Abstract:
Dimethyldichlorosilane is directly prepared from methyl chloride and silicon, in high productivity, selectivity and degree of silicon conversion, by reacting methyl chloride with a solid contact mass comprising silicon and a catalytically effective amount of a catalyst which includes (1) elemental copper or a copper compound, (2) from about 30 to 1,000 ppm (calculated as metallic tin and/or antimony) of at least one of the metals tin and antimony, or at least one compound of at least one of the metals tin and antimony, and (3) from about 0.05 to 2% by weight, (calculated as alkali metal) of at least one of the alkali metals lithium, sodium, potassium and rubidium, or compound thereof, the amounts of said components (2) and (3) being based upon the total weight of said solid contact mass.

Description:
BACKGROUND OF THE INVENTION 
     Cross-Reference To Related Application 
     Our copending application, Ser No. 655,715, filed Sept. 28, 1984 and assigned to the assignee hereof. 
     Field of the Invention 
     The present invention relates to a process and catalyst for the direct synthesis of dimethyldichlorosilane from methyl chloride and silicon. 
     Description of the Prior Art 
     The industrial process for the production of organochlorosilanes and in particular of dimethyldichlorosilane, hereinafter referred to as DMCS, is well known and is described in detail in U.S. Pat. No. 2,380,995, as well as in the Walter Noll text, Chemistry and Technology of Silicones, pp. 26-41, Academic Press, Inc. (1968). 
     According to this so-called &#34;direct synthesis&#34; or &#34;Rochow synthesis&#34; process, the organochlorosilanes and, in particular, DMCS are directly produced by reacting methyl chloride over solid silicon in the presence of copper as a catalyst, in accordance with the reaction scheme: 
     
         2HC.sub.3 Cl+Si→(CH.sub.3).sub.2 Cl.sub.2 Si. 
    
     In reality, other compounds are formed during such direct synthesis, especially CH 3  Cl 3  Si, hereinafter referred to as MTCS, and (CH 3 ) 3  ClSi, hereinafter referred to as TMCS. 
     Other byproducts are also formed, such as, for example, MeHSiCl 2  and Me 2  HSiCl (Me=methyl) and non-volatile materials which are polysilanes, especially disilanes. 
     Among all of the compounds produced by the aforesaid direct synthesis, DMCS is the most desired. From this compound it is possible to prepare, after hydrolysis and polymerization, oils and gums which are base materials used in the production of silicones. Thus, DMCS is used for the preparation of polyorganosiloxane resins, as described in U.S. Pat. Nos. 2,258,218 to 2,258,222, for the preparation of oils described in U.S. Pat. Nos. 2,469,888 and 2,469,830 and for the preparation of polyorganosiloxane elastomers, described in U.S. Pat. No. 2,448,756. 
     The copper or copper compounds employed as the catalyst in the aforesaid direct synthesis reaction may be in the form of an alloy or in mechanical admixture with silicon, optionally deposited upon an inorganic carrier material. 
     It has also been proposed to add various additives to the copper to improve the yield of DMCS. These additives can be zinc or a zinc halide (U.S. Pat. No. 2,464,033), aluminum (U.S. Pat. Nos. 2,403,370 and 2,427,605), tin, manganese, nickel and silver (British Patent Specification No. 1,207,466), cobalt (British Patent Specification No. 907,161) and potassium chloride (U.S.S.R. Pat. No. 307,650). 
     The immediately aforesaid processes which employ such additives undoubtedly make it possible to improve the direct synthesis process, but they nevertheless suffer from at least one of the following disadvantages: 
     (1) the selectivity with respect to DMCS, measured as the average weight ratio MTCS/DMCS, and/or in terms of the molar percentage of DMCS relative to the total amount of silanes obtained, remains inadequate; 
     (2) the starting time and starting temperature of the reaction are too high; 
     (3) the mean activity of the catalyst system, also referred to as the productivity, measured in weight of methylchlorosilanes (MCS) obtained per hour and per kg of silicon introduced, and the maximum degree of conversion of the silicon, remain inadequate; 
     (4) the catalyst system is too sensitive to impurities; and 
     (5) the formation of byproducts and in particular of disilanes remains high. 
     SUMMARY OF THE INVENTION 
     Accordingly, a major object of the present invention is the provision of an improved process/catalyst for the direct synthesis of DMCS from methyl chloride and silicon, which improved process is conspicuously devoid of the above disadvantages and drawbacks to date characterizing the state of the art, or which at very least dramatically reduces the adverse effects thereof. 
     Indeed, by use of the improved process/catalyst according to this invention, there are attained: 
     (i) a high mean selectivity with respect to DMCS, while at the same time increasing productivity, namely, increasing the amount of MCS produced per unit time and per unit contact mass; 
     (ii) a high initial selectivity upon commencement of the reaction, which can be maintained up to the final deterioration of the catalyst system; 
     (iii) a high maximum degree of conversion of the silicon; 
     (iv) a low proportion by weight of &#34;non-volatile&#34; products relative to the MCS obtained; 
     (v) a lesser sensitivity of the catalyst system to impurities which are a catalyst poison (in particular, to lead); 
     (vi) a reaction temperature which is not too high. 
     Briefly, the present invention features an improved process for the direct synthesis of dimethyldichlorosilane by reacting methyl chloride with a solid contact mass of silicon and a catalyst comprising (1) copper or a copper compound, (2) from about 30 to 1,000 ppm (calculated as tin and/or antimony metal) of at least one of the metals tin and antimony, or of a compound of tin and/or antimony, and (3) from about 0.05 to 2% by weight, preferably from 0.1 to 1% by weight (calculated as alkali metal) of at least one of the alkali metals lithium, sodium, potassium and rubidium, or compound thereof, relative to total amount by weight of the solid contact mass comprising the silicon and catalyst. 
     DETAILED DESCRIPTION OF THE INVENTION 
     More particularly according to the present invention, the subject catalyst is advantageously used in an amount ranging from 1 to 30% by weight, preferably from 5 to 12% by weight, of the total weight of the contact mass, i.e., the mixture of silicon plus catalyst. 
     The catalyst can be incorporated into the silicon in the form of an alloy or in mechanical admixture therewith. 
     In addition to metallic copper, a copper compound may also be used, notably a copper halide or a copper oxide, for example, CuO and Cu 2  O, as described in U.S. Pat. No. 2,464,033. 
     Exemplary of the copper halides, cupric chloride or cuprous chloride are representative. It has in fact been shown according to the present invention, that best results, especially with respect to selectivity and degree of conversion of silicon, are obtained if the copper is introduced in the form of cuprous chloride or cupric chloride. 
     In a preferred embodiment of the invention, the catalyst further contains metallic zinc or a zinc compound, preferably zinc chloride or zinc oxide. 
     The zinc can be present in an amount by weight ranging from 0.1 to 3%, preferably from 0.2 to 1% (calculated as zinc metal) by weight, relative to the total weight of the solid contact mass. Up to 90%, preferably up to 50%, by weight of the zinc can be replaced by some other metal which catalyzes the chlorination of copper and/or which forms a eutectic, or a phase of low melting point, with the copper salts and/or the alkali metal salts. 
     As suitable such metals, representative are aluminum, cadmium, manganese, nickel and silver. 
     In addition to the pure alkali metals, Li, Na, K and Rb, whether used singly or in admixture thereof as the catalyst component (3), compounds of such alkali metals may also be used, notably the halides and preferably the chlorides. Rubidium, and to a lesser extent potassium, whether alone or in admixture, or in the form of compounds thereof, advantageously the chlorides, are the preferred catalyst components (3). 
     It is most preferred that the silicon be in particulate form, with the particle sizes thereof being such that the diameter of at least 50% by weight of the particles ranges from 10 to 500 microns. 
     Likewise, the catalyst is also preferably in the form of particles whose mean diameter advantageously ranges from 1 to 100 microns. Under these conditions of particle size of the contact mass, the direct synthesis reaction can be carried out using a contact mass in the form of a fluidized bed. 
     The direct synthesis according to the invention can typically be carried out in one of the following three types of apparatus: a reactor of the stirred bed type, such as that described in U.S. Pat. No. 2,449,821, a reactor of the fluidized bed type, as described in U.S. Pat. No. 2,389,931, or a rotary furnace. 
     The catalyst can also be used when deposited onto a particulate inorganic carrier material, such as sand, ground silica, silica gel, alumina, ground refractory brick, petroleum cracking catalysts, zeolites and calcined clays, as described in French Pat. No. 1,545,407. 
     The reaction advantageously takes place at a temperature ranging from 280° to 450° C., preferably from 290° to 370° C. 
     The reaction can be directly carried out at the temperature selected without commencing the reaction at a higher temperature, especially if the reaction temperature selected is on the order of 330° C. or more and the reaction is carried out in a fluidized bed. 
     The amount by weight of the alkali metal or alkali metal compound, calculated as the alkali metal, advantageously ranges from about 0.05 to 2% by weight relative to the weight of the total amount of contact mass, preferably from 0.1 to 1% by weight. Below 0.05%, the influence of the alkali metal is not genuinely detectable and above 2% by weight the alkali metal tends to poison the catalyst which significantly lowers the selectivity. 
     The amount by weight of tin and/or antimony, or tin compound and/or antimony compound (calculated as tin and/or antimony metal), advantageously ranges from about 30 to 1,000 ppm, preferably from 80 to 250 ppm, relative to the total amount by weight of contact mass. 
     It is necessary to use at least about 30 ppm of tin and/or antimony. It has in fact been shown according to the invention that the beneficial effects of the alkali metal or alkali metal compound are only obtained in the presence of tin and/or of antimony. Moreover, an amount by weight greater than 1,000 ppm would adversely affect the reaction and especially the selectivity thereof. Tin, which is the preferred metal, can be added in the form of bronze or as a tin compound, for example, tin chloride. 
     It too has been shown that if it is desired to carry out the reaction at a temperature below 350°-360° C., while retaining substantially the same advantages, zinc or a zinc compound, preferably zinc chloride, can be added in an amount by weight ranging from 0.1 to 3%, preferably from 0.2 to 1%, relative to the total amount of contact mass. 
     By using a catalyst according to the invention, very high selectivities can be achieved if the reaction is carried out in a stirred bed at a temperature of 330° to 350° C. 
     Thus, it is possible to obtain a mean ratio by weight of MTCS/DMCS typically ranging from 0.05 to 0.15, most commonly ranging from 0.07 to 1.2, and a mean molar % of DMCS, relative to the total silanes obtained, on the order of or greater than 80% and even as high as 90% or more, a maximum degree of conversion of silicon on the order of or greater than 55% and even as high as about 70% and a mean activity on the order of or greater than 125 g of MCS/h/kg of Si and even as high as 180 g of MCS/h/kg of Si, or more. 
     A selectivity on the order of or greater than 80% is strikingly unexpected and surprising in comparison with the selectivities which are obtained using catalyst masses of the same type, but not containing the alkali metal, as will be seen from the examples of French Pat. No. 1,545,407. 
     Moreover, if a contact mass according to the invention, but not containing tin and/or antimony is used, a contact mass which has very low activity and thus cannot be used industrially is obtained. 
     The percentage of non-volatiles obtained relative to the MCS obtained, can be on the order of 2% and is typically less than about 4%. 
     These results can be further improved if the reaction temperature is increased. Similar results are obtained if the reaction is carried out in a fluidized bed. 
     If the reaction is carried out at a temperature below 340° C. in a stirred bed, it is desirable to begin the reaction for about 20 to 30 minutes or so at a temperature above 340° C. This starting procedure is unnecessary if the reaction is carried out at a temperature above 340° C. in a stirred bed. 
     In order to further illustrate the present invention and the advantages thereof, the following specific examples are given, it being understood that same are intended only as illustrative and in nowise limitative. 
     In said examples which follow, unless otherwise indicated, a cylindrical pilot reactor having an internal diameter of 60 mm and a height of 250 mm height was used, equipped at its base with a sintered glass gas distributor. The silicon and the catalyst were introduced therein in the form of a powder of a mean size such that at least 50% of the particles ranged in size from 60 to 200 μm. 
     The reaction was carried out in a stirred bed and the reactor was equipped with an external heating element. 
    
    
     EXAMPLE 1 
     Catalyst system: CuCl/ZnCL 2  /Sn/KCl 
     A powder consisting of 210 g of silicon, 16.37 g of cuprous chloride, 0.835 g of potassium chloride, 1.53 g of ZnCl 2  and 1.99 g of bronze containing 1.9% of tin, the percentage by weight of KCl relative to the total weight of the contact mass being 0.36, was introduced into a vertical cylindrical reactor made of glass and equipped with a metal stirrer and a sintered glass gas distributor. 
     The reactor was gradually heated to 200° C. under a stream of nitrogen. Thereafter, while continuing to raise the temperature of the reactor, the nitrogen valve was closed and the introduction of methyl chloride was commenced at a flow rate of 16 liters/hour, measured at 20° C. 
     After 1 hour of heating, regulated to 345° C., the flow rate of methyl chloride was increased to 26 liters/hour and maintained at this value until the reaction spontaneously completely stopped. The reaction temperature was 330° C. 
     This experiment produced chlorosilanes for 21 hours at a mean productivity or mean activity of 184 g of MCS per hour and per kg of Si introduced into the reactor. The mixture produced was characterized by a mean weight ratio MTCS/DMCS of 0.126 and a mean molar % of DMCS of 82.23. 
     The proportion of non-volatiles (polysilanes) obtained was 3.62% by weight. 
     Vapor phase chromatography evidenced the following mean molar selectivities: 
     Me 3  SiCl: 5.58% 
     MeSiCl 3  : 8.97%. 
     The maximum degree of conversion of the silicon was 84.3%. 
     EXAMPLE 2 
     Catalyst system: CuCl 2  /ZnCl 2  /Sn/RbCl 
     A powder consisting of 210 g of silicon, 1.53 g of ZnCl 2 , 16.37 g of cuprous chloride, 1.355 g of potassium chloride and 1.99 g of bronze containing 1.9% of tin was introduced into a vertical cylindrical reactor made of glass and equipped with a metal stirrer and a sintered glass gas distributor. 
     The percentage by weight of RbCl relative to the total weight of the contact mass was 0.58. 
     The reactor was gradually heated to 200° C. under a stream of nitrogen. Thereafter, while continuing to raise the temperature of the reactor, the nitrogen valve was closed and the introduction of methyl chloride was commenced at a flow rate of 16 liters/hour, measured at 20° C. 
     After 1 hour of heating, regulated to 345° C., the flow rate of methyl chloride was increased to 26 liters/hour and maintained at this value until the reaction spontaneously stopped completely. The reaction temperature was 330° C. 
     This experiment produced chlorosilanes for 20 hours at a mean productivity or mean activity of 178 g of MCS per hour and per kg of silicon introduced into the reactor. The mixture produced was characterized by a mean weight ratio of methyltrichlorosilane to dimethyldichlorosilane, MTCS/DMCS, of 0.113 and a mean molar % of DMCS of 84.44%. 
     The proportion of non-volatiles (polysilanes) obtained was 3.16% (by weight). 
     Vapor phase chromatography evidenced the following mean molar selectivities: 
     Me 3  SiCl: 4.32% 
     MeSiCl 3  : 8.26%. 
     The maximum degree of conversion of the silicon was 77.5%. 
     EXAMPLES 3 and 4 
     The reaction was carried out in the same manner as in Example 1, using 210 g of silicon, except that the composition of the catalyst was altered. 
     The results obtained are reported in Table I below: 
     
                       TABLE I______________________________________EXAMPLE                3        4______________________________________Catalyst (in g)bronze (containing 1.9% of Sn)                  1.99     1.99CuCl                   16.37    16.37ZnCl.sub.2             1.53     1.53KCl                    0.15     0.278T° C.Start                  345      345Reaction               330      330Productivity           162      165(g of MCS/h/kg of Si) ##STR1##              0.081    0.097Maximum degree of conversion of Si (%)                  72.4     62.7Mean selectivity, in molar %, of DMCS                  86.49    83.51relative to the silanes obtained______________________________________ 
    
     While the invention has been described in terms of various preferred embodiments, the skilled artisan will appreciate that various modifications, substitutions, omissions, and changes may be made without departing from the spirit thereof. Accordingly, it is intended that the scope of the present invention be limited solely by the scope of the following claims.