catalyst to be used in practising the process of the present invention is preferably in the range of 10⁻⁶ mole to 0.2 mole, more preferably 10⁻⁵ mole to 0.05 mole, per 1 mole of β-isophorone. Even molar ratios outside this range may be adopted as long as they are not an obstacle to the reaction selectivity. The reaction is performed in the presence of an organic base. As the organic base an alkylamine (mono-, di- or trialkylamine wherein the alkyl preferably has 1 to 8 carbon atoms) is preferred. Examples, which are particularly preferred, are secondary and tertiary amines, such as dimethylamine, trimethylamine, diethylamine, methyl ethyl amine, triethylamine, dibutylamine, diisopropylamine and ethyl butyl amine. The amount of the organic base to be used is preferably in the range of 0.02 to 20 moles, more preferably 0.1 to 5 moles, per 1 mole of β-isophorone. Although the reaction can be carried out in the presence of the organic base alone, it is preferably conducted in the presence of both the organic base and a solvent. As examples of the reaction solvent there are mentioned hydrocarbon solvents such as hexane, benzene, toluene and xylene; ether solvents such as diethyl ether, diisopropyl ether, dibutyl ether, tetrahydrofuran, dioxane, ethylene glycol dimethyl ether, ethylene glycol monomethyl ether, diethylene glycol dimethyl ether, diethylene glycol monomethyl ether, tetrahydropyran and dioxane; ketone solvents such as as acetone, methyl isobutyl ketone, methyl ethyl ketone and methyl butyl ketone; halogen solvents such as monochloroethane, dichloromethane, chloroform, carbon tetrachloride and 1,2-dichloroethane; alcohol solvents such as methanol, ethanol, butanol and propanol; carboxamide solvents such as dimethylformamide, dimethylacetamide, diethylformamide and N-methylpyrrolidone; nitrile solvents such as acetonitrile, propionitrile and butyronitrile; ester solvents such as methyl acetate, ethyl acetate and butyl acetate; water; isophorone; and optional mixtures thereof. The addition of water is effective in increasing the conversion rate of β-isophorone. The reaction time is preferably in the range of 0.1 to 60 hours, more preferably 0.5 to 20 hours, and the reaction temperature is preferably in the range of -30° to 80°C, more preferably 0° to 50°C. The reaction can be carried out at atmospheric pressure or under the application of pressure. Then, the solvent and the organic base are recovered under reduced pressure, followed by reduced-pressure distillation or steam distillation, or the reaction solution is filtered and the filtrate is poured into an excess amount of a peroxide deactivator such as an aqueous sodium sulfite solution, an aqueous ferric sulfate solution or an aqueous ferric chloride solution, followed by extraction using a suitable extraction solvent such as, for example, ethyl acetate, benzene, toluene, diethyl ether, carbon tetrachloride, chloroform, or dichloroethane, then the solvent layer is washed with saturated sodium hydrogencarbonate or saturated aqueous Nacl, followed by drying using a desiccant, e.g. magnesium sulfate, and the solvent is recovered by distillation to obtain 3,5,5-triethylcyclohexa-2-en-1,4-dione, which may be purified, if necessary, by such means as reduced-pressure distillation, column chromatography, or recrystallization. The present invention will be described by the following Examples. Example 1 501 mg (2.62 x 10⁻³mole) of β-isophorone, 143 mg (1.41 x 10⁻³ mole) of triethylamine, 4.4 ml of ethylene glycol dimethyl ether and 7.5 mg (1.07 x 10⁻⁵ mole) of chloro-5,10,15,20-tetraphenyl porphyrinato manganese were placed and mixed in a 10ml flask equipped with a thermometer, a stirrer and an oxygen introducer. and the vapor phase portion in the flask was purged with oxygen. Stirring was started and reaction was allowed to proceed while introducing oxygen gas corresponding to that consumed in the reaction, into the vapor phase portion at atmospheric pressure under control of the reaction temperature at 30°C. After stirring at 30°C for 4 hours, ethylene glycol dimethyl ether and triethylamine were recovered from the reaction solution at reduced pressure to obtain 592 mg of a liquid residue. As a result of quantitative analysis by gas chromatography, the liquid residue was found to contain 88.8wt.% of 3,5,5-trimethylcyclohexa-2-en-1,4-dione. (Reaction yield: 94.0 mole%) Example 2 1,001 mg (7.24 x 10⁻³ mole) of β-isophorone, 285 mg (2.82 x 10⁻³ mole) of triethylamine, 366 mg of water, 8.8 ml of ethylane glycol dimethyl ether and 2.0 mg (2.84 x 10⁻⁶ mole) of chloro-5,10,15,20-tetraphenyl porphyrinato manganese were placed and mixed in a 20 ml flask equipped with a thermometer, a stirrer and an oxygen introducer and the vapor phase portion in the flask was purged with oxygen, followed by the same reaction operation as in Example 1. After stirring at 30°C for 1.5 hours, ethylene glycol dimethyl ether and triethylamine were recovered from the reaction solution at reduced pressure to obtain 1,312 mg of a liquid residue. As a result of quantitative analysis by gas chromatography, the liquid residue was found to contain 82.1 wt.% of 3,5,5-trimethylcyclohexa-2-en-1,4-dione. (Reaction yield: 96.4 mole%) Example 3 1,000 mg (7.24 x 10⁻³ mole) of β-isophorone, 287 mg (2.84 x 10⁻³ mole) of triethylamine, 356 mg of water, 8.8 ml of ethylene glycol dimethyl ether, 1.0 ml of methylene chloride and 2.0 mg (1.84 x 10⁻⁶ mole) of 5,10,15,20-tetraphenyl porphyrinato manganese were placed and mixed in the reactor described in Example 2 and the vapor phase portion in the flask was purged with oxygen, followed by the same reaction operation as in Example 1. After stirring at 30°C for 2.5 hours, ethylene glycol dimethyl ether and triethylamine were recovered from the filtrate at reduced pressure to obtain 1,329 mg of a liquid residue. As a result of quantitative analysis by gas chromatography, the liquid residue was found to contain 82.3 wt.% of 3,5,5-trimethylcyclohexa-2-en-1,4-dione. (Reaction yield: 98.0 mole%) Example 4 500 mg (3.62 x 10⁻³ mole) of β-isophorone, 144 mg (1.42 x 10⁻³ mole) of triethylamine, 4.4 ml of ethylene glycol dimethyl ether and 75 mg (1.12 x 10⁻⁴ mole) of 5,10,15,20-tetraphenyl porphyrinato cobalt were placed and mixed in the reactor described in Example 1 and the vapor phase portion in the flask was purged with oxygen, followed by the same reaction operation as in Example 1. After stirring at 30°C for 6.5 hours, the reaction solution was filtered using Celite, then ethylene glycol dimethyl ether and triethylamine were recovered from the filtrate at reduced pressure to obtain 559 mg of a liquid residue. As a result of quantitative analysis by gas chromatography, the liquid residue was found to contain 72.4 wt.% of 3,5,5-trimethylcyclohexa-2-en-1,4-dione. (Reaction yield: 72.5 mole%) Example 5 500 mg (3.62 x 10⁻³ mole) of β-isophorone, 144 mg (1.42 x 10⁻³ mole) of triethylamine, 0.16 ml of ethyl acetate, 4.4 ml of ethylene glycol dimethyl ether and 66 mg (9.33 x 10⁻⁵ mole) of chloro-5,10,15,20-tetraphenyl porphyrinato cobalt were placed and mixed in the reactor described in Example 1 and the vapor phase portion in the flask was purged with oxygen, followed by the same reaction operation as in Example 1. After stirring at 30°C for 6.5 hours, the reaction solution was filtered using Celite, then ethylene glycol dimethyl ether and triethylamine were recovered from the filtrate at reduced pressure to obtain 569 mg of a liquid residue. As a result of quantitative analysis by gas chromatography, the liquid residue was found to contain 78.0 wt.% of 3,5,5-trimethylcyclohexa-2-en-1,4-dione. (Reaction yield: 79.6 mole%) Example 6 499 mg (3.61 x 10⁻³ mole) of β-isophorone, 148 mg (1.46 x 10⁻³ mole) or triethylamine, 0.16 ml of ethyl acetate, 4.4 ml of ethylene glycol dimethyl ether and 75 mg (1.07 x 10⁻⁴ mole) of chloro-5,10,15,20-tetraphenyl porphyrinato iron were placed and mixed in the reactor described in Example 1 and the vapor phase portion in the flask was purged with oxygen, followed by the same reaction operation as in Example 1. After stirring at 30°C for 6.5 hours, the reaction solution was filtered using Celite, then ethylene glycol dimethyl ether and triethylamine were recovered from the filtrate at reduced pressure to obtain 532 mg of a liquid residue. As a result of quantitative analysis by gas chromatography, the liquid residue was found to contain 50.7 wt.% of 3,5,5-trimethylcyclohexa-2-en-1,4-dione. (Reaction yield: 48.4 mole%)

Claims: A process for preparing 3,5,5-trimethylcyclohexa-2-en-1,4-dione in which 3,5,5-trimethylcyclohexa-3-en-1-one is oxidized with molecular oxygen or a molecular oxygen-containing gas in the presence of an organic base and an organometallic complex catalyst characterized in that the organometallic complex catalyst comprises a porphyrin complex of manganese, cobalt, iron or copper. A process as set forth in Claim 1, wherein said organic base is a di- or trialkylamine. A process as set forth in Claim 1, wherein said organometallic complex catalyst is used in an amount of 10⁻⁶ mole to 0.2 mole per mole of the 3,5,5-trimethylcyclohexa-3-en-1-one. A process as set forth in Claim 1, wherein said organic base is used in an amount of 0.02 to 20 moles per mole of the 3,5,5-trimethylcyclohexa-3-en-1-one. A process as set forth in Claim 1, wherein the reaction temperature is in the range of -30°C to 80°C.

Inventors: ETO, TAKEAKI, ITO, NOBUHIKO, KINOSHITA, KIMIO, SUZUKI, KIYONORI
Applicants: SODA AROMATIC COMPANY, LIMITED
Application year: 1988
Main classification: C07C49
IPC codes: A61K8, A61Q13, C07C45, C07B61, B01J31, C07C49, C07C67, C11B9