Table 1 Maximum yield of 8 achieved during temperature ramp over
various catalysts from the self condensation of 6 at flow rates of 0.1 mL
min-1 6, 1.0 mL min-1 CO2 at 10 MPa (base catalysts in italics)
Catalyst
% Yield 8a
% Sel. 8
Temp/◦C
g-Alumina
78
76
10
49
39
48
63
70
89
88
83
77
95
84
81
83
210
135
180b
125
240
125
155
285
AmberlystꢀR 15
AmberlystꢀR A26
DeloxanꢀR ASP
Magnesium oxide
NafionꢀR SAC13
PuroliteꢀR CT175
Supported NaOH
a Determined by GC. b Catalyst undergoing rapid degradation.
Fig. 1 The formation of the unsaturated butyraldehyde aldol product
4 in scCO2 showing the temperature dependence of the conversion (᭜)
and selectivity (᭛) of the self aldol condensation of 2 at flow rates of
0.1 mL min-1 of 2 and 1.0 mL min-1 of CO2 at 8 MPa using a 10 mL
reactor filled with AmberlystꢀR 15.
Matsui et al.17,18 have explored the effect of a pressure of CO2,
in a batch reaction, on the selectivity of the aldol condensation
of 6 whilst using a MgO catalyst. At 12 MPa, under supercritical
conditions, 94% selectivity towards 8 was achieved, whereas at
the subcritical pressure of 5 MPa, 85% selectivity towards the
aldol product was observed.
This result indicates that it is indeed possible to conduct the
aldol reaction effectively in scCO2 using a heterogeneous acid
catalyst to produce the unsaturated aldol product in high yields.
Our aim was to use the continuous flow scCO2 apparatus7 to
screen rapidly a variety of both acidic and basic heterogeneous
catalysts, see Table 1, for their suitability for the selective self con-
densation of propionaldehyde across a range of temperatures.
Once a suitable catalyst has been found it would then be tested
under a wide variety of conditions to optimise the performance
of the reaction further. The high solubility of gaseous hydrogen
Reaction of propionaldehyde
Following this successful proof of concept experiment with
butyraldehyde, we have studied the self aldol condensation of
propionaldehyde (6) to yield 2-methylpentenal (8) (Scheme 3).
19
and organic compounds in scCO2 can be used in combination
with the aldol reaction to allow hydrogenation of the unsaturated
product in situ if desired.5,6
Catalyst screening
Scheme 3 The self aldol condensation of propionaldehyde (6) showing
both the aldol intermediate, 3-hydroxy-2-methylpentanal (7), and the
unsaturated dehydration product 2-methylpentenal (8).
For each catalyst system the reaction was performed using
identical reaction conditions at a pressure of 10 MPa. Further
details of the catalysts used in this study are outlined later in
Table 4 (Experimental section). Fig. 2 shows the conversion and
selectivity towards 8 for each catalyst across the temperature
range tested. The maximum yields are summarised in Table 1.
However, from the point of view of environmental sustainabil-
ity, selectivity towards the desired product, Table 2, is more
important than conversion, because of the ease of separation
of unreacted 6 from the product 8 by simple distillation due to
the large difference in boiling point of the two compounds; this
enables unreacted 6 to be easily repassed through the reaction
system.
Aims and strategy
Compound 8 is a commercially important compound that is
used widely in the fragrance, flavour,8 and cosmetic industries9
as well as being an important intermediate in the synthesis of
pharmaceuticals10,11 and plasticisers.12 Compound 8 is manufac-
tured industrially by the aldol condensation of 6 in the presence
of stoichiometric amounts of an aqueous base such as NaOH
or KOH. Under optimum conditions, 99% conversion of 6 is
achieved with 86% selectivity to 8. Additionally, it has been
demonstrated that the inclusion of an inert solvent can reduce
the formation of any unwanted by-products.12
Mehnert et al. have studied the base catalysed aldol condensa-
tion of 6 in ionic liquids. They reported 100% conversion at 80 ◦C
in 3 h with 83% selectivity for 8 using NaOH in [BMIM][PF6].13,14
The solvent-free condensation of 6 has also been explored using
a batch process at 100 ◦C using solid base catalysts by Sharma
et al.15 Their optimum results were achieved using an activated
Mg/Al hydrotalcite catalyst, giving 97% conversion of the 6 with
99% selectivity to 8. The aldol condensation of 6 has also been
carried out by Scheidt16 in the gas phase over lithium phosphate
at 270 ◦C. This gave 95% selectivity to 8 at 32% conversion of 6.
At temperatures <70 ◦C, with Brønsted acid catalysts such
R
R
as Amberlystꢀ 15 or Puroliteꢀ CT-175 (Fig. 2b and 2e), the
by-products consisted of the aldol intermediate, 7, and a variety
of other compounds including C9 aldehydes. These arise from
further aldol reactions, and Michael additions to the
a,b-unsaturated product 8. A typical product distribution can
be seen in the gas chromatogram, shown in Fig. 3.
A similar profile of conversion and selectivity was obtained
with the basic catalyst, NaOH/silica, although higher
temperatures were required to achieve this reactivity (Fig. 2h).
Magnesium oxide (Fig. 2f) also gave excellent selectivity
albeit with a poor conversion. The experiments suggested that
the MgO underwent rapid deactivation with a decrease in the
410 | Green Chem., 2009, 11, 409–416
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The Royal Society of Chemistry 2009
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