A PROCESS FOR THE PRODUCTION OF 4,4'-DIALKYLATED BIPHENYL COMPOUNDS

Abstract: This invention is a process for the monoalkylation or dialkylation of aromatic (preferably biphenyl compounds) to produce alkylated aromatics (particularly dialkylated biphenyl compounds), using specific catalysts (preferably dealuminated mordenite) having an Si/Al ratio between 5 and 100 and having <27>Al-MAS-NMR ratio less than about 5.

Description: A PROCESS FOR THE PRODUCTION OF 4,4'-DIALKYLATED BIPHENYL COMPOUNDS RELATED APPLICATION This is a continuation-in-part of USSN 07/404,665 filed September 8, 1989, the entirety of which is incorporated by notice. FIELD OF THE INVENTION This invention relates to a process for the production of 4,4'-dialkylated biphenyl compounds by the alkylation of biphenyl compounds. Certain shape selective catalysts have been found to maximize the yield of these aromatic isomers. These isomers can be oxidized to yield monomers which are useful as precursors for thermotropic liquid crystal polymers and polyester films. BACKGROUND OF THE INVENTION The compounds 4,4'-dihydroxybiphenyl and 4,4'-dicarboxybiphenyl are key monomers used as precursors for liquid crystal polymers and polyester film, respectively. The compound 4,4'-dihydroxybiphenyl is currently prepared by a multi-step route and is not readily available for general use. Members of the 4,4'dialkylbiphenyl class (such as 4,4'-diisopropylbiphenyl) can be readily converted to either monomer by oxidation under the appropriate conditions. These monomers may be prepared following Equations 1 and 2: EQUATION 1 EQUATION 2 The generally accepted procedure for numbering the substituent positions and thereby identifying the various isomers of biphenyl is as follows: The isomers derived from substitution in the two, three, and four positions are denoted as ortho, meta and para isomers, respectively. The various combination of isomers of isopropyl alkyiates of biphenyl are shown in the following table: Isomers of Isopropyl Alkyiates of Biphenyl Alkylate Total Number lsomer Mono-IPBP 3 o, m, p Di-DIPBP 10 2,6; 2,4; 2,5; 3,5; 2,2'; 2,3'; 2,4'; 3,3'; 3,4'; 4,4' As noted from the above table, the isopropyl mono-alkylate of biphenyl has three possible isomers. These are derived from substitution of (in this case) propylene in the two, three, and four positions. Other mono-alkyl isomers (such as those having C^Cu, moieties) have the same number of mono-alkyl isomers. Dialkylation of biphenyl can occur in two ways: same ring and adjacent ring disubstitution. For same ring alkylation, it is likely that for subsituents larger than an ethyl group ortho disubstitution cannot take place due to the steric bulk of the alkyl group. For such groups in same ring alkylation, the isomers expected are the 2,6; 2,4; 2,5; and 3,5. A greater number of isomers are possible for adjacent ring disubstitution, namely, 2,2'; 2,3'; 2,4'; 3,3'; 3,4;' and 4,4'. For the trialkylate, there are many more possible isomers making the total number of products possible in a typical alkylation of biphenyl with a non- shape selective catalyst quite large. If .high conversion to dialkylbiphenyl with substituents smaller than C_, is sought, it is possible to create tetraalkylates complicating the mixture of products even further. As such, it is desirable for a practical process for producing compounds such as 4,4'-diisopropylbiphenyl that the number of isomers be reduced so that the recycle and re-equilibration of byproducts be minimized. The alkylation of biphenyl with olefins is a well known reaction. For example, K. Hyska teaches (in Chem. Prun. 1971, 21, pp.264-70) that AICI 3 can be used as a catalyst for the propylation of biphenyl. However, the 3- and 4- isomers predominate for the case of the monoalkylate and complex mixtures of the dialkylate are present as reaction products. In addition, U.S. Patent No. 4,480,142 discloses the use of Nation as a catalyst which gives an enhancement to the 2-alkyl products. This is probably due to the low reaction temperature of approximately 200 * C taught by the referenced patent wherein result, the 2-isomer becomes the preferred product. As a result, the total amount of the 3,3', 3,4' and 4,4' isomers are low since the concentration of 3- and 4- isopropylbiphenyl is also low. Notably, the selective preparation of 4,4'-diisopropylbiphenyl is taught in Japanese Kokai 63-122635. The Japanese reference teaches that the 4,4'- isomer can be made in relatively high selectivity using a mordenite zeolite catalyst while combining biphenyl with propylene at elevated pressures. The use of certain mordenites as preferred catalysts was further substantiated by a recent report by Lee et al. (Catalysis Letters 2, 1989, pp. 243-248). In this reference the author teaches the preference of a specific zeolite source and treatment by a dealumination procedure to obtain a suitable catalyst. This process is also shown in U.S. Patent No. 4,891,448 and EPO 317907. The present invention improves upon the lifetime and yield in these references by choice of suitable catalysts. For ZSM-12, it is particularly desirable to minimize the amount of olefins (such as propylene) in contact with the catalyst at any given time. This allows maximization of catalyst life since it prevents the generation of carbonaceous residues on the surface of the zeolite catalyst. As a result, -the effective shape selective catalyst of this invention may be operated to minimize the olefin contact with the shape selective catalyst. This can be accomplished most effectively by operating at low propylene pressures. The shape selective catalysts used in this process are those having pore size and configuration such that they maximize the yield of the desired 4,4'-dialkylbiphenyl isomer relative to the sum of the other dialkylate species while minimizing the formation of higher substituted species. Similarly, the preferred dealuminated mordenite provides high yields of dialkylated biphenyl and yet has significant lifetime. The absence of detrital aluminum in the zeolite appears to contribute to this enhanced catalyst life. It is sometimes found that beneficial performance (for example, longer catalyst life and/or higher catalyst activity) ensues when hydrogen alone or in combination with hydrogen sulfide are added at moderate pressures to the reactants. The advantageous use of hydrogen in this way is often enhanced if a hydrogenating metal (for example, nickel or palladium) is incorporated into the zeolite. Hydrogen sulfide is often used to partially deactivate the hydrogenating metal in such a manner as to only hydrogenate diene species present and not olefins or aromatics. A flow system can be used to operate the process of the invention, the unused hydrogen, and/or hydrogen sulfide may be removed from the products and recycled. The zeolite catalyst may be used in the form of suitable aggregates which are prepared by well known techniques (for example, with or without a binder such as silica-alumina or by inclusion into a matrix such as silica or alumina) in a manner analogous to that often used in the manufacture of fluid catalytic cracking catalysts. If desired, the external surface of the zeolite may be poisoned or deactivated so as to reduce or remove catalytic activity thereon, especially the catalysts of unwanted reactions (for example, the isomerization of the selectively alkylated biphenyl compounds of this invention). In some cases, zeolites treated with magnesium, phosphorous, or silicon compounds have beneficial properties in the process of this invention. SUMMARY OF THE INVENTION This invention is a process for reacting biphenyl, 4-isoalkylbiphenyl, or a mixture of the two with an alkylating agent in the presence of an acidic molecular sieve catalyst having a longest pore aperture dimension of 6.0A to 7.1A, preferably a catalyst selected from the group of SAPO-11, ZSM-12, or dealuminated mordenites having substantially no Cmmm phase under conditions sufficient to convert biphenyl or 4-isoalkylbiphenyl and the alkylating agent to 4,4'-dialkylbiphenyl. The preferred alkylating agents are olefins, particularly propylene. DESCRIPTION OF THE INVENTION This invention is a process for the dialkylation of biphenyl compounds using an alkylating agent over certain catalytic materials. The biphenyl compounds used in the process may be biphenyl, 4-alkyl biphenyl, or a mixtures of the two. The alkyl group on the mono-alkyl biphenyl must be the same as the final dialkylated biphenyl product. The alkylating agents may be selected from C 3 to C 12 alphaolefins, diolefins, polyolefins, alcohols, ethers, alkylhalides, alkylsulfates, alkylphosphates, dialkylethers, and alkylaromatics. Suitable olefins include propylene, n-butene, mixed butenes, 1-pentene, 1-hexene, cyclohexene, and 1- octene. A suitable diolefin is 1,3-butadiene. Alcohols useful as alkylating agents include methanol, ethanol, isopropyl alcohol, isobutyl alcohol, pentanol, hexanol, and the like. Methylbromide, methylchloride, methyliodide, isopropyl halides, and ethyl halides may also be used. The preferred alkylating agent is an olefin, preferably selected from the group of propylene, n-butene, and isobutene; most preferrably it is propylene. In order to demonstrate the shape selective effect for the dialkylation of biphenyl intrinsic to a particular catalyst, it is necessary to establish a base line for a given catalyst. Initial experiments were designed and conducted to achieve an assessment of the equilibrium concentration of mono and dialkylates. Using propylene and biphenyl as examples, only the zeolite catalysts which show a high selectivity to 4,4'-diisopropylbiphenyl under these reaction conditions are the proper examples of shape selective catalysts. In each case, propylene was fed at a low rate over an Si0 2 /Al 2 0 3 catalyst with a low biphenyl/catalyst ratio, e.g., 9:1. The results which were achieved confirmed that equilibrium was reached since the ratios of the products- did not change as the conversion increased. For biphenyl, the predominant monoalkylate was the 3-isomer comprising ca. 63% with 35% being the 4- isomer. The remaining 2% of the product mixture was the 2-isomer. For the dialkylate, the 3,4'-isomer was the predominant product; for known dialkylates (at equilibrium) the ratio of the 3,3'-isomer; 3,4'-isomer; and 4,4'-isomer was 2.1:2.8:1. A percent selectivity of 4,4'-diisopropylbiphenyl/total dialkylates higher than 20% and a 4,4'/3,4' ratio greater than 0.36 obtained under these conditions is evidence for a shape selective effect. The shape selective catalysts of choice allowing high selectivity to the 4,4'-isomer has been found to be certain synthetic mordenites, SAPO-11, and ZSM-12 which are acidic crystalline molecular sieves. Pore structure (dimensions and network) varies greatly among zeolites. Without modification to the zeolite structure, the smallest pore aperture dimension is about 2.6A and the largest is 7.4A. Pores may lead to linear, parallel, or interconnected channels or may give access to larger intracrystalline cavities, sometimes referred to as cages. For all zeolites, the pore opening is determined by the free aperture of the oxygen ring that limns the pore aperture. The free diameter values given in the channel description and on the ring drawings (not shown here) are based upon the atomic coordinates of the type species in the hydrated state and an oxygen radius of 1.35A, as determined from x-ray crystallographic data. Both minimum and maximum values are given for non-circular apertures. In some instances, the corresponding interatomic distance vectors are only approximately coplanar; in other cases the plane of the ring is not normal to the direction of the channel. Close inspection of the framework and ring drawings should provide qualitative evidence of these factors. Some ring openings are defined by a very complex arrangement of oxygen atoms. It should be noted that crystallographic free diameters may depend upon the hydration state of the zeolite, particularly for the more flexible frameworks. It should also be borne in mind that effective free diameters can be temperature dependent. Maximum values for the 4-, 6-, 8-, 10-, and 12- membered oxygen rings have been calculated to be 2.6A, 3.6A, 4.2A, 6.3A and 7.4A, respectively. As used throughout the instant specification, the term "pore aperture" is intended to refer to both the pore mouth at the external surface of the crystalline structure and to the intracrystalline channel, exclusive of cages. When a crystalline molecular sieve is hereinafter characterized by a "pore aperture dimension", this term is intended to adopt the geometric dimensional analysis defined as "crystallographic free diameter of channels" in Meier, W.M., Olson, D.H., Atlas of Zeolite Structure Types. (Butterworth's, 1987, 2nd Rev. Ed.). The term "dimension" is preferred over "diameter" because the latter term implies a circular opening, which is not always accurate in describing crystalline molecular sieves. When citing the term "pore aperture dimension or width" we mean (for non-circular zeolite openings) the longest dimension of the pore. For example, ZSM-12 is an irregularly shaped zeolite with pore aperture dimensions of 5.5A x 5.7A x 6.2A. Likewise, SAPO-11 has pore aperture dimensions of 3.9A x 6.3A and mordenite has pore aperture dimensions of 6.5A X 7.0A. SO for ZSM-12, the "pore aperture dimension" is 6.2A; for SAPO-11, 6.3A; and for mordenite, 7.0A. Shape selective reactions occur when the zeolite framework and its pore structure allow substrate molecules of a given size and shape to reach active sites located in the intracrystalline free space and allow product molecules of a given size and shape to diffuse out of the intracrystalline free space. It is, therefore, important to characterize accurately the pore structure that is encountered in the various crystalline molecular sieve frameworks. Crystalline sieve structures are often defined in terms of the number of the tetrahedral units (T. atoms). For example, in sodalite, the silica and alumina tetrahedra are linked together to form a cubooctahedron, an octahedron truncated perpendicularly to all C A -axes. The sodalite unit is built from 4- and 6-member oxygen rings. A more complete characterization of zeolites can be found in E.G. Derouane, "Diffusion and Shape-Selective Catalysis in Zeolites", Intercalation Chemistry. Ed. by M. Stanley Whittingham (Academic Press 1982). SAPO-11 belongs to the family of silicoaluminophosphate molecular sieves, first reported in 1984 in U.S. Patent No. 4,440,871. The pore structure of SAPO-11 consists of linear, non-interconnected channels which are limited by 10- membered rings and possess pore aperture dimensions of 3.9A and 6.3A. See Bennett, J.M., et al.. Zeolites, 7 (1987) 160. See also Meyer, W.M., and Olson, D.H., "Atlas of Zeolite Structure Types", 2nd Ed., Structure Commission of the International Zeolite Association. Butterworths, 1987. The synthesis procedure for ZSM-12 has been described in a previous reference. See Jacobs, et al. "Synthesis of high-Silica Aluminosilicate Zeolites", Elsevier. (Amsterdam, 1987, page 303.). Typically, the Si/AI ratio for ZSM-12 is limited to the lower end of the range of 10 to pure Si0 2 . The preferable range is from 10 to 100, most preferably from 15 to about 45. Synthetic mordenite is merely the man-made analog of the mineral of the same name and is widely available commercially. The synthetic mordenite of choice in this invention is substantially devoid of any Cmmm phase material. The preferred synthetic mordenite catalyst has also been dealuminated to an Si/AI ratio between about five and about 100 (preferably between five and 50) and most preferably between 15 and 35. The 27 AI-MAS-NMR ratio (as described below) for those materials is between zero and five, preferably between zero and two, and most preferably between zero and one. The dealumination of the molecular sieve is carried out by the combination of steam treatment and mild acid leaching described below. The dealumination technique and the method for producing 27 AI-MAS-NMR are additionally described in USSN 07/254,284 and 07/438,496, the entirety of which is incorporated by notice. It should be noted that ZSM-12 and synthetic mordenite are available in cationic form. Calcination may be necessary if the zeolite contains an organic template; only an ion exchange is needed then to convert these to the hydrogen form. The catalysts may be optimized to yield greater selectivities of the desired dialkylbiphenyl without substantially altering its pore aperture dimensions. One such modification to the preferred catalysts is to dealuminate. The dealumination of acidic crystalline molecular sieve materials may be achieved by exposing the solid catalyst to mineral acids such as HCl. The desired degree of dealumination will dictate the strength of acid used and the time during which the crystalline structure is exposed to the acid. Nevertheless, our desired method of dealumination is via steam treatment followed by a mild acid treatment and calcination as discussed below. The preferred steam treatment parameters are as follows: After the steam treatment is completed, the next step should desirably be a mild acid treatment or leach. The preferred acid leach conditions are as follows: Parameter Acid type Concentration Temperature (°C) Time For additional methods of preparing aluminum deficient zeolites see J. Scherzer, "The Preparation and Characterization of Aluminum-Deficient Zeolites", Thaddeus E. Whyte et al.. "Catalytic Materials: Relationship between Structure and Reactivity", at pp. 156-160, ACS Symposium Series 24g (American Chemical Society, 1984). We have found that although a wide variety of dealuminated zeolitic materials are initially suitable for the isopropylation reaction, only certain materials retain that suitability for prolonged periods. For instance, dealumination techniques employing strong acid leaches typically produce catalysts which initially are very active but short lived. In certain circumstances such an activity profile might be desirable but, typically, a catalyst with a longer life is preferred. The zeolites having certain NMR characteristics (in conjunction with the preferred Si/AI ratio discussed below) have been found to be especially suitable for the disclosed process. Specifically, materials in which the ratio of the broad component of the 27 AI-MAS-NMR to the narrow component is less than five have been shown to be particularly preferred. In general, this ratio can be considered a measure of the non-framework aluminum (from whatever source) found in the interstices of the zeolite as compared to the aluminum in the zeolite framework. One method of dealumination which has been found to produce such a preferred material is a steam treatment (in one or more stages) followed by a mild acid leach. Dealumination according to the instant invention is intended to achieve a Si/AI ratio between five and 100, preferably between five and 50, and most preferably at least 15 to 35. Additionally, the noted 27 AI-MAS-NMR ratio for these materials is desirably between zero and five, preferably between zero and two, and most preferably between zero and one. A dealuminated crystalline molecular sieve may be calcined at temperatures between 400°C and 1000°C, preferably between 400°C and 600°C. Calcination serves to dehydrate or "heal" Si-OH bonds (or "nests") after dealumination. Healing these nests provides for a more uniform pore structure within the crystalline material leading to structural stability and, ultimately, resulting in improved selectivity and lifetime. The calcination conditions of a catalyst can critically effect the catalytic activity. The selected calcination gas (for example, oxygen or nitrogen) can effect catalyst species differently. In general, calcination temperatures for crystalline molecular sieve catalysts can vary from 300°C to 1000°C. For a zeolite such as hydrogen mordenite, the optimal temperature ranges were found experimentally to lie between 400°C and 600°C but, preferentially, at 500°C. (Mathur, Kuldeep, Narain, PhD. Thesis, University of Pittsburgh, 1977.) In the case of hydrogen mordenite, removal of extra- and intra-crystalline water can be accomplished effectively in the presence of an atmosphere of oxygen or nitrogen. This, however, would not be true in the case of organic residues present on the catalyst surface. In this case, the calcination temperature and the calcination gas are both important. When organic residues are present, an atmosphere (preferably nitrogen) is used so that a minimal amount of water results when bringing the catalyst to calcination temperature. After a period of time sufficient to carbonize the organic residue, the atmosphere is changed to oxygen at a temperature sufficient to combust the carbonized residue to C0 2 while minimizing water formation. The distribution of framework and non-framework aluminum in the zeolite samples may be determined by 27 AI-MAS-NMR. We have used the following equipment and procedures for such measurement. Spectra may be obtained on a Bruker MSL400 spectrometer by spinning samples at ten kHz in 4 mm zirconia rotors in a Bruker double air bearing CPMAS probe. The resonance frequency for aluminum was 104.261 MHz. The radio frequency power may be adjusted to give 7 μsec 90" pulse on an aqueous solution of AICI 3 . The signal from this solution sample may be also used as a chemical shift reference and set to 0.0 ppm. An excitation pulse length of 3 μsec (35 * tip angle) may be used for all experimental determinations of aluminum distribution. Shorter (1 μsec to 2 μsec) and longer (>5 μsec) excitation pulses have been tested and found to give unreliable aluminum distributions. A spectral width of 100 kHz is desirable. One thousand free induction decays (FID's) should be co-added to produce the final spectrum. Spectrometers used for such measurements should meet certain criteria. The primary requirement is a fast recovery receiver/probe combination (ringdown of 5 μsec or less) to allow the observation of broad line width components in the aluminum spectrum. The procedure for determining aluminum distribution is as follows. The 27 AI-MAS-NMR spectrum of the sample is obtained per the description above. The FID may contain two components: a fast decaying signal (line width typically 20 kHz) and a slow decaying component (line width typically one kHz). Fourier transformation of the FID's show that the narrower signal has a chemical shift of 54-55 ppm whereas the broad signal has a chemical shift of approximately 0 ppm. The narrower component corresponds to the aluminum in the zeolite framework. The broader signal corresponds to non-framework aluminum. Quantitation of the relative amounts of each component is accomplished by graphical evaluation of the FID's. See, "Perspectives in Molecular Sieve Science", ed. W.H. Flank and T.E. Whyte, ACS Series 368, 1988, p. 2032. The narrow and broad components are extrapolated back to zero time and the initial intensity of each component then determined. The ratio of the intensities of the broad component to the narrower component (B/N) is then calculated. Thus a zeolite with little non-framework aluminum present will have a small value for for B/N. A sample with a large B/N will have significant amounts of the aluminum in the sample present as non- framework species. Throughout the specification we will use the shorthand notation "NMR ratio" to mean this B/N value. According to the present invention biphenyl, 4-isoalkylbiphenyl, or mixtures may be fed to an alkylation reactor together with the alkylation agent in the presence of a shape selective catalyst which is an acidic, crystalline molecular sieve under conditions sufficient to convert the biphenyl compound and alkylation agent to dialkylbiphenyl. The reactor can be a fixed bed or trickle bed type of reactor. A batch reactor (such as a stirred tank reactor) is suitable as well. Specifically for the preferred product, the reaction of a biphenyl with the alkylating agent may take place in any convenient reaction medium and reactor. The biphenyl compound may be in liquid form or in a solution. The alkylating agent may be in a liquid or gaseous form and, depending upon the reaction device chosen, may be added continuously or in a single batch at the beginning of a reaction cycle in the batch reactor. The catalyst may be also in the particulate or granular form and may be placed in a fluidized bed, a stirred bed, a moving bed, or a fixed bed. The catalyst may be in suspension or in a spouted bed. Reactive distillation columns may also be utilized. The ratio of alkylating agent to biphenyl compound should be between 0.01 and 100 and preferably between 1.0 and 10.0. The reaction is preferably carried out in the liquid state and the temperature should be between 100°C and 400°C, preferably between 225°C and 350°C and the pressure should be between one to 100 atmospheres. The amount of catalyst is easily determinable and in general should be enough to promote the reaction to produce a product having, in general, a 4,4'-dialkyIated product in excess of that expected on an equilibrium catalyst such as silica-alumina. Typically the weight ratio of aromatic compound to catalyst would be in the range of 1:1 to 200:1. Some optimization within that range would obviously be appropriate. Separation of the dialkylated biphenyl product may be by standard techniques such as a distillation, crystallization, adsorption, or the like. Reaction conditions when using ZSM-12 to make 4,4'-diisopropybiphenyI can utilize low propylene flow rates and low partial pressures of propylene. In addition the contact time can be sufficient to obtain equilibrium distribution of products were the reation to take place in the absence of a truly shape selective catalyst. In order to confirm the enhancement of 4,4'-isomer production using ZSM-T2 the catalysts of the present invention, various other catalysts were employed in the alkylation reactor as well. The present invention involves the use of particular zeolitic materials in their acidic or hydrogen form. It was surprisingly found that ZSM-12 would form 4,4'-diisopropylbiphenyl in high yield by the combination of propylene with biphenyl or 4-isopropylbiphenyl under conditions where equilibrium can be achieved. For the mordenite catalysts to give the highest yields of 4,4'- diisopropylbiphenyl, propylene pressures and flow rates needed are typically greater than parameters used for ZSM-12 but are not limited to those parameters. Conditions Used in the Examples A stirred autoclave reactor was chosen for this work. It is conveniently operated and was suitable for the purposes of screening for selectivity improvements. The experiment is not limited to this type of reactor. A fixed bed or trickle bed reactor would work as well. The catalysts were tested in a 300 cc Autoclave Engineers autoclave. The reaction used gaseous propylene. The propylene feed rate was regulated via a mass flow controller or a pressure regulator. By regulating the propylene feed rate, the system could be operated between propylene-limited conditions and propylene-rich conditions. The former conditions simulate an equilibrium limited reaction. The analytical results were obtained by gas chromatography. In testing a catalyst, 90 g biphenyl and from 0.5 g to 3.0 g of catalyst were charged and gaseous propylene was fed at either a constant flow from a mass flow controller or through a pressure regulator. In all cases unless noted, periodic samples were withdrawn and analyzed by GLC. The reaction temperature was between 40 * C and 285°C although the reaction temperature varied from 225°C and 350 * C. The propylene pressure can be from 0.1 to 100 atmospheres, preferably one to ten atmospheres. All data expressed in the tables are as mole percent selectivity. The methods used in this study to calculate these parameters used for comparing catalyst performance are as follows: Moles "X" Peak Area of "X" Number of Carbons in "X" Mole Percent "X" = Moles "X" 100 Sum of Moles of all Species in Sample Mole Percent = Moles "X" x 100 Selectivity Sum of Moles of All Alkylated Species in Sample % Conversion 100 - Mole Percent Substrate in Sample % 4,4'-Dialkylate Moles 4.4' x 100 Sum of Moles of Dialkylates in Sample 4,473,4' = Moles 4.4' Moles 3,4' It was recognized that for comparative purposes on issues dealing solely with selectivity that a more useful measure of performance other than selectivity to the 4,4' isomer was needed. Instead, a more convenient measure of relative performance was devised, that is, the 4,4'/3,4' ratio gave an assessment of the primary objective, which was to produce more 4,4' than 3,4'. The percentage of 4,4'/dialkylates gave a measure of the amount of desired isomer produced among all dialkylates. A series of comparative examples were conducted under equilibrium limiting conditions. In this series, the uniqueness of ZSM-12 over a particular non-inventive, non-dealuminated mordenite and certain other catalysts is clearly evident. Example 1 In this example, 90 g of biphenyl and 2.0 g of a silica-alumina (SA) catalyst were charged to an autoclave reactor (300 cc) and gaseous propylene was fed at a constant flow from a mass flow controller. The flow rate was 100 cc/minute and the reaction temperature was 275°C. In this way the amount of propylene was at a minimum and the distribution of products were at equilibrium. This was shown by following the 4,473,4' and the percenetage 4,4'/total DIPBP ratios for silica-alumina as a function of conversion. At equilibrium these values are nearly constant (see Table I below). Table I Following the procedure in Example 1, zeolite catalysts were tested under conditions where an equilibrium distribution of products were obtained with a non-shape selective catalyst. These data show the uniqueness of ZSM- 12 and SAPO-11 over a non-dealuminated H-Mordenite as a shape selective catalyst under equilibrium conditions. Table II In order to demonstrate the preferred Si/AI ratio, the following ZSM-12 catalysts were tested according to Example 2. As can be seen, the most preferred ZSM-12 catalyst (Si/AI = 18) shows a higher rate of alkylation and a longer catalyst lifetime than the less preferred ratio (Si/AI = 47). The less preferred catalyst was essentially inactive after 7 hours. Table III We have found a reproducible method to synthesize ZSM-12 in various particle sizes (Table IV). At 165°C and a constant gel water content the particle size was varied by changing the Si/AI ratio in the starting gel. The source of the various reactants were: Si = colloidal Si0 2 , Al = AI(N0 3 ) 3 hydrate. In a typical synthesis, 160 g H 2 0 and 3.36 g NaOH were combined and stirred. To this solution 29.6 g triethylmethylammonium bromide was dissolved and 3.36 g of AI(N0 3 ) 3 was added and dissolved by stirring. To this solution 42.0 g of 30% collodial Si0 2 was added. This gel was placed in a Teflon lined autoclave and heated to 165°C for several days. The crystallized ZSM-12 was isolated by filtration and washed with water. The bulk ICP analysis shows that the crystallized ZSM-12 has a Si/AI ratio which is quite similar to the stoichiometry used in the synthesis. In all cases, the zeolite is 100% crystalline and free from major contaminants. Table IV also shows that changes in both the water content and Si/AI ratio can dramatically effect the particle size. Table IV EΞxample Gel StoichiometrvfAI:Si:H-,Q^ Si AI Particle size fSEM^ 1 23:2400 21 0.1 x 0.5 mm 2 35:2400 29 1 x 1 mm 3 50:2400 43 1 x 2 mm 4 75:2400 66 1 x 3.5 mm 5 33:8700 30 1 x 3.5 mm 6 1400:9000 430 2 x 15 mm The ZSM-12 is obtained from the reaction mixture is in the template- sodium form. In order to activate the catalyst it must first be calcined in air at 650°C for eight hours. Subsequent ion exchange with 5 N NH 4 CI for two hours at 100°C yields the ammonium form which after calcination at 110°C for two hours followed by calcination at 650°C for twelve hours (both in air) yields the acid form. Example 5 ZSM-12 catalyst similar to the Example 4 material was tested in a stirred autoclave at 275°C at 50 psi propylene pressure. The catalyst loading was 90 g biphenyl to 1 g ZSM-12 in its acidic active form. The reactor was sampled periodically and the results from the GC analysis are shown in Table IV. A catalyst similar to that in Example 4 was tested under different reaction conditions. These data show that the highest yields of 4,4' diisopropylbiphenyl are obtained when high reaction temperature and low to moderate propylene pressures are used. Table VI In Examples 7 to 9 the diisopropylation of biphenyl is shown using dealuminated mordenites as a method for producing the desired dealuminated mordenites. Example 12 shows that neither ZSM-12 nor the preferred mordenite are suitable choices for the diethylation of biphenyl. Example 7 This example shows the production of a preferred mordenite catalyst. Ten grams of Toyo Soda H-Mordenite was loaded in a fritted quartz tube and placed vertically in a tube furnace. A slow helium flow of about 200 cc/minute was introduced and the furnace heated to 400°C. At 400°C, steam- saturated helium was introduced at a flow rate of about 1.5 liters/minute. After 30 minutes the steam was discontinued, the helium flow was lowered to about 200 cc/minute and the furnace cooled to room temperature. The solid was then transferred to a 500 ml round-bottom flask equipped with a condenser and a stir bar. Two-hundred milliliters of 0.5 N hydrochloric acid was introduced and the resultant mixture and refluxed for four hours. After cooling, the solution was filtered and washed with distilled water until the filtrate was free of chloride ions by a AgN0 3 test. The solid was first dried at 110°C for two hours then calcined at 500°C for twelve hours. The Si/AI ratio of this material was 19.0. This mordenite was then analyzed using x-ray diffraction. The resulting spectrum was compared to the line intensities reported for two (of the four known) crystal symmetries for mordenite: Cmmm and Cmcm. Definitions of these symetries may be found in the work of N.F.M. Henry et al.. International Tables for X-Rav Crvstalloαraphy. 3rd Ed. Vol. 1, Knyoch Press (1960). The calculated values for the intensities of the various peaks have been reported by J.D. Sherman et al.. "Framework Structures Related to the Zeolite Mordenite", Molecular Sieves. W.M. Meier and J.B. Uytterhoeven Eds., Advances in Chemistry Series, 121 1973, pp. 52-65. Calculated values for both sodium substituted and hydrogen form Cmmm and Cmcm crystalline phases are shown in Table VII as are the values for the as-received zeolite and its dealuminated form. As should be clear from the calculated data, the most relevent peaks for differentiating between the Cmmm and Cmcm phases are the [001], [401], and [601] reflections, all of which correspond to a plane reflection of the Cmmm symmetry. These peaks are missing both from the beginning zeolite and its dealuminated analog. Consequently, there is no Cmmm phase material in the inventive mordenite. Additionally, since the peaks match well with the calculated peaks for the Cmcm phase, an amount of that phase is present. **as-received H-form mordenite ***dealuminated mordenite Example 8 The method of dealumination used in this comparative example generally follows the procedure disclosed in Example 1 of EPA 0,317,907 (EPA '907) which also shows a process for the production of dialkylated biphenyl. This material began as a Toyo Soda H-Mordenite. It was calcined in air at 700°C for two hours, refluxed in 6N-HN0 3 for two hours, washed, rinsed, and again calcined in air at 700°C for two hours. This procedure resulted in a material having a Si/AI ratio of 120, a value above the desired range of this invention but within the most preferred range of EPA '907. Example 9 The preferred mordenite catalyst sample produced in Example 7 was then tested for activity. Into a stirred 300 cc autoclave were introduced 90 g of biphenyl and 1.0 g of zeolite sample. After an initial pressurization of nitrogen, the autoclave was heated to 275°C. Propylene gas was continuously introduced and the reactor pressure was manually maintained at about 110 psig. The reactor temperature was maintained at about 275°C. Samples were taken about once an hour and analyzed using a gas chromatograph. The results from each of the three runs made using the catalyst are shown below: Table VIII 2nd Run Example 10 The Example 9 procedure was repeated using the comparative catalyst of Example 8. The results of these are shown below: Table IX Results of Diisopropylation of Biphenyl Using Catalyst of Example 8 (Si/AI = 1.20) Reaction % 4,4 in Time (Hrs.) Conversion % Mono % Di's % Other Di's 1st Run 0.25 0.50 1.00 2.00 3.25 2nd Run 0.75 1.10 2.20 3.0 It is clear that the overall conversion with the non-preferred mordenite catalyst is lower and shows lower stability than the preferred mordenite. Example 11 A preferred mordenite catalyst similar to Example 7 was tested under different reaction conditions. These data show that the highest yields of 4,4' diisopropylbiphenyl are obtained when low reaction temperature and moderate to high propylene pressures are used. Table X RxnTfC) C'Pres BP/Ca 240 C 150 psi 180:1 285 C 3 5 psi 180:1 This comparative example attempts the alkylation of biphenyl using ethylene as the olefin. A sample of three g of zeolite (ZSM-12) was similar to that obtained from Example 4 and the preferred mordenite was similar to that obtained from Example 7 to 90 g biphenyl in a stirred autoclave. The reactor was heated to 300°C and ethylene was introduced until the ethylene pressure was maintained to 80 psi. Periodic samples were withdrawn and the results of the analysis are shown below. Table XI These data show the effectiveness of these catalysts for the selective diethylation of biphenyl. The invention has been shown both by description and by example. The examples are only examples; they should not be used in any fashion to limit the scope of the invention otherwise described here. Additionally, it should be clear that one having ordinary skill in this art would envision equivalents to the processes described in the claims that follow and these equivalents would be within the scope and spirit of the claimed invention.

Claims: WE CLAIM AS OUR INVENTION: 1. A process for producing a dialkylbiphenyl stream containing more than an equilibrium amount of 4,4'-dialkylbiphenyl comprising the steps of: a. providing biphenyl, isoalkylbiphenyl, or mixtures of them and an alkylating agent to an acid shape selective catalyst characterized as having pore aperture dimensions between 6.0A and 7.1 A; and b. reacting said biphenyl, 4-isoalkylbiphenyl, or mixtures with the alkylating agent in the presence of said catalyst under conditions sufficient to convert said biphenyl or 4-alkyIbiphenyl to 4,4'- dialkylbiphenyl and thereby produce a dialkylbiphenyl stream containing 4,4'- dialkylbiphenyl. 2. The process of Claim 1 where the alkylating agent is propylene. 3. The process of Claim 2 where the dialkylbiphenyl stream is a diisopropylbiphenyl stream and contains both 3,4'- diisopropylbiphenyl and 4,4'-diisopropylbiphenyl and where the 4,4'-diisopropylbiphenyl/3,4'-diisopropylbiphenyl ratio is equal to or greater than 0.36 at a process temperature higher than 200 * C. The process of Claim 3 where diisopropylbiphenyl stream additionally comprises dialkylate isomers and the percentage of 4,4'-diisopropylbiphenyl in the dialkylate isomers is equal or greater than 20%. 5. The process of Claim 1 where said catalyst is a member selected from the group consisting of SAPO-11, ZMS-12, and dealuminated synthetic mordenites having a Si/AI ratio between five and 100 and an NMR ratio between zero and five. 6. The process of Claim 1 where said catalyst is ZSM-12. 7. The process of Claim 1 where said reaction is not carried to equilibrium. 8. The process of Claim 1 where said catalyst is ZSM-12 and is characterized as possessing a Si:AI ratio of between approximately ten to 100. 9. The process of Claim 8 where said Si:AI ratio of the ZSM-12 is between approximately 15 to 45. 10. The process of Claim 1 where the reaction step is carried out under a propylene pressure between one and 50 atmospheres. 11. The process of Claim 10 where the propylene pressure is between one and ten atmospheres. 12. The process of Claim 1 additionally comprising the step of oxidizing the 4,4'-dialkybiphenyl to 4,4'-dihydroxybiphenyl or 4,4'- dicarboxybiphenyl. 13. A process for producing dialkylated biphenyls comprising the steps of: a. contacting a biphenyl compound with an alkylating agent in the presence of an acid crystalline molecular sieve catalyst selected from ZSM-12, SAPO-11, and synthetic dealuminated mordenites having Si/AI ratios between five and 100 substantially no Cmmm phase under conditions sufficient to convert the biphenyl compound and alkylating agent to dialkyl biphenyl; and b. recovering the dialkylated biphenyl. 14. The process of Claim 13 where the biphenyl compound is - selected from the group of biphenyl, 4-alkyl biphenyl, and mixtures. 15. The process of Claim 14 where the alkylating agent is a C 3 to C 12 olefin. 16. The process of Claim 15 where the C 3 to C 12 olefin is propylene. 17. The process of Claim 14 where the catalyst is a mordenite having a 27 AI-MAS-NMR ratio between zero and five. 18. The process of Claim 17 where the 27 AI-MAS-NMR ratio is between zero and one. 19. The process of Claim 14 additionally comprising the step of oxidizing the 4,4'-dialkylbiphenyl to 4,4'-dihydroxybiphenyl or 4,4'- dicarboxybiphenyl.

Inventors: DEROUANE ERIC G, FELLMANN JERE D, LU PHAT T, MASSIANI PASCALE, SAXTON ROBERT J, WENTRCEK PAUL R, DEROUANE, ERIC, G., FELLMANN, JERE, D., LU, PHAT, T., MASSIANI, PASCALE, SAXTON, ROBERT, J., WENTRCEK, PAUL, R.
Applicants: CATALYTICA INC, CATALYTICA, INC.
Application year: 1990
Main classification: C07C2
IPC codes: C07C2, C07C37, C07C51