Halosilane Production via Ternary Intermetallic Reactants
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Solution Overview
Problem
The production of halosilanes through the Mueller-Rochow Direct Process is energy-intensive due to the need for high-temperature carbothermic reduction of SiO2, leading to high costs, and existing methods lack selectivity in producing desired halosilanes.
Innovation Solution
A process involving the contact of an unsaturated hydrocarbyl halide with a ternary intermetallic compound comprising copper, silicon, and a transition metal like silver, cobalt, chromium, iron, molybdenum, or rhodium at temperatures between 300° C. to 700° C. to form halosilanes with specific formulas, allowing for selective production of halosilanes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the Mueller-Rochow Direct Process is used to produce halosilanes, then halosilanes can be produced commercially, but the process requires extremely high temperatures for carbothermic reduction of SiO2, making it energy intensive and costly
Solution Approach 1:
The invention changes the temperature parameter from extremely high temperatures (required for carbothermic reduction of SiO2) to moderate temperatures (300-700°C) by using a different chemical pathway involving ternary intermetallic compounds as reactants, thereby reducing energy consumption while maintaining commercial production capability
Solution Approach 2:
The invention extracts and eliminates the energy-intensive carbothermic reduction step (SiO2 reduction) from the process by using pre-formed ternary intermetallic compounds containing silicon, copper and a transition metal as the starting material, thereby removing the harmful high-temperature requirement while preserving the ability to produce halosilanes commercially
2Productivity
If the Mueller-Rochow Direct Process is used with unsaturated hydrocarbyl halides, then organohalosilanes can be produced, but only mixtures of products are obtained, lacking selectivity
Solution Approach 1:
The invention applies local quality by using specific ternary intermetallic compounds with defined compositions (silicon, copper, and specific transition metals) as reactants, which creates a controlled reaction environment that directs the formation of specific halosilane products rather than mixtures, thereby achieving both productivity and manufacturing precision
Solution Approach 2:
The invention changes the chemical composition parameter of the reactant from zero-valent silicon to ternary intermetallic compounds with specific metal combinations, which fundamentally alters the reaction pathway to enable selective formation of desired halosilane products while maintaining high productivity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method reduces energy consumption and enables the selective production of halosilanes, such as dimethyldichlorosilane and polyorganosiloxanes, by converting unsaturated hydrocarbyl groups into saturated groups, even without additional reactants, thereby improving process efficiency and product diversity.
Implementation Method 1
contacting an unsaturated hydrocarbyl halide and a ternary intermetallic compound comprising copper (Cu), silicon (Si) and a transition metal selected from the group consisting of silver (Ag), cobalt (Co), chromium (Cr), iron (Fe), molybdenum (Mo), and rhodium (Rh) at a temperature of 300° C. to 700° C. to form the reaction product
Data Source
AI summary
A process for preparing a reaction product including a halosilane includes: contacting an unsaturated hydrocarbyl halide and a ternary intermetallic compound at a temperature of 300° C. to 700° C. to form the reaction product. The ternary intermetallic compound includes copper, silicon and a transition metal. The halosilane in the reaction product has formula R1mR2n—HoSiX(4−m−n−o)> where each R1 is independently a saturated monovalent hydrocarbyl group, each R2 is independently an unsaturated monovalent hydrocarbyl group; each X is independently a halogen atom; subscript m is 1, 2, or 3; subscript n is 0, 1, or 2; subscript o is 0, 1, or 2; and a quantity (m+n+o) is 1, 2, or 3. At least a portion of the unsaturated hydrocarbyl groups in the unsaturated hydrocarbyl halide are converted to saturated hydrocarbyl groups (R1) in the halosilane.