Patent Description:
Carbonylation is a process that can be used to react carbon monoxide and an epoxide to make a lactone. In some cases, additional steps are taken to react the lactones to make polymers. These lactones or polymers thereof are often used as plastics and disinfectants. When making these lactones, a carbonylation catalyst is used to optimize the efficiency of the reaction to produce lactones at competitive prices. Carbonylation catalysts are expensive, and thus, new carbonylation catalysts and new techniques to synthesize the carbonylation catalysts from simple components are needed. Further, some current carbonylation catalysts can create unwanted side products that need to be later filtered out. Some carbonylation catalysts can be found in US Patent Nos. <CIT>, <CIT>, and <CIT>. Some of these carbonylation catalysts may provide slow reaction times, can become unstable, and can deactivate during the course of the catalytic carbonylation. <CIT> relates to epoxides, aziridines, thiiranes, oxetanes, lactones, lactams and analogous compounds are reacted with carbon monoxide in the presence of a catalytically effective amount of catalyst having the general formula [Lewis acid]{[QM(CO)x]}y where Q is any ligand and need not be present, M is a transition metal selected from the group consisting of Groups <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> and <NUM> of the periodic table of elements, z is the valence of the Lewis acid and ranges from <NUM> to <NUM>, w is the charge of the metal carbonyl and ranges from <NUM> to <NUM> and y is a number such that w times y equals z, and x is a number such as to provide a stable anionic metal carbonyl for {[QM(CO)x]}y and ranges from <NUM> to <NUM> and typically from <NUM> to <NUM>. <CIT> relates to unimolecular metal complexes having increased activity in the copolymerization of carbon dioxide and epoxides. Also disclosed are methods of using such metal complexes in the synthesis of polymers. Also disclosed are metal complexes comprising an activating species with co-catalytic activity tethered to a multidentate ligand that is coordinated to the active metal center of the complex. <CIT> relates to catalysts and methods for the double carbonylation of epoxides. Each epoxide molecule reacts with two molecules of carbon monoxide to produce a succinic anhydride. The reaction is facilitated by catalysts combining a Lewis acidic species with a transition metal carbonyl complex. The double carbonylation is achieved in single process by using reaction conditions under which both carbonylation reactions occur without the necessity of isolating or purifying the product of the first carbonylation. <CIT> relates to a phenol-phenanthroline IVB group metal complex as well as preparation and application thereof. The complex prepared by the invention not only has higher catalytic activity and good thermal stability when being applied to olefin polymerization, especially olefin/alpha olefin copolymerization, but also is more suitable for a high-temperature polymerization reaction system. The scientific articles <NPL>; <NPL>, and <NPL> provide further technical background information regarding the disclosed subject-matter.

Accordingly, a catalyst is needed that can be used in a carbonylation reaction and that can be recycled, possesses a longer catalytic lifetime, has an increased rate of formation of lactone product, and/or avoid undesirable side products.

Disclosed are compounds that have catalytic activity with one or more of an epoxide, succinic anhydride, or a lactone according to one of the following formulas:
<CHM>
<CHM>
<CHM>
<CHM>
In these compounds, R is separately in each occurrence an hydrogen, alkyl, or aryl group; R<NUM> is separately in each occurrence hydrogen, alkyl, or aryl groups; R<NUM> is separately in each occurrence an alkyl, aryl, or alkoxide group; R<NUM> is separately in each occurrence an alkyl or aryl group; R<NUM> may be separately in each occurrence an alkyl group or a halogen; PL is the residue of a polar ligand; and M is separately in each occurrence a Lewis Acid metal. The invention is as claimed in the appended claims.

Disclosed herein are methods for preparing the above compounds by contacting a compound according to one of the following formulas:
<CHM>
<CHM>
<CHM>
<CHM>
with a metalating agent to form one of the compounds according to the following formula
<CHM>
<CHM>
<CHM>
<CHM>
and contacting the formed compounds with a metal carbonyl under condition such that one of the following compounds are formed:
<CHM>
<CHM>
<CHM>
<CHM>
where R, R<NUM>, R<NUM>, R<NUM>, R<NUM>, PL, and M are described above. The methods may further include contacting the formed compounds, the metal carbonyl, or both with a polar ligand so that that one of the compounds are formed.

Disclosed herein are methods of preparing one of the compounds according to the one of the following formulas:
<CHM>
or
<CHM>
by contacting a phenol which may be substituted at the <NUM> and/or <NUM> position with a hydrogen, alkyl, or aryl group with a halogenating agent under conditions such that a halogen atom is added at the <NUM> carbon atom to form a halogenated phenol. The method further includes contacting the halogenated phenol with a halo-di(aryl or alkyl) phosphine in the presence of an alkyl lithium under conditions to replace the halogen on the phenol with di(alkyl or aryl) phosphate to form a dialkyl or diaryl phosphate substituted phenol. The method further includes contacting the dialkyl or diaryl phosphate substituted phenol with a diamine, an ortho phenylene amine or ortho cyclohexyl diamine in the presence of a source of bromine and a trialkyl amine to form a compound according to the formulas. The method may further include, first, contacting the dialkyl or diaryl phosphate substituted phenol with the source of bromine to form an activated dialkyl or diaryl phosphate substituted phenol, and second, contacting the activated dialkyl or diaryl phosphate substituted phenol with the ethylene diamine, ortho phenylene amine, or the cyclohexyl diamine in the presence of the trialkyl amine to form the compound according to the formulas.

Disclosed herein are methods for preparing one of the compounds according to one of the following formulas:
<CHM>
by:
by contacting a phenol which may be substituted at the <NUM> and/or <NUM> position with a hydrogen, alkyl, or aryl group with a halogenating agent under conditions such that a halogen atom is added at the <NUM> carbon atom to form a halogenated phenol. The method further includes contacting the formed halogenated phenol with a trialkyl borate in the presence of an alkyl lithium compound to replace the halogen atom with a boron dihydroxide group. The method further includes contacting phenol containing a boron dihydroxide group with bipyridine or phenanthroline having halogen groups on carbons adjacent to the nitrogen atoms in the presence of a palladium catalyst and an alkali metal carbonate under conditions to form one of the compounds of the formulas. The trialkyl amine may consume bromic acid to form an ammonium salt. The method may further include contacting the phenol containing a boron dihydroxide group with hydrochloric acid to quench the reaction.

Disclosed herein are methods of preparing one of the compounds according to one of the following formulas:
<CHM>
<CHM>
by contacting a phenol which may optionally be substituted at the <NUM> position with an hydrogen, alkyl, or aryl group with a halogenating agent and silyl halide under conditions such that a halogen atom is added at the <NUM> and <NUM> carbon atoms of the aromatic ring and the <NUM> hydroxyl group is converted to silyl ether group which may optionally be substituted at the <NUM> position with an hydrogen, alkyl, or aryl group. The method further includes contacting the formed <NUM>, <NUM>-halogenated <NUM>-silylether substituted benzene with an alkyl lithium compound and dimethylformamide to form a phenol having a silyl and an acetaldehyde group at the <NUM> and <NUM> positions which may optionally be substituted at the <NUM> position with a hydrogen, alkyl, or aryl group. The method further includes contacting the phenol having a silyl and an acetaldehyde group at the <NUM> and <NUM> positions which may optionally be substituted at the <NUM> position with a hydrogen, alkyl, or aryl group with one of o-phenylene diamine, ethylene diamine, or cyclohexanediamine and optionally in the presence of a Lewis acid or Bronsted acid catalyst and an alkali metal or ammonium salt form one of the compounds corresponding to one of the formulas. The method may further include first contacting the phenol which may optionally be substituted with the halogenating agent to form a halogenated phenol, and second, contacting the halogenated phenol with the silyl halide under conditions such that <NUM> hydroxyl group is converted to silyl ether group which may optionally be substituted at the <NUM> position with an hydrogen, alkyl, or aryl group. The method may further include contacting the halogenated phenol and the silyl halide with a tertiary amine to consume any acid byproduct so that the phenol having a silyl and an acetaldehyde group at the <NUM> and <NUM> positions which may optionally be substituted at the <NUM> position with a hydrogen, alkyl, or aryl group is formed. The method may further include first contacting the formed <NUM>, <NUM>-halogenated <NUM>-silylether substituted benzene with the alkyl lithium compound to form the phenol having the silyl at the <NUM> or <NUM> position, and second, contacting the phenol having the silyl at the <NUM> or the <NUM> position with dimethylformamide to form the phenol having the silyl and the acetaldehyde group at the <NUM> and <NUM> positions which may optionally be substituted at the <NUM> position with a hydrogen, alkyl, or aryl group.

The present disclosure provides carbonylation catalysts containing phosphasalen, phosphasalph, phosphasalcy ligands, <NUM>,<NUM>'-di(<NUM>,<NUM>-disubstituted-<NUM>-hydroxybenzene)-<NUM>,<NUM>'-bipyridine ("Rdhbpy(H)<NUM>" where R is in each occurrence hydrogen, alkyl, or aryl) or <NUM>,<NUM>'-di(<NUM>,<NUM>-disubstituted-<NUM>-hydroxybenzene)-<NUM>,<NUM>'-phenanthroline ("Rdhphen(H)<NUM>" where R is in each occurrence hydrogen, alkyl, or aryl) ligands, and/or silyl substituted salen, salph or salcy ligands that possess catalytic activity with one or more of ethylene oxide, betapropiolactone, and/or succinic anhydride. The present disclosure provides carbonylation catalysts containing phosphasalen, phosphasalph, phosphasalcy ligands, Rdhbpy(H)<NUM> or Rdhphen(H)<NUM> ligands, and/or silyl substituted salen, salph or salcy ligands that have improved steric and electron qualities which improve reaction yields, reduce time of reaction, reduce side products, increase catalyst longevity, increase catalyst stability and are more easily recoverable after a carbonylation reaction.

In accordance with the present invention, PL is the residue of tetrahydrofuran, dioxane, diethyl ether, acetonitrile, carbon disulfide, pyridine, epoxide ester, lactone, or a combination thereof; and M is separately in each occurrence aluminum or chromium.

One or more as used herein means that at least one, or more than one, of the recited components may be used as disclosed. Residue with respect to an ingredient or reactant used to prepare the polymers or structures disclosed herein means that portion of the ingredient that remains in the polymers or structures after inclusion as a result of the methods disclosed herein. Substantially all as used herein means that greater than <NUM> percent of the referenced parameter, composition, structure or compound meet the defined criteria, greater than <NUM> percent, greater than <NUM> percent of the referenced parameter, composition or compound meet the defined criteria, or greater than <NUM> percent of the referenced parameter, composition or compound meet the defined criteria. Portion as used herein means less than the full amount or quantity of the component in the composition, stream, or both. Precipitate as used herein means a solid compound in a slurry or blend of liquid and solid compounds. Phase as used herein means a solid precipitate or a liquid or gaseous distinct and homogeneous state of a system with no visible boundary separating the phase into parts. Parts per weight means parts of a component relative to the total weight of the overall composition. A catalyst component as used herein means a metal centered compound, a metal carbonyl, a Lewis acid, a Lewis acid derivative, a metal carbonyl derivative, or any combination thereof. A catalyst as used herein includes at least cationic compound and an anionic compound. An organic compound as used herein includes any compound that is free of a metal atom. An inorganic compound as used herein includes compounds that include at least one metal atom. Composition as used herein includes all components in a stream, reactant stream, product stream, slurry, precipitate, liquid, solid, gas, or any combination thereof that are containable within a single vessel.

Disclosed herein are compounds and methods useful as carbonylation catalysts that improve steric properties so that reaction with epoxide is improved, reaction with lactones is avoided, and the polymer bonds to the metal centers are weakened, which facilitates faster ring closure and improves stability of the carbonylation catalyst by not being susceptible to hydrolysis. This provides an advantage of reduced side products, improved recovery yields of the carbonylation catalyst after using to make lactones, and improved steric and electron properties so that release time of a lactone product is minimized, which reduces side reactions.

The carbonylation catalysts may include a Lewis acid containing phosphasalen, phosphasalph, or phosphasalcy ligands, Rdhbpy(H)<NUM> or Rdhphen(H)<NUM> ligands, silyl substituted salen, salph, or salcy ligands and may function to catalyze the carbonylation reactions where an epoxide and carbon monoxide react to form one or more lactones described herein. The carbonylation catalysts described herein may also be used to react an aziridine and carbon monoxide to form a lactam.

The phosphasalen, phosphasalph, or phosphasalcy ligands ligand may have the following structure according to Compounds <NUM>, <NUM>, and/or <NUM>:
<CHM>
<CHM>
or
<CHM>
wherein R<NUM> may separately in each occurrence be hydrogen, alkyl or aryl, group; and wherein R<NUM> may separately in each be occurrence an alkyl, aryl, or alkoxide group.

After a metalation step described below, as Lewis acid precursor containing the phosphasalen, phosphasalph, or phosphasalcy ligands is formed, which may have the following structure according to Compounds <NUM>, <NUM>, and/or <NUM>:
<CHM>
<CHM>
or
<CHM>.

To form the carbonylation catalyst, the Lewis acid precursor containing the phosphasalen, phosphasalph, or phosphasalcy ligands is reacted with a metal carbonyl additive, as described below. The final carbonylation catalyst having a Lewis acid precursor containing phosphasalen, phosphasalph, or phosphasalcy may have the following structure according to compounds <NUM>, <NUM>, and/or <NUM>:
<CHM>
<CHM>
;or
<CHM>.

The Rdhbpy(H)<NUM> or Rdhphen(H)<NUM> ligands may have the following structure according to compounds <NUM> and/or <NUM>:
<CHM>
or
<CHM>
wherein R is separately in each occurrence an hydrogen, alkyl, or aryl group.

After a metalation step described below, as Lewis acid precursor containing the Rdhbpy(H)<NUM> or Rdhphen(H)<NUM> ligands is formed, which may have the following structure according to compounds <NUM> and/or <NUM>:
<CHM>
or
<CHM>
wherein R, M, and R<NUM> are described in relation to compounds <NUM>-<NUM>.

To form the carbonylation catalyst, the Lewis acid precursor containing the Rdhbpy(H)<NUM> or Rdhphen(H)<NUM> ligands is reacted with a metal carbonyl additive, as described below. The final carbonylation catalyst having a Lewis acid precursor containing the Rdhbpy(H)<NUM> or Rdhphen(H)<NUM> ligandmay have the following structure according to compounds <NUM> and/or <NUM>:
<CHM>
or
<CHM>
wherein R, M, and PL are described in relation to compounds <NUM>-<NUM>.

The silyl substituted salen, salph, or salcy ligand may have the following structure according to compounds <NUM>, <NUM>, and/or <NUM>:
<CHM>
<CHM>
or
<CHM>.

After a metalation step described below, as Lewis acid precursor containing the silyl substituted salen, salph, or salcy ligand is formed, which may have the following structure according to compounds <NUM>, <NUM>, and/or <NUM>:
<CHM>
<CHM>
;or
<CHM>
wherein R, R<NUM>, R<NUM>, and M are described in relation to compounds <NUM>-<NUM>.

To form the carbonylation catalyst, the Lewis acid precursor containing the silyl substituted salen, salph, or salcy ligand is reacted with a metal carbonyl additive, as described below. The final carbonylation catalyst having a Lewis acid precursor containing the silyl substituted salen, salph, or salcy ligand may have the following structure according to compounds <NUM>, <NUM>, and/or <NUM>:
<CHM>
<CHM>
or
<CHM>
wherein R, R<NUM>, M, and PL are described in relation to compounds <NUM>-<NUM>.

The carbonylation reaction may include contacting one or more epoxides, lactones, or both with carbon monoxide in the presence of catalyst. This step may occur in a reactor that has one or more inlets, two or more inlets, three or more inlets, or a plurality of inlets. The one or more epoxides, the lactones, the carbon monoxide, and the catalyst may be added in a single inlet, multiple inlets, or each may be added in a separate inlet as separate or combined feed streams. The carbonylation reaction may produce one or more product streams or compositions.

The epoxide used in the carbonylation reaction may be any cyclic alkoxide containing at least two carbon atoms and one oxygen atom. For example, the epoxide may have a structure shown by formula (I):
<CHM>
where R<NUM> and R<NUM> in the context of formula (I) are each independently selected from the group consisting of: hydrogen; C<NUM>-C<NUM> alkyl groups; halogenated alkyl chains; phenyl groups; optionally substituted aliphatic or aromatic alkyl groups; optionally substituted phenyl; optionally substituted heteroaliphatic alkyl groups; optionally substituted <NUM> to <NUM> membered carbocycle; and optionally substituted <NUM> to <NUM> membered heterocycle groups, where R<NUM> and R<NUM> can optionally be taken together with intervening atoms to form a <NUM> to <NUM> membered, substituted or unsubstituted ring optionally containing one or more hetero atoms; or any combination thereof.

The lactone formed from the carbonylation reaction may be any cyclic carboxylic ester having at least one carbon atom and two oxygen atoms. For example, the lactone may be an acetolactone, a propiolactone, a butyrolactone, a valerolactone, caprolactone, or a combination thereof. Anywhere in this application where a propiolactone or lactone is used or described, another lactone may be applicable or usable in the process, step, or method. Where a propiolactone is a used or produced in the carbonylation reaction, the propiolactone may have a structure corresponding to formula (II):
<CHM>
where R<NUM> and R<NUM> in the context of formula (II) are each independently selected from the group consisting of: hydrogen; C<NUM>-C<NUM> alkyl groups; halogenated alkyl chains; phenyl groups; optionally substituted aliphatic or aromatic alkyl groups; optionally substituted phenyl; optionally substituted heteroaliphatic alkyl groups; optionally substituted <NUM> to <NUM> membered carbocycle; and optionally substituted <NUM> to <NUM> membered heterocycle groups, where R<NUM> and R<NUM> can optionally be taken together with intervening atoms to form a <NUM> to <NUM> membered, substituted or unsubstituted ring optionally containing one or more hetero atoms; or any combination thereof.

The product stream or composition may include one or more organic compounds including a propiolactone, a polypropiolactone, succinic anhydride, polyethylene glycol, poly-<NUM>-hydroxypropionate, <NUM>-hydroxy propionic acid, <NUM>-hydroxy propionaldehyde, a polyester, a polyethylene, a polyether, unreacted epoxides, any derivative thereof, any other monomer or polymer derived from the reaction of an epoxide and carbon monoxide, or any combination thereof. The product stream or composition may include one or more inorganic compounds that include catalyst components such as metal carbonyls, metal carbonyl derivatives, metal centered compounds, Lewis acids, Lewis acid derivatives, or any combination thereof. A metal carbonyl derivative is a compound that includes one or more metals and one or more carbonyl groups that can be processed to form an anionic metal carbonyl component for use in a carbonylation catalyst. A Lewis acid derivative is a compound that includes one or more metal centered Lewis acids bonded to one or more undesirable compounds at the metal center that can be processed into a cationic Lewis acid for use in a carbonylation catalyst. The product stream or composition may include a catalyst that has not been spent or used up in the process of forming propiolactones. The product stream or composition may include one or more unreacted epoxides or carbon monoxide.

To make the carbonylation catalysts described herein, a phenol may be halogenated to form the basis of the Lewis acid of the carbonylation catalyst in a halogenation step. The phenol may be contacted with a polar solvent a halogenating agent under conditions such that a halogen atom is added at the <NUM> and/or <NUM> carbon atom to form a halogenated phenol. The phenol and the halogenating agent may be added in a molar ratio of about <NUM>:<NUM> or more, about <NUM>:<NUM> or more, or about <NUM>:<NUM> or more. The phenol may be substituted at the <NUM> and/or <NUM> position with a hydrogen, alkyl, or aryl group. The halogenation step may be performed in a polar solvent that is aprotic or protic depending on halogenating agent and the substituted groups of the phenol. The halogenation step may be performed at room temperature and in ambient air. After mixing the phenol and the halogenating agent, the halogenation reaction may be stirred through a known means, such as with a magnetic stir bar. The halogenation reaction may be stirred for about <NUM> hour or more, about <NUM> hours or more or more, or about <NUM> hours or more. The halogenation reaction may be stirred for about <NUM> hours or less, about <NUM> hours or less, or about <NUM> hours or less. The reaction may be quenched, for example, by addition of sodium bicarbonate, which causes the aqueous and organic layers to separate. The halogenated phenol may be isolated using any technique described herein or any known technique. For example, the halogenated phenol may be isolated using simple organic/aqueous extraction to remove aqueous layers, and the organic layers can be dried by adding MgSO<NUM> or Na<NUM>SO<NUM>, stirring with basic alumina, and then filtering over a combination of silica gel and diatomaceous earth.

After making and isolating the halogenated phenol, the halogenated phenol may be further modified with a silyl group in silylation step. The halogenated phenol may be contacted with a polar aprotic solvent and a silyl halide under such conditions such that the <NUM> hydroxyl group of the halogenated phenol is converted to a silyl ether group to form a <NUM>, <NUM>-halogenated <NUM>-silylether substituted benzene. The halogenated phenol and the silyl halide may be added in a molar ratio of about <NUM>:<NUM>. This silylation step may be performed in the presence of a catalyst that functions to facilitate conversion of the hydroxyl group to a silyl ether group. This silylation step may be performed in the presence of a scavenger that may consume any acid formed during the conversion of the hydroxyl to the silyl ether. The scavenger may include one or more of a tertiary amine. The scavenger may include one or more of triethylamine. The scavenger and the halogenated phenol may be added in a molar ratio of about <NUM>:<NUM>, about <NUM>:<NUM>, or about <NUM>:<NUM>. Before addition of the silyl halide, the aprotic solvent and the halogenated phenol may be cooled to about -<NUM> degrees Celsius or more, about -<NUM> degrees Celsius of more, or about <NUM> degrees Celsius or more. The aprotic solvent and the halogenated phenol may be cooled to about <NUM> degrees Celsius or less, about <NUM> degrees Celsius or less, or about <NUM> degrees Celsius or less. After addition of the silyl halide, the silylation step then may be allowed to warm to room temperature and stirred. After addition of the ingredients, the silylation step may be stirred for about <NUM> hours or less, about <NUM> hours or less, or about <NUM> hours or less at room temperature. The silylation step may be stirred for about <NUM> hours or more, about <NUM> hours or more, or about <NUM> hours or more at room temperature. After stirring, the <NUM>, <NUM>-halogenated <NUM>-silylether substituted benzene may be isolated using any known means or any means discussed herein. For example, the solvent may be removed by vacuum filtration, the remaining product stream may be dissolved in a nonpolar solvent, the product stream may be filtered over a filtration bed, such diatomaceous earth, and remove the nonpolar solvent by vacuum filtration.

After making and isolating the halogenated phenol, the halogenated phenol may be subjected to an elimination step to replace the halogen atom on the phenol with a di(aryl or alkyl) phosphate. The halogenated phenol may be contacted with an alkyl lithium compound and a halo-di(aryl or alkyl) phosphine in a polar aprotic solvent to form a dialkyl or diaryl phosphate substituted phenol. The halogenated phenol and the halo-di(aryl or alkyl) phosphine may be added in a molar ratio of about <NUM>:<NUM> or more. The alkyl lithium may be added in an amount sufficient to replace the halogen atom on the phenol. First, the halogenated phenol may be dissolved in the polar aprotic solvent and cooled to about <NUM> degrees Celsius or less, about <NUM> degrees Celsius or less, or about <NUM> degrees Celsius or less. The polar aprotic solvent and the halogenated phenol may be cooled to about <NUM> degrees Celsius or more, about <NUM> degrees Celsius or more, or about <NUM> degrees Celsius or more. After cooling, the halogenated phenol may be contacted with the alkyl lithium compound in the polar aprotic solvent to form an intermediate composition. The intermediate composition may be allowed to warm to about room temperature (i.e., about <NUM> degrees Celsius) and may be stirred for about stirred for about <NUM> hours or more, about <NUM> hours or more, or about <NUM> hour or more. The intermediate composition may be stirred for about <NUM> hours or less, about <NUM> hours or less, or about <NUM> hours or less.

After stirring and before addition of the halo-di(aryl or alkyl) phosphine, the intermediate composition including the halogenated phenol, the alkyl lithium compound, or residues thereof in the polar aprotic solvent may be cooled to about <NUM> degrees Celsius or less, about <NUM> degrees Celsius or less, or about <NUM> degrees Celsius or less. The intermediate composition may be cooled to about <NUM> degrees Celsius or more, about <NUM> degrees Celsius or more, or about <NUM> degrees Celsius or more. After cooling and without isolating any compound within the intermediate composition, the intermediate composition including the halogenated phenol, the alkyl lithium compound, or residues thereof in the polar aprotic solvent may be contacted with the halo-di(aryl or alkyl) phosphine to form the dialkyl or diaryl phosphate substituted phenol in a product composition. After contacting with the halo-di(aryl or alkyl) phosphine, the product composition may be allowed to warm to about room temperature (i.e., about <NUM> degrees Celsius) and may be stirred for about <NUM> hours or more, about <NUM> hours or more, or about <NUM> hours or more. The product composition may be stirred for about <NUM> hours or less, about <NUM> hours or less, or about <NUM> hours or less. The product composition may be washed with a buffer solution to and the organic phase may be removed by any means discussed herein or known by the skilled artisan, such as organic/aqueous extraction. The buffer solution may be potassium phosphate. Accordingly, the dialkyl or diaryl phosphate substituted phenol may be removed or isolated from the product stream by any other known isolation or extraction means. The elimination step may be performed under an inert gas, such as nitrogen, and/or in a dry box or a Schlenk line.

After making and isolating the halogenated phenol, the halogenated phenol may be subjected to an elimination step to replace the halogen atom on the phenol with a boron dihydroxide group. In this step, halogenated phenol may be contacted with an alkyl lithium compound and a trialkyl borate in a polar aprotic solvent to from a phenol containing a boron dihydroxide group at the <NUM> position. The halogenated phenol, the alkyl lithium, and the trialkyl borate may be added in a molar ratio of about <NUM>:<NUM>:<NUM> or more. First, the halogenated phenol may be dissolved in the polar aprotic solvent and cooled to about <NUM> degrees Celsius or less, about <NUM> degrees Celsius or less, or about <NUM> degrees Celsius or less. The polar aprotic solvent and the halogenated phenol may be cooled to about <NUM> degrees Celsius or more, about <NUM> degrees Celsius or more, or about <NUM> degrees Celsius or more. After cooling, the halogenated phenol may be contacted with the alkyl lithium compound in the aprotic polar solvent to from an intermediate composition. The intermediate composition may be warmed to about room temperature (about <NUM> degrees Celsius) and may be stirred for about <NUM> hours or more, about <NUM> hours or more, or about <NUM> hour or more. The intermediate composition may be stirred for about <NUM> hours or less, about <NUM> hours or less, or about <NUM> hours or less. After stirring and before addition of the trialkyl borate, the intermediate composition may again be cooled to about <NUM> degrees Celsius or less, about <NUM> degrees Celsius or less, or about <NUM> degrees Celsius or less. The polar aprotic solvent and the halogenated phenol may be cooled to about <NUM> degrees Celsius or more, about <NUM> degrees Celsius or more, or about <NUM> degrees Celsius or more.

After cooling, the intermediate composition containing halogenated phenol, the alkyl lithium compound, or residues thereof in the aprotic polar solvent may be contacted with the trialkyl borate to form a phenol containing a borate ester at the <NUM> position in a product composition. After contacting with the trialkyl borate, the product composition may be allowed to warm to room temperature and stirred for about <NUM> hours or less, about <NUM> hours or less, or about <NUM> hours or less. The product composition may be stirred for about <NUM> hours or more, about <NUM> hours or more, or about <NUM> hours or more. Subsequently, an acid may be contacted with the product stream containing the phenol containing a borate ester at the <NUM> position in an aprotic solvent to catalyze hydrolysis and form the phenol containing a boron dihydroxide group at the <NUM> position. The acid may include acetic acid, hydrochloric acid, sulfuric acid, nitric acid, boric acid, perchloric acid, or any combination thereof. The acid may have a molarity of about <NUM> or more, about <NUM> or more, or about <NUM> or more. The acid may have a molarity of about <NUM> or less, about <NUM> or less, or about <NUM> or less. After hydrolyzing, the phenol containing a boron dihydroxide group at the <NUM> position may be isolated using any known technique or technique described herein, for example aqueous/organic extraction. The elimination step may be performed under an inert gas, such as nitrogen, and/or in a dry box or a Schlenk line.

After making the <NUM>,<NUM>-halogenated <NUM>-silylether substituted benzene, the <NUM>,<NUM>-halogenated <NUM>-silylether substituted benzene may be subjected to an elimination step to exchange one halogen with an aldehyde at the <NUM> position and rearrange the silyl group to exchange with the other halogen at the <NUM> position. In this step, the <NUM>,<NUM>-halogenated <NUM>-silylether substituted benzene may be contacted with an alkyl lithium compound and dimethylformamide in a polar aprotic solvent to form a phenol having a silyl and an acetaldehyde group at the <NUM> and <NUM> positions. The halogenated phenol, the alkyl lithium, and the dimethylformamide may be added in a molar ratio of about <NUM>:<NUM>:<NUM>. First, <NUM>,<NUM>-halogenated <NUM>-silylether substituted benzene may be dissolved in the polar aprotic solvent and may be cooled to about <NUM> degrees Celsius or less, about <NUM> degrees Celsius or less, or about <NUM> degrees Celsius or less. The polar aprotic solvent and the <NUM>,<NUM>-halogenated <NUM>-silylether substituted benzene may be cooled to about <NUM> degrees Celsius or more, about <NUM> degrees Celsius or more, or about <NUM> degrees Celsius or more. After cooling, the <NUM>,<NUM>-halogenated <NUM>-silylether substituted benzene is contacted with the alkyl lithium compound in the polar aprotic solvent to form an intermediate composition and may be allowed to warm to <NUM> degrees Celsius and stirred for about <NUM> hours or more, about <NUM> hours or more, or about <NUM> hours or more. In other examples, the intermediate composition may allowed to warm to room temperature. The intermediate composition may be stirred for about <NUM> hours or less, about <NUM> hours or less, or about <NUM> hours or less.

After stirring and without an isolation step, the intermediate composition may be cooled to about <NUM> degrees Celsius or less, about <NUM> degrees Celsius or less, or about <NUM> degrees Celsius or less. The intermediate composition may be cooled to about <NUM> degrees Celsius or more, about <NUM> degrees Celsius or more, or about <NUM> degrees Celsius or more. After cooling, the intermediate composition containing the <NUM>,<NUM>-halogenated <NUM>-silylether substituted benzene, the alkyl lithium compound, and/or residues thereof in the polar aprotic solvent may be contacted with dimethylformamide to form phenol having a silyl and an acetaldehyde group at the <NUM> and <NUM> positions in a product composition. In addition to the dimethylformamide, a quenching agent diluted in a polar aprotic solvent may be added to form the phenol having a silyl and an acetaldehyde group at the <NUM> and <NUM> positions. Quenching agents may include NH<NUM>Cl (aqueous). After cooling and after addition of the dimethylformamide, the product composition may be warmed to about <NUM> degrees Celsius and stirred for about <NUM> hours or more, about <NUM> hours or more, or about <NUM> hour or more. The product composition may be stirred for about <NUM> hours or less, about <NUM> hours or less, or about <NUM> hours or less. After formation of the phenol having a silyl and an acetaldehyde group at the <NUM> and <NUM> positions, the phenol having a silyl and an acetaldehyde group at the <NUM> and <NUM> positions may be purified or isolated using any known technique or any technique discussed herein, such as aqueous/organic extraction. The entire elimination step may be performed under an inert gas, such as nitrogen, and/or in a dry box or a Schlenk line.

After isolating the dialkyl or diaryl phosphate substituted phenol, the dialkyl or diaryl phosphate substituted phenol may be subjected to an addition step to form a phosphasalen, phosphasalph, or phosphasalcy ligand. For example, the phosphasalen, phosphasalph, or phosphasalcy ligand may have a structure according to compounds <NUM>, <NUM>, and/or <NUM> as described above.

In this step, the dialkyl or diaryl phosphate substituted phenol may be contacted with a bromine and a diamine in the presence of a polar aprotic solvent and a trialkyl amine to form the phosphasalen, phosphasalph, or phosphasalcy ligand. The dialkyl or diaryl phosphate substituted phenol, the bromine, and the diamine may be added in a molar ratio of about <NUM>:<NUM>:<NUM> or more. First and under a nitrogen stream (i.e., glove box or Schlenk line), the dialkyl or diaryl phosphate substituted phenol may be dissolved in the aprotic solvent and cooled to about <NUM> degrees Celsius or less, about <NUM> degrees Celsius or less, or about <NUM> degrees Celsius or less. The polar aprotic solvent and the dialkyl or diaryl phosphate substituted phenol may be cooled to about <NUM> degrees Celsius or more, about <NUM> degrees Celsius or more, or about <NUM> degrees Celsius or more. After cooling, the dialkyl or diaryl phosphate substituted phenol may be contacted with the bromine in the polar aprotic solvent to form an intermediate composition, and the intermediate composition may be warmed to room temperature (i.e., about <NUM> degrees Celsius) and stirred for about <NUM> hours or more, about <NUM> hours or more, or about <NUM> hours or more. The intermediate composition may be stirred for about <NUM> hours or less, about <NUM> hours or less, or about <NUM> hours or less. After stirring, the intermediate composition may be cooled to about <NUM> degrees Celsius or less, about <NUM> degrees Celsius or less, or about <NUM> degrees Celsius or less. The intermediate composition may be cooled to about <NUM> degrees Celsius or more, about <NUM> degrees Celsius or more, or about <NUM> degrees Celsius or more.

After cooling, the intermediate composition containing the bromine, the dialkyl or diaryl phosphate substituted phenol, and/or residues thereof in the polar aprotic solvent may be contacted with the diamine in the presence of the trialkyl amine to form the phosphasalen, phosphasalph, or phosphasalcy ligand in a product composition. After contacting, the product composition may be warmed to room temperature (i.e., about <NUM> degrees Celsius) and stirred overnight. For example, the product composition may be stirred for about <NUM> hours or more, about <NUM> hours or more, or about <NUM> hours or more. The product composition may be stirred for about <NUM> hours or less, about <NUM> hours or less, or about <NUM> hours or less. After stirring, any byproducts, such as ammonium bromide, may be precipitated from the composition using any known filtration technique, such as gravity filtration. The phosphasalen, phosphasalph, or phosphasalcy ligand may be isolated from the product composition by any known technique or any technique described herein. For example, the phosphasalen, phosphasalph, or phosphasalcy ligand may be isolated from the product composition by removing solvent through rotary evaporation and subjecting the phosphasalen, phosphasalph, or phosphasalcy to an additional precipitation step and an additional purification step in column chromatography. The entire addition step may be performed under an inert gas, such as nitrogen, and/or in a dry box or a Schlenk line.

After isolating the phenol containing a boron dihydroxide group at the <NUM> position, the phenol containing a boron dihydroxide group at the <NUM> position may be subjected to a Suzuki reaction step to form a Rdhbpy(H)<NUM> or Rdhphen(H)<NUM> ligand. For example, the Rdhbpy(H)<NUM> or Rdhphen(H)<NUM> ligand may have a structure according to compounds <NUM> and/or <NUM>.

In this Suzuki reaction step, the phenol containing a boron dihydroxide group at the <NUM> position may be contacted with a dibromo bipyridine or a dibromo phenanthroline containing one or more halogens adjacent to the nitrogen atom in the presence of one or more polar solvents, an alkali metal carbonate, and a palladium catalyst to form a ligand according to compound <NUM> and/or <NUM> in a product composition. The one or more polar solvents may be a combination of solvents to dissolve one or more compounds in the reaction. The one or more polar solvents may be protic, aprotic, or a combination of both protic and aprotic solvents. The phenol containing a boron dihydroxide group at the <NUM> position and the dibromo bipyridine or the dibromo phenanthroline containing one or more halogens adjacent to the nitrogen atom may be added in a molar ratio of about <NUM>:<NUM> or more. Additionally, bromic acid may be added to the combination of phenol containing a boron dihydroxide group at the <NUM> position and the dibromo bipyridine or dibromo phenanthroline in a molar ratio of about <NUM>:<NUM>:<NUM> or more. The palladium catalyst may be added in a solution of about <NUM> mole percent or more, about <NUM> mole percent or more, or about <NUM> mole percent or more. The palladium catalyst may be added in a solution of about <NUM> mole percent or less, about <NUM> mole percent or less, or about <NUM> mole percent or less. The alkali metal carbonate may be added in a solution of about <NUM> or more, about <NUM> or more, or about <NUM> or more. The alkali metal carbonate may be added in a solution of <NUM> or less, about <NUM> or less, or about <NUM> or less. After contacting the ingredients, the Suzuki reaction step may be carried out at reflux for about <NUM> hours or less, about <NUM> hours or less, or about <NUM> hours or less. The Suzuki reaction step may be carried out at reflux for about <NUM> hours or more, about <NUM> hours or more, or about <NUM> hours or more. After reflux, the ligand according to compound <NUM> and/or <NUM> is removed from the product composition using any known extraction technique described herein or known by the skilled artisan. For example, the ligand according to compound <NUM> and/or <NUM> may be removed by adding a solvent that dissolves the ligand, such as a polar aprotic solvent, adding a brine (i.e., aqueous solution), extracting the brine, and evaporating the polar aprotic solvent to leave a dry ligand. The Suzuki reaction step may be conducted under an inert gas, such as nitrogen, and in a dry box and/or Schlenk line.

After isolating the phenol having a silyl and an acetaldehyde group at the <NUM> and <NUM> positions, the phenol having a silyl and an acetaldehyde group at the <NUM> and <NUM> positions may be subjected to a condensation step to form a silyl substituted salen, salph, or salcy ligand. For example, the silyl substituted salen, salph, or salcy ligand may have a structure according to compounds <NUM>, <NUM>, and/or <NUM>. In this step, the phenol having a silyl and an acetaldehyde group at the <NUM> and <NUM> positions may be contacted with a diamine in the presence of a Lewis acid or Bronsted acid and a alkali metal or ammonium salt in the a polar solvent subjected to form the silyl substituted salen, salph, or salcy ligand in a product composition. In other examples, the reaction may be free of a Lewis acid or Bronsted acid so that the diamine and the phenol having a silyl and an acetaldehyde group at the <NUM> and <NUM> positions may be contacted in a polar solvent. These steps may be completed in ambient air and may be completed at room temperature (e.g., about <NUM> degrees Celsius) or may be completed at reflux of the polar solvent. The phenol having a silyl and an acetaldehyde group at the <NUM> and <NUM> positions and the diamine, may be added in a molar ratio of about <NUM>:<NUM> or more. The Lewis acid or Bronsted acid may be added in an amount sufficient to catalyze the condensation reaction. The silyl substituted salen, salph, or salcy ligand may be isolated from the product composition by any known technique or any technique described herein. For example, the silyl substituted salen, salph, or salcy ligand may be collected as a precipitate by gravity filtration after the product composition has cooled.

After forming the phosphasalen, phosphasalph, or phosphasalcy ligand, the Rdhbpy(H)<NUM> or Rdhphen(H)<NUM> ligand, or the silyl substituted salen, salph, or salcy ligand, the ligands may be subjected to a metalation step to form a Lewis acid containing a halogen or an alkyl group. The Lewis acids containing the halogen or the alkyl group may have a structure according to compounds <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, and/or <NUM> described above. The halogen or the alkyl group of the Lewis acid may be bonded to the metal center of the Lewis acid. In the metalation step, a metal alkyl compound may be contacted with the phosphasalen, phosphasalph, or phosphasalcy ligand, the Rdhbpy(H)<NUM> or Rdhphen(H)<NUM> ligand, or the silyl substituted salen, salph, or salcy ligand in a nonpolar solvent at room temperature to form a Lewis acid containing a halogen or alkyl group. The metal alkyl compound and phosphasalen, phosphasalph, or phosphasalcy ligand, the Rdhbpy(H)<NUM> or Rdhphen(H)<NUM> ligand, or the silyl substituted salen, salph, or salcy ligand may be added in a molar ratio of about <NUM>:<NUM>. The metalation step may be stirred for any amount of time sufficient to form the Lewis acid containing the halogen or the alkyl group. For example, the metalation step may be stirred for about <NUM> hours or less, about <NUM> hours or less, or about <NUM> hours or less. The metalation step may be stirred for about <NUM> hours or more, about <NUM> hours or more, or about <NUM> hours or more. The metalation step may be conducted under an inert gas, such as nitrogen, and in a dry box and/or Schlenk line. The metalation step may be conducted in open air or may be conducted in an inert atmosphere free of oxygen and water, such as a dry box or Schlenk line. The metalation step may be similar to the metalation steps described in <CIT>, incorporated herein by reference in its entirety. After the metalation step is complete, the Lewis acid containing the halogen or the alkyl group may be isolated using any known technique, such as collecting the Lewis acid containing the halogen or the alkyl group by gravity filtration. The steps to form the Lewis acid containing the halogen or alkyl group may be performed under conditions that are moisture and oxygen free, for example, under an inert gas, like nitrogen, in a dry box or Schlenk line.

After forming and isolating one of the Lewis acids containing the halogen or the alkyl group above, the Lewis acids containing the halogen or the alkyl group may be subjected to a catalyst formation step to form the carbonylation catalyst. The carbonylation catalyst may have one of the structures described above in compounds <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, and/or <NUM>. The catalyst formation step may include contacting the Lewis acids containing the halogen or the alkyl group with a polar ligand, a metal carbonyl additive, or both to from the carbonylation catalyst. The Lewis acid containing the halogen or alkyl group may be added in a molar ratio of about <NUM>:<NUM>. The metal carbonyl additive may contain at least a metal carbonyl that is anionic and a cationic group that is configured to cleave and bond with the alkyl group or the halogen of the metal centered compound. The cationic group may be one or more of an alkali metal, (R<NUM>)<NUM>Si-, any counterion sufficient to ionically bond and/or balance the metal carbonyl, or any combination thereof, where R<NUM> is independently selected from a phenyl, halophenyl, hydrogen, alkyl, alkylhalo, alkoxy, or any combination thereof. In examples where the metal carbonyl additive cleaves or decouples the alkyl group, the alkyl group may couple with the cationic group, and the alkyl group and cationic group could be removed via any filtration or removal means described herein. In examples where the metal carbonyl additive cleaves the halogen from the metal centered compound and is contacted with the polar compound, the halogen bonds with the cationic group of the metal carbonyl additive and the Lewis acid containing the polar compound is formed. Any byproducts can be removed by any other removal or separation steps described herein. After the metal carbonyl additive cleaves or decouples the alkyl group, the Lewis acid may combine with the polar ligand to form a cationic species. The Lewis acid containing the polar ligand then contacts with the anionic metal carbonyl of the metal carbonyl additive and forms the regenerated carbonylation catalyst.

The steps to form the carbonylation catalyst may be performed under conditions that are moisture and oxygen free. For example, the catalyst formation steps may be performed within a dry glove box, on a Schlenk line, or in a reactor under an inert atmosphere (i.e., nitrogen). The catalyst formation steps may be performed under a nitrogen, argon, or any other inert gas. During the catalyst formation steps, the Lewis acid, the polar ligand, the metal carbonyl, or any combination thereof may be contacted and agitated by stirring for a period of time sufficient to form the carbonylation catalyst. The period of time for stirring the components may be about <NUM> minutes or more, about <NUM> minutes or more, about <NUM> minutes or more. The period of time for stirring the components may be about <NUM> hours or less, about <NUM> hours or less, or about <NUM> hours or less. The components in the catalyst formation steps may be completed under ambient temperature and/or pressure. Additional steps to make the regenerated catalyst can be found in <CIT> and <CIT>.

The filtering, isolating, or removing steps taught herein function to remove from the composition any unwanted components that may interfere with the formation of a carbonylation catalyst or any precursor of the carbonylation catalyst. For example, one or more of solvents, polymers, unreacted acid compounds, inorganic compounds, organic compounds, or any combination thereof may be removed from the composition so that the carbonylation catalyst may be regenerated from the Lewis acid containing a halogen or a alkyl compound and have catalytic activity with one or more of succinic anhydride, propiolactone, or an epoxide. The filtering, isolating, or removing steps may include one or more of vacuum filtration, gravity filtration, centrifugation, decantation, precipitation, phase layer extraction, or any combination thereof. The filtering, isolating, or removing steps may utilize any method sufficient to separate one or more of solvents, polymers, unreacted acid compounds, inorganic compounds, organic compounds, or any combination thereof and the Lewis acid containing the halogen or a alkyl group, the ligands, or any combination thereof. The filtering, isolating, or removing steps may remove a single type of compound at a time, such as a precipitate, or may remove a collection of compounds at a time, such as all components dissolved in a solvent. The filtering or removing steps may include forming multiple phases including one or more of one or more organic phases, an aqueous phase, a solid phase (i.e., a precipitate), one or more gaseous or vapor phases, or any combination thereof. The one or more separation or removal steps/methods described herein may be performed at any temperature, pressure, agitation rate, time, or any combination thereof sufficient to separate or remove any undesirable component from the composition including the ligands, the Lewis acid containing the halogen or alkyl group, or any combination thereof.

The carbonylation catalyst as described herein functions to catalyze a reaction of an epoxide and carbon monoxide to produce one or more propiolactones and other products. The carbonylation catalyst includes at least a metal carbonyl that is anionic and a Lewis acid that is cationic.

The metal carbonyl of the carbonylation catalyst functions to provide the anionic component of the carbonylation catalyst. The carbonylation catalyst may include one or more, two more, or a mixture of metal carbonyls. The metal carbonyl may be capable of ring-opening an epoxide and facilitating the insertion of CO into the resulting metal carbon bond. In some examples, the metal carbonyl may include an anionic metal carbonyl moiety. In other examples, the metal carbonyl compound may include a neutral metal carbonyl compound. The metal carbonyl may include a metal carbonyl hydride or a hydrido metal carbonyl compound. The metal carbonyl may be a pre-catalyst which reacts in situ with one or more reaction components to provide an active species different from the compound initially provided. The metal carbonyl includes an anionic metal carbonyl species. in some examples, the metal carbonyl may have the general formula [QdM'e(CO)w]y+, where Q is an optional ligand, M' is a metal atom, d is an integer between <NUM> and <NUM> inclusive, e is an integer between <NUM> and <NUM> inclusive, w is a number such as to provide the stable anionic metal carbonyl complex, and y is the charge of the anionic metal carbonyl species. The metal carbonyl may include monoanionic carbonyl complexes of metals from groups <NUM>, <NUM> or <NUM> of the periodic table or dianionic carbonyl complexes of metals from groups <NUM> or <NUM> of the periodic table. The metal carbonyl may contain cobalt, manganese, ruthenium, or rhodium. Exemplary metal carbonyls may include [Co(CO)<NUM>]-, [Ti(CO)e]<NUM>-, [V(CO)<NUM>]-, [Rh(CO)<NUM>]-, [Fe(CO)<NUM>]<NUM>-, [Ru(CO)<NUM>]<NUM>-, [Os(CO)<NUM>]<NUM>-, [Cr<NUM>(CO)<NUM>]<NUM>-, [Fe<NUM>(CO)<NUM>]<NUM>-, [Tc(CO)<NUM>]-, [Re(CO)<NUM>]-, and [Mn(CO)<NUM>]-. The metal carbonyl may be a mixture of two or more anionic metal carbonyl complexes in the carbonylation catalysts used in the methods.

The halogenating agent may function to couple a halogen atom to a phenol. The halogenating agent may be any compound containing one or more halogens that can be coupled to a phenol. The halogenating agent may be one or more of N-bromosuccinimide, bromine (i.e., Br<NUM>), dibromisocyanuric acid, or any combination thereof.

The alkyl lithium compound may function to replace a halogen group on a phenol with another compound. The alkyl lithium compound may be n-butyllithium, t-butyllithium, or any combination thereof. Where n-butyllithium is used, an additive to activate the n-butyllithium may be used, such as tetramethylethylenediamine, hexamethylphophoramid, N,N'-Dimethylpropyleneurea, or any combination thereof.

The halo-di(aryl or alkyl) phosphine may function to form a disubsituted phosphine group on a phenol compound. The halo-di(aryl or alkyl) phosphineinclude one or more of chloro-di(aryl) phosphine, chloro-di(alkyl) phosphine, or both.

The silyl halide may function to form a silyl ether on a phenol group. The silyl halide may include one or more of fluorine, chlorine, bromine, and/or iodine. The silyl halide may contain a trisubstituted silicone group, for example, having a structure of Si(R<NUM>)<NUM>, where R<NUM> is described above in relation to compounds <NUM> to <NUM>.

The trialkyl borate may function to form a compound suitable for a Suzuki coupling reaction. The trialkyl borate may be trimethyl borate, or any combination thereof.

The diamines used herein may function to form a ligand by connecting two substituted phenol groups. The diamine may be any substituted compound containing at least two amine groups that are separated by at least two carbon atoms. The diamine may be one or more of an ethylene diamine, an ortho phenylene amine, an ortho cyclohexyl diamine, or any combination thereof.

The trialkyl amine may be a compound sufficient to consume generated HBr in the form of an ammonium salt, such as tributylammonium bromide. The trialkyl amine may be one or more of tributyl amine, triethyl amine, trimethyl amine, or any combination thereof.

The Lewis acid or Bronsted acid catalyst may function to catalyze a condensation reaction. The Lewis acid or Bronsted acid catalyst may be one or more of formic acid, acetic acid, aluminum chloride, or any combination thereof.

The alkali metal carbonate may function to decompose a boron dihydroxide. The alkali metal carbonate may include one or more of Na<NUM>CO<NUM>, or any combination thereof. In lieu of the alkali metal carbonate, a alkali metal, alkoxide, and/or alkali metal hydroxide could be used to decompose the boron dihydroxide.

The metal alkyl compound may function to coordinate a metal in one or more ligands to form a Lewis acid containing a halogen or an alkyl group. The metal alkyl compound may be any compound containing a metal and/or one or more alkyl groups and/or halogen group. The metal of the metal alkyl compound may be one or more of aluminum, chromium, or any combination thereof. The meal alkyl compound may include one or more of CrCl<NUM>, (Et)2AlCl or (Et)3Al, or any combination thereof.

A metal carbonyl additive functions to deliver a metal carbonyl to a Lewis acid that is suitable to combine and form the carbonylation catalyst. The metal carbonyl additive may function to decouple a halogen or a alkyl group from a Lewis acid to form the carbonylation catalyst that includes the Lewis acid and metal carbonyl combination. The metal carbonyl additive includes at least a metal carbonyl as described herein and a cationic compound. The cationic compound may include lithium, sodium, potassium, rubidium, cesium, beryllium, magnesium, calcium, strontium, barium, radium, or any combination thereof. The metal carbonyl additive may be a salt. The metal carbonyl additive may be a silicon salt in the form of R<NUM>Si-, where R is independently selected from a phenyl, halophenyl, hydrogen, alkyl, alkylhalo, alkoxy, or any combination thereof. The metal carbonyl additive may be NaCo(CO)<NUM>, Co<NUM>(CO)<NUM>, HCo(CO)<NUM>, or any combination thereof. Where a Lewis acid containing a halogen is formed after the metalation step, NaCo(CO)<NUM> may be used to form the carbonylation catalyst. Where a Lewis acid containing an alkyl group is formed, Co<NUM>(CO)<NUM> or HCo(CO)<NUM> may be used to form the carbonylation catalyst.

In some Lewis acids, one or more polar ligands may coordinate to M, or a combination thereof and fill the coordination valence of the metal atom. The polar ligand may be a solvent. The polar ligand may be any compound with at least two free valence electrons. The polar ligand may be aprotic. The compound may be tetrahydrofuran, dioxane, diethyl ether, acetonitrile, carbon disulfide, pyridine, epoxide, ester, lactone, or a combination thereof.

The solvent may be a polar aprotic solvent, a polar protic solvent, or a nonpolar solvent that functions to dissolve one or more compounds described herein. One solvent may be soluble in one or more other solvents to increase solubility of one or more of the compounds described herein. A first solvent may be combined with a second solvent that is miscible in the first solvent to precipitate components that are insoluble in the second solvent. The solvents may be selected to form an organic phase or an aqueous phase layer that is distinct from another aqueous phase layer, another organic phase layer, a precipitate, or any some combination. The solvent may be one or more of water, methanol, ethanol, propanol, hexane, heptane, nonane, decane, tetrahydrofuran, methyltetrahydrofuran, diethyl ether, sulfolane, toluene, pyridine, diethyl ether, <NUM>,<NUM>-dioxane, acetonitrile, ethyl acetate, dimethoxy ethane, acetone, chloroform, dichloromethane, or any combination thereof.

Several techniques have been theorized to illustrate the teaching of the present disclosure. Each teaching is simply an example of the disclosure and is not intended to limit the teachings to any single technique.

<FIG> is a synthetic scheme to form a carbonylation catalyst with a Lewis acid containing a silyl substituted salen, salph, or salcy ligand. After isolating two equivalents of Br<NUM> for one equivalent of appropriate <NUM>-substituted phenol are added to a reaction vessel equipped with a stir bar in the amounts of <NUM> mol of appropriate pre-isolated <NUM>,<NUM>-dibromophenol in <NUM> of THF solvent. The solution is cooled with an ice bath (<NUM>) and a slight excess of triethylamine (<NUM> mol) is added and a subsequently a slight excess of appropriate trisubstituted chlorosilane. The mixture is stirred for <NUM> hours at room temperature and the solvent is then removed by reduced pressure methods. The residue is taken up into hexanes and filtered over diatomaceous earth and the solvent is once again removed to yield the desired product. In a reaction vessel equipped with a stir bar the appropriate <NUM>,<NUM>-dibromophenol silylether (<NUM> mol) in diethyl ether (<NUM>) is cooled to -<NUM> and treated with four equivalents of t-butyllithium (<NUM> mol). The reaction is stirred for <NUM> at <NUM>. In the same reaction vessel, the reaction mixture is cooled to -<NUM> and <NUM> mol of DMF is added and stirred at <NUM> C for <NUM>. The reaction is then quenched with <NUM> of saturated NH<NUM>Cl solution and diluted with <NUM> diethyl ether. The organic and aqueous phases are separated, and the organic phase is dried to yield the desired product. The ligand synthesis is completed by reacting the silyl salicylaldehyde with orthophenylene diamine in a ratio of <NUM> to <NUM>. Salicylaldehyde in an amount of <NUM> mol is dissolved in <NUM> of ethanol (EtOH) and added <NUM> mol ortho-phenylene diamine and refluxed overnight. The temperature subsequently is reduced and the product is isolated by gravity filtration after precipitation of the ligand from the EtOH. using standard methods for condensation reaction between aldehyde of the salicylaldehyde precursor containing a silyl group and a diamine. After the ligand is formed, a reaction vessel under an inert atmosphere is charged with <NUM> mol of ligand in <NUM> toluene solvent (<NUM>). One equivalent of Et<NUM>AlCl is added to the solution slowly and allowed to stir at room temperature overnight. Product is collected by filtration after precipitation from solution. To form the carbonylation catalyst, a reaction vessel under an inert atmosphere is charged with <NUM> mol of metalated ligand in <NUM> THF solvent (<NUM>). One equivalent of NaCo(CO)<NUM> is added to the solution slowly and allowed to stir at room temperature overnight. Product is filtered to removed NaCl byproduct. The product is collected by precipitating the catalyst from THF solvent by addition of anti-solvent hexanes which is then collected by filtration.

<FIG> is a synthetic scheme to form a carbonylation catalyst with a Lewis acid containing phosphasalen, phosphasalph, or phosphasalcy ligand. A reaction vessel is charged with appropriate <NUM>,<NUM>-disubstituted phenol (<NUM> mol) in <NUM> of acetonitrile. The reaction is cooled to <NUM> and <NUM> mol of N-bromosuccinimide is added and is stirred overnight at room temperature. The reaction mixture is washed with Na<NUM>SO<NUM> and the phases are separated. The organic layer is then collected, and the solvent is removed by rotary evaporation. After isolating, to a reaction vessel under an inert atmosphere is added the appropriate <NUM>-bromo-<NUM>,<NUM>-disubstituted phenol (<NUM> mol) in <NUM> of diethyl ether and is reduced in temperature to -<NUM>. To the cooled solution, <NUM> mol of n-butyl lithium, a slight excess, is added slowly. The reaction mixture is brought back to room temperature for <NUM> hour. Subsequently, the reaction mixture is cooled to -<NUM> and <NUM> mol of the appropriate chlorophosphine (R<NUM>PCl) is added and stirred overnight at room temperature. The solution is washed with KH<NUM>PO<NUM>. The layers are separated and the organic is layer is dried and the solvent removed by rotary evaporation. To a reaction vessel under an inert atmosphere is added the appropriate <NUM>,<NUM>-disubstituted-<NUM>-(R<NUM>phosphaneyl)phenol (<NUM> mol) in <NUM> dichloromethane solvent. The temperature is reduced to -<NUM> and liquid bromine (<NUM> mol) is added slowly and then stirred at room temperature for <NUM> hours. The reaction mixture is reduced in temperature again to -<NUM> and <NUM> mol of tributylamine and <NUM> mol of ethylene diamine is added slowly and stirred at room temperature overnight. The reaction mixture is filtered, and the filtrate is dried by reduced pressure. The oil is the stirred in THF to afford a white solid that is further purified by column chromatography. After the ligand is formed, a reaction vessel under an inert atmosphere is charged with <NUM> mol of ligand in <NUM> toluene solvent (<NUM>). One equivalent of Et<NUM>AlCl is added to the solution slowly and allowed to stir at room temperature overnight. Product is collected by filtration after precipitation from solution. To form the carbonylation catalyst, a reaction vessel under an inert atmosphere is charged with <NUM> mol of metalated ligand in <NUM> THF solvent (<NUM>). One equivalent of NaCo(CO)<NUM> is added to the solution slowly and allowed to stir at room temperature overnight. Product is filtered to removed NaCl byproduct. The product is collected by precipitating the catalyst from THF solvent by addition of anti-solvent hexanes which is then collected by filtration.

<FIG> is a synthetic scheme to form a carbonylation catalyst with a Lewis acid containing a Rdhbpy(H)<NUM> or Rdhphen(H)<NUM> ligand. A reaction vessel under an inert atmosphere is charged with <NUM> mol of <NUM>,<NUM>-disubsitituted phenol in <NUM> of solvent (<NUM> reaction). Added at -<NUM> is one equivalent (<NUM> mol) of Br<NUM> and stirred for <NUM> hours at room temperature. The reaction mixture is then quenched with <NUM> of sat. NaHCO<NUM> solution and the organic and aqueous layers are separated. The organic phase after drying with MgSO<NUM> or Na<NUM>SO<NUM> is slurried with basic alumina and then is filtered over a combo of silica gel and diatomaceous earth. After isolating, a reaction vessel under an inert atmosphere is charged with the <NUM>-bromo-<NUM>,<NUM>-disubstituted phenol (<NUM> mol) in <NUM> diethyl ether solvent (~<NUM>). Solution is reduced in temperature to -<NUM> and a slight excess of n-butyllithium (<NUM> mol) of n-BuLi is added to the reaction vessel slowly. After addition, the reaction is stirred at room temperature for <NUM> hours. The reaction mixture is then reduced to in temperature to -<NUM> again <NUM> mol of trimethylborate is added. The reaction is allowed to reach room temperature and is stirred for <NUM> hours. The reaction is then reduced in temperature to <NUM> and is quenched with <NUM> HCl solution. The organic and aqueous phases are separated and the product is collected by reduced pressure evaporation of solvent. Subsequently, a reaction vessel under an inert atmosphere is charged with <NUM> mol of dibromo pyridine linker ligand (either <NUM>,<NUM>'-dibromobipyridine or <NUM>,<NUM>-dibromo-<NUM>,<NUM>-phenanthroline) in <NUM> toluene with <NUM> mol of the previously synthesized <NUM>,<NUM>-disubstituted-<NUM>-hydroxy-phenyl)boronic acid, <NUM> of MeOH, <NUM> of <NUM> Na<NUM>CO<NUM>, and <NUM> mol % Pd(PPh<NUM>)<NUM>. The mixture is refluxed for <NUM> under an inert atmosphere. After cooling, the organic and aqueous phases are separated and the organic solvent is removed under reduced pressure to yield the desired ligand. After the ligand is formed, a reaction vessel under an inert atmosphere is charged with <NUM> mol of ligand in <NUM> toluene solvent (<NUM>). One equivalent of Et<NUM>AlCl is added to the solution slowly and allowed to stir at room temperature overnight. Product is collected by filtration after precipitation from solution. To form the carbonylation catalyst, a reaction vessel under an inert atmosphere is charged with <NUM> mol of metalated ligand in <NUM> THF solvent (<NUM>). One equivalent of NaCo(CO)<NUM> is added to the solution slowly and allowed to stir at room temperature overnight. Product is filtered to removed NaCl byproduct. The product is collected by precipitating the catalyst from THF solvent by addition of anti-solvent hexanes which is then collected by filtration.

The following examples are provided to illustrate the invention but are not intended to limit the scope thereof. All parts and percentages are by weight unless otherwise indicated.

The NMR analysis is conducted on a Bruker Advance III-HD spectrometer operating at <NUM>. The sample is dissolved in THF-d8 before testing.

The in-situ-FTIR analysis tracking the catalytic activity of the regenerated catalyst is conducted on a Mettler Toledo ReatIR <NUM> equipped with a silicone tipped sentinel that is directly affixed to the bottom of the reactor.

<FIG> is a <NUM> NMR spectrum of the isolated carbonylation catalyst with a Lewis acid containing a bipyridine or phenanthroline ligand. This shows the desired catalyst from the tbudhbpy(H)<NUM> ligand metalated with Et<NUM>AlCl and reacted with NaCo(CO)<NUM> that is successfully isolated. The inlet image is a zoomed in view of the aromatic region of tbudhbpy(H)<NUM> ligand metalated with Et<NUM>AlCl.

Claim 1:
A catalyst compound according to one of the following formulas:
<CHM>
wherein R is separately in each occurrence a hydrogen, alkyl, or aryl group;
PL is the residue of tetrahydrofuran, dioxane, diethyl ether, acetonitrile, carbon disulfide, pyridine, epoxide, ester, lactone, or a combination thereof; and
M is separately in each occurrence aluminum or chromium.