Silicon-Copper Catalyst Preparation for Organohalosilanes
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Solution Overview
Problem
Conventional methods for producing organohalosilanes, such as the Mueller-Rochow Direct Process, are energy-intensive and generate costly by-products like aluminum chloride or zinc chloride, increasing production costs and environmental disposal challenges.
Innovation Solution
A method involving contacting a copper catalyst with a mixture of hydrogen gas and halogenated silane monomers to form a silicon-containing copper catalyst, which is then reacted with an organohalide to produce organohalosilanes, reducing energy consumption and minimizing metal halide by-product generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If the Mueller-Rochow Direct Process is used to produce organohalosilanes, then organohalosilanes can be manufactured, but extremely high temperatures are required which consume significant energy and increase production costs
Solution Approach 1:
The patent changes the temperature parameter from extremely high temperatures (electric arc furnace) to moderate temperatures (room temperature or slightly elevated), dramatically reducing energy consumption while maintaining product formation through the novel copper catalyst system
Solution Approach 2:
The patent introduces copper catalyst as an intermediary substance that mediates the reaction between organohalide and silicon source, enabling the reaction to proceed under milder conditions without requiring extreme energy input
2Productivity
If aluminum or zinc is used as catalyst to produce diorganodihalosilanes, then diorganodihalosilanes can be formed, but large amounts of aluminum chloride or zinc chloride by-products are generated which are costly to dispose of
Solution Approach 1:
The patent converts the harmful by-product generation issue into a benefit by using copper catalyst which produces copper halide by-products that are less problematic and can be more easily managed or recycled, while still achieving high diorganodihalosilane production
Solution Approach 2:
The patent changes the catalyst material parameter from aluminum or zinc to copper, which fundamentally alters the by-product composition from problematic aluminum chloride or zinc chloride to more manageable copper halide, reducing disposal costs and environmental impact
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 is more economical, reduces the production of costly by-products, and offers better selectivity for valuable diorganodihalosilanes, enabling their subsequent use in various industries with improved environmental sustainability.
Implementation Method 1
contacting a copper catalyst with a mixture of hydrogen gas and one or more halogenated silane monomers to form a silicon-containing copper catalyst
Implementation Method 2
contacting the silicon-containing copper catalyst with an organohalide to form at least one organohalosilane
Data Source
AI summary
The application relates to a method for preparing organohalosilanes in a two-step process: Steps (i) contacting a copper catalyst with hydrogen gas and halogenated silanes forming a silicon-containing copper catalyst; and Step (ii) contacting said silicon-containing copper catalyst with an organohalide to form the organohalosilane.