Catalyst composition and method for halogenating aromatic compounds

1. A method for ring-halogenating an aromatic compound, which comprises contacting with chlorine or bromine, a mixture comprising the aromatic compound and a mixed copper salt of formula Cu(Y)X, wherein Y comprises a counterion derived from an organic acid, said organic acid having a pKa relative to water of 0 or greater; and X comprises Cl, Br, I, or (SO 4 2− ) 1/2 ; to produce a reaction mixture comprising a haloaromatic compound and a copper(II) halide residue.

2. The method of claim 1 , wherein said mixture further comprises at least one organic sulfur compound.

3. The method of claim 2 , wherein said at least one organic sulfur compound comprises a dialkyl sulfide, a diaryl sulfide, an alkyl mercaptan, an aryl mercaptan, a phenoxathiin, a thiophene, a dibenzothiophene, a thianthrene, a phenothiazine, or mixtures of the foregoing organic sulfur compounds.

4. The method of claim 2 , wherein said at least one organic sulfur compound is selected from the group consisting of phenothiazine-N-carbonyl chloride, N-trifluoroacetylphenothiazine, 3-chloro-N-trifluoroacetylphenothiazine, 3-trifluoromethyl-N-trifluoroacetylphenothiazine, and mixtures of the foregoing organic sulfur compounds.

5. The method of claim 1 , wherein said organic acid is selected from the group consisting of a monocarboxylic acid or a derivative, and a 2,4-dione or a derivative.

6. The method of claim 1 , wherein Y comprises acetate, benzoate, 1,1,1-trifluoro-2,4-pentanedionate, 1,1,1,5,5,5-hexafluoro-2,4-pentanedionate, or 2,4-pentanedionate; and X comprises Cl, Br, I, or SO 4 .

7. The method of claim 1 , wherein said mixed copper salt is selected from the group consisting of cupric(benzoate)chloride, cupric(benzoate)bromide, cupric(benzoate)sulfate; cupric(acetate)chloride, cupric(acetate)bromide, cupric(acetate)sulfate, cupric(trifluoroacetate)chloride, cupric(trifluoroacetate)bromide, cupric(trifluoroacetate)iodide, cupric(trifluoroacetate)sulfate, cupric(stearate)chloride, cupric(stearate)bromide, and cupric(stearate)sulfate, cupric(pentafluorophenylbenzoate)chloride, cupric(pentafluorophenylbenzoate)bromide, cupric(pentafluorophenyl)sulfate, and mixtures of the foregoing mixed copper salts.

8. The method of claim 1 , wherein said contacting takes place in the liquid phase.

9. The method of claim 1 , wherein said contacting comprises a reaction temperature of about 0-100° C.

10. The method of claim 1 , wherein said contacting comprises shielding from exposure to ambient light and ambient moisture.

11. The method of claim 1 , wherein the aromatic compound is a monocyclic hydrocarbon.

12. The method of claim 1 , wherein the aromatic compound is toluene or ortho-xylene.

13. The method of claim 1 , wherein said mixed copper salt is present in an amount from about 0.005-10.0% by weight based on the aromatic compound.

14. The method of claim 1 , wherein said mixed copper salt is present in an amount from about 0.07-3.0% by weight based on the aromatic compound.

15. The method of claim 2 , wherein the proportion of said at least one organic sulfur compound is present in an amount from about 0.005-10.0% by weight based on the aromatic compound.

16. The method of claim 2 , wherein said at least one organic sulfur compound is present in an amount from about 0.01-0.1% by weight based on the aromatic compound.

17. A method for ring-chlorinating toluene or ortho-xylene, which comprises contacting with chlorine, a mixture comprising toluene or ortho-xylene, and a mixed copper salt of formula Cu(Y)X, wherein Y comprises a counterion derived from an organic acid, said organic acid having a pKa relative to water of 0 or greater; and X comprises Cl, Br, I, or (SO 4 2− ) 1/2 .

18. The method of claim 17 , wherein said mixture further comprises at least one organic sulfur compound.

19. The method of claim 18 , wherein said at least one organic sulfur compound comprises a dialkyl or diaryl sulfide, an alkyl or aryl mercaptan, a phenoxathiin, a thiophene, a dibenzothiophene, a thianthrene, a phenothiazine, or mixtures of the foregoing organic sulfur compounds.

20. The method of claim 18 , wherein said at least one organic sulfur compound is selected from the group consisting of phenothiazine-N-carbonyl chloride, N-trifluoroacetylphenothiazine, 3-chloro-N-trifluoroacetylphenothiazine, 3-trifluoromethyl-N-trifluoroacetylphenothiazine, and mixtures of the foregoing organic sulfur compounds.

21. The method of claim 17 , wherein Y comprises acetate, benzoate, 1,1,1-trifluoro-2,4-pentanedionate, 1,1,1,5,5,5-hexafluoro-2,4-pentanedionate, 2,4-pentanedionate, or oxalate; and X comprises Cl or Br.

22. A method for ring-chlorinating toluene or ortho-xylene, which comprises contacting toluene or ortho-xylene with chlorine in the presence of a catalyst composition, wherein said catalyst composition comprises:

at least one mixed copper salt having a formula: Cu(Y)X, wherein Y comprises a counterion derived from an organic acid, said organic acid having a pKa relative to water of 0 or greater; and X comprises Cl, Br, I, or (SO 4 2− ) 1/2 ; and

at least one organic sulfur compound selected from the group consisting of phenothiazine-N-carbonyl chloride, N-trifluoroacetylphenothiazine, 3-chloro-N-trifluoroacetylphenothiazine, and 3-trifluoromethyl-N-trifluoroacetylphenothiazine.

23. The method of claim 22 , wherein said at least one mixed copper salt is selected from the group consisting of cupric (benzoate)chloride, cupric (benzoate)bromide, cupric(benzoate)sulfate; cupric(acetate)chloride, cupric(acetate)bromide, cupric(acetate)sulfate, cupric(trifluoroacetate)chloride, cupric(trifluoroacetate)bromide, cupric(trifluoroacetate)iodide, cupric(trifluoroacetate)sulfate, cupric(stearate)chloride, cupric(stearate)bromide, and cupric(stearate)sulfate, cupric(pentafluorophenylbenzoate)chloride, cupric(pentafluorophenylbenzoate)bromide, cupric(pentafluorophenyl)sulfate, and mixtures of the foregoing mixed copper salts.

24. The method of claim 22 , wherein the catalyst composition comprises at least one reaction product of said at least one mixed copper salt, said at least one organic sulfur compound, and a chlorine atom source.

25. The method of claim 24 , wherein said chlorine atom source comprises molecular chlorine or hydrogen chloride.

26. A method for chlorinating an aromatic compound, which comprises contacting the aromatic compound with chlorine in the presence of a catalyst composition prepared by combining in the presence of a chlorine atom source, a mixture comprising at least one organic sulfur compound, and a mixed copper salt of formula: Cu(Y)X, wherein Y comprises a counterion derived from an organic acid, said organic acid having a pKa of 0 or greater; and X comprises Cl, Br, I, or (SO 4 2− ) 1/2 .

27. The method of claim 26 , wherein said at least one organic sulfur compound is selected from the group consisting of phenothiazine-N-carbonyl chloride, N-trifluoroacetylphenothiazine, 3-chloro-N-trifluoroacetylphenothiazine and 3-trifluoromethyl-N-trifluoroacetylphenothiazine.

28. The method of claim 26 , wherein said catalyst composition comprises at least one reaction product of said mixed copper salt, said at least one organic sulfur compound, and said chlorine atom source.

29. The method of claim 26 , wherein said chlorine atom source is selected from the group consisting of molecular chlorine, hydrogen chloride, and phenothiazine-N-carbonyl chloride.

30. The method of claim 29 , wherein said hydrogen chloride is generated from reaction of molecular chlorine with said aromatic compound.

31. The method of claim 26 , wherein said at least one organic sulfur compound comprises a dialkyl sulfide, a diaryl sulfide, an alkyl mercaptan, an aryl mercaptan, a phenoxathiin, a thiophene, a dibenzothiophene, a thianthrene, a phenothiazine, or mixtures of the foregoing organic sulfur compounds.

32. A method for chlorinating an aromatic compound, which comprises contacting the aromatic compound with chlorine in the presence of a catalyst composition prepared by (1) combining a chlorine atom source with a mixed copper salt of formula: Cu(Y)X, wherein Y comprises a counterion derived from an organic acid, said organic acid having a pKa of 0 or greater; and X comprises Cl, Br, I, or (SO 4 2− ) 1/2 to form an activated copper(II) chloride; and (2) combining said activated copper(II) chloride with at least one organic sulfur compound to form said catalyst composition.