Method of preparation of methyl-benzyl-ketone

Abstract

A catalytic process for producing ketones and particularly methyl-benzyl-ketone is provided. A catalyst comprising thorium oxide and a second metal oxide, preferably MnO, is formed on a substrate, preferably pumice. Phenylacetic acid and acetic acid are reacted in the presence of the catalyst to form methyl-benzyl-ketone.

1 . A catalyst for producing ketones comprising: 
 thorium dioxide and a second metal oxide supported on an inert substrate and    wherein the second metal oxide is selected from the group of metal oxides consisting of manganese, cobalt, magnesium, aluminum, and nickel oxides.    
     
     
         2 . The catalyst according to  claim 1  wherein: 
 the second metal oxide comprises manganese oxide (MnO).    
     
     
         3 . The catalyst according to  claim 1  wherein: 
 the substrate comprises pumice.    
     
     
         4 . The catalyst according to  claim 1  wherein: 
 the substrate comprises titanium dioxide.    
     
     
         5 . The catalyst according to  claim 1  wherein: 
 the substrate comprises silicon dioxide.    
     
     
         6 . The catalyst according to  claim 1  wherein: 
 the substrate comprises zirconium dioxide.    
     
     
         7 . The catalyst according to  claim 1  wherein: 
 the thorium dioxide and the second metal oxide form an inorganic polymer having a repeating structure;    the repeating structure being —O-M-O—ThO 2 —; and    wherein M is the metal of the second metal oxide.    
     
     
         8 . A process for creating a catalyst useful for producing ketones comprising: 
 washing pumice with a strong acid;    mixing the pumice with a solution of thorium nitrate in water to form a pumice/thorium nitrate mixture;    drying the pumice/thorium nitrate mixture while mixing the pumice/thorium nitrate mixture;    heating the pumice/thorium nitrate mixture;    adding a solvent and a second powder-like metal oxide to the pumice/thorium nitrate mixture to form a catalyst mixture;    mixing the catalyst mixture; and    evaporating the solvent from the catalyst mixture.    
     
     
         9 . The process according to  claim 8  wherein: 
 the second metal oxide is selected from the group of metal oxides consisting of manganese, cobalt, magnesium, aluminum, and nickel oxides.    
     
     
         10 . The process according to  claim 9  wherein: 
 the second metal oxide comprises manganese oxide (MnO).    
     
     
         11 . The process according to  claim 8  wherein: 
 the strong acid comprises nitric acid.    
     
     
         12 . The process according to  claim 8  wherein: 
 the solvent comprises diethyl ether.    
     
     
         13 . The process according to  claim 10  wherein: 
 the second metal oxide is added in a mole ratio in a range of mole ratios of about 6:1 to about 12:1 ThO 2  to MnO.    
     
     
         14 . The process according to  claim 13  wherein: 
 the second metal oxide is added in a mole ratio of about 9:1 ThO 2  to MnO.    
     
     
         15 . A process for creating a catalyst useful for producing ketones comprising: 
 mixing thorium nitrate and manganese nitrate with pumice to form a catalyst mixture and    heating the mixture until the NO 2  has been removed.    
     
     
         16 . The process according to  claim 15  wherein: 
 the thorium nitrate and the manganese nitrate are in about equal quantities.    
     
     
         17 . The process according to  claim 15  wherein: 
 the heating takes place at a temperature of about 650° C.    
     
     
         18 . The process according to  claim 15  wherein: 
 the pumice has been washed in a strong acid.    
     
     
         19 . The process according to  claim 18  wherein: 
 the strong acid comprises nitric acid.    
     
     
         20 . A process for producing ketones comprising: 
 combining at least a first carboxylic acid and a second carboxylic acid;    reacting the acids in the presence of a catalyst wherein the catalyst is comprised of thorium dioxide and a second metal oxide supported on an inert substrate; and    wherein the second metal oxide is selected from the group of metal oxides consisting of manganese, cobalt, magnesium, aluminum, and nickel oxides.    
     
     
         21 . The process according to  claim 20  wherein: 
 the second metal oxide comprises MnO.    
     
     
         22 . The process according to  claim 20  wherein: 
 the substrate comprises pumice.    
     
     
         23 . The process according to  claim 20  wherein: 
 the substrate comprises silicon dioxide.    
     
     
         24 . The process according to  claim 20  wherein: 
 the first carboxylic acid comprises phenylacetic acid and    the second carboxylic acid comprises acetic acid.    
     
     
         25 . The process according to  claim 24  wherein: 
 the first carboxylic acid and the second carboxylic acid are combined based on a specific mole ratio and    the specific mole ratio of the first carboxylic acid to the second carboxylic acid being in the range of about 1:2 to about 1:4.    
     
     
         26 . The process according to  claim 25  wherein: 
 the mole ratio of the first carboxylic acid to the second carboxylic acid is about 1:2.    
     
     
         27 . The process according to  claim 20  further comprising: 
 reacting the combined first carboxylic acid and second carboxylic acid in a reactor and    heating the reactor to a temperature between about 430 to about 470° C. to form a reaction product.    
     
     
         28 . The process according to  claim 27  wherein: 
 the temperature is about 455° C.    
     
     
         29 . The process according to  claim 27  further comprising: 
 gathering the reaction production which comprises a first oily layer and a second water layer,    washing the reaction product with H 2 O;    alkalizing the reaction product; and    extracting the methyl-benzyl-ketone.    
     
     
         30 . The process according to  claim 29  wherein extracting further comprises: 
 extracting the water layer with benzene for form a benzene extract;    combining the benzene extract with the oily layer;    distilling off the benzene; and    separating the resulting methyl-benzyl-ketone from any byproducts.    
     
     
         31 . A process for producing methyl-benzyl-ketone comprising: 
 combining phenylacetic acid and acetic acid to form a reaction mixture;    reacting the reaction mixture in a reactor containing a catalyst comprised of thorium dioxide and manganic oxide on a pumice substrate; and    extracting the resulting methyl-benzyl-ketone.