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The synthesis of acrylic acid and its derivatives with the use of CO2 and ethylene The Bigger Picture
feedstock is an exciting yet extremely challenging reaction. In addition to Acrylic and its derivatives are
the inherent stability of CO2, other challenges arise, such as the elimination important raw materials for the
of b-hydride from metallalactone to release free acrylate. Since the ground- manufacture of a wide variety of
breaking work more than three decades ago, tremendous efforts have been industrial and consumer products.
made to realize an effective catalytic system. From historical findings to recent In the theme of sustainability,
progress, this review gives a comprehensive overview of this reaction. Reac- more economical methods that
tions mediated by different transition-metal complexes and mechanistic details utilize cheaper and less toxic
are discussed in depth. feedstock are urgently needed.
Clean pathways can be realized
INTRODUCTION through the direct
Acrylic acid and its derivatives are extremely important building blocks for functionalization of CO2, which
the manufacture of various industrial and consumer products, such as plastics, plays a dual role of reducing the
textiles, coatings, elastomers, adhesives, and paints.1,2 The global annual market CO2 emission rate and producing
demand for sodium acrylate alone is 4 million tons. The world capacity of chemicals with added value.
acrylic acid is 6 million tons as of 2013 and is still rapidly increasing. Traditionally, Because ethylene is one of the
acrylates have been synthesized exclusively via a two-step oxidation of propene most abundant industrial
with O2 (via a transient acrolein intermediate) over heterogeneous catalysts feedstocks, manufacturing acrylic
at high temperature, in almost quantitative yield.3–5 As an alternative to oxida- acid and acrylates directly from
tive processes, carboxylation of unsaturated hydrocarbon using C1 feedstock CO2 and ethylene becomes both
has also garnered much attention. The most popular processes utilize CO and scientifically fascinating and
H2O as the C1 source with nickel6,7 or palladium8,9 complexes as catalysts; industrially relevant. As a dream
some processes, such as the Reppe process, have been shown to be commer- reaction in catalysis and CO2
cially viable.10,11 The acid-catalyzed Koch reaction is also an important process utilization, this challenging
to achieve direct carboxylation of alkenes.12 However, for olefinic substrates, transformation has drawn close
most of these methods produce saturated aliphatic acids rather than their un- attention for nearly 40 years. With
saturated counterparts. Moreover, although many of these processes are consid- continuous efforts from both
ered clean routes to manufacture carboxylic acids (including acrylic acid), more academia and industry, scientists
economical methods utilizing cheaper and less toxic feedstock are urgently are getting close to realizing an
needed. effective catalytic system. This
review covers critical discoveries
From a low carbon point of view, one fundamental strategy to reduce the CO2 and discusses possible future
emission rate is by means of carbon capture and utilization (CCU) through direct directions in this area.
functionalization of CO2, which serves a dual purpose of reducing greenhouse gas
emissions and producing value-added chemicals. Thus, ideally, it would be attrac-
tive to explore the preparation of acrylates with CO2 as an abundant, cheap, and sus-
tainable C1 feedstock. Manufacturing acrylates via the addition of ethylene and
CO2 is challenging and considered one of the ‘‘dream reactions’’ in catalysis
(Scheme 1). The thermodynamic stability of CO2 has led to challenges in its utiliza-
tion as a feedstock in synthetic applications. Few reactions and catalysts have
been developed to enable the straightforward conversion of CO2 to other chemi-
cals,13,14 and even fewer have been industrialized.15 Nevertheless, since pioneering
work in the late 1970s, impressive progress has been made toward establishing an
effective CO2-to-acrylate process.16,17
Nickel-Mediated Reactions
Ligand-modified nickel(0) complexes are by far the most intensively investigated pro-
moters for the coupling of CO2 with ethylene. In 1982, Hoberg and Schaefer discov-
ered that in the presence of 2,20 -bipyridine (bpy), Ni(0) could undergo an addition
reaction with norbornene and CO2 to form a five-membered adduct (known as
Hoberg’s complex or nickelalactone) in 93% yield at 60 C (Scheme 2).18 The com-
plex could be hydrolyzed to give norbornane-2-carboxylic acid in 95% yield. In a
follow-up study, (dicyclohexylphosphino)ethane (dcpe) was used at the same tem-
perature (60 C), and saturated acid product was obtained in 80% yield.19 The addi-
tion reaction of CO2 with cyclopentene was also investigated by Hoberg et al.20
At almost the same time, Walther and Dinjus21 and Walther et al.22 reported
the Ni(bpy) and Ni(TMEDA)-mediated (TMEDA = N,N,N0 ,N’-tetramethylethylene-
diamine) addition of 2,3-dimethylbutadiene and CO2. The structure of the
7-membered nickelalactone formed was confirmed by X-ray analysis. When treated
with HX (X = halide) or H2SO4, the nickelalactone could be hydrolyzed to give
3,4-dimethylpent-3-enoic acid (Scheme 3). However, when treated with MeI, the ma-
jor product was 3,4-dimethylhex-3-enoic acid as a result of C alkylation. Additional O
alkylation was only observed when excessive MeI was used.
five-membered ring transition state (+104.1 kJ/mol) (Figure 1). The solvent-cor-
rected Gibbs free energy of the overall coupling process was strongly unfavorable
as well (+42.7 kJ/mol). Pápai et al.26 also performed DFT calculations for a series
of nickelalactone with substituted bpy ligands on the B3LYP/6-311++G(d,p) level
of theory. The computed activation barrier for the nickelalactone formation was
80–110 kJ/mol.
An important breakthrough was made in 2006, when Fischer et al.28 found that
b-hydride elimination of a nickelalactone could be achieved if the flexible and
compact bidentate ligand bis(dicyclohexylphosphino)methane (dppm) was used.
Other related studies by this group include Ni-mediated addition of CO2 with
dicyclopentadiene29 or alkyne,30 and TMEDA-pyridine ligand exchange for nickel-
alactone and ring-opening reactions by disulfides.31 In their research on the
Ni-dppm complex, the reactive intermediate [(dppm)2Ni(CH2CH2COO)] under-
went two distinct transformations: (1) b-hydride elimination to give a NiH(acrylate)
(dppm)2 complex and (2) reductive decoupling to give Ni(dppm)3, CO2, and
ethylene (Scheme 6). In the first pathway, however, the expected reductive elimi-
nation to release free acrylic acid was not successful. Instead, NiH(acrylate)
(dppm)2 combined with Ni(dppm)3 to form a binuclear Ni(I) complex with bridging
acrylate, dppm, and anionic diphenylphosphido groups, releasing one molecule of
Ph2PMe as confirmed by 31P nuclear magnetic resonance (NMR). The binuclear
complex was isolated, and the structure was confirmed by single-crystal X-ray anal-
ysis. Although the primary goal of producing acrylic acid was not achieved, this
study illustrated that the crucial step of b-hydride elimination could be realized
by choosing the right ligand.
Later, Lee et al.38 demonstrated that the diamine or diphosphine ligand of nickela-
lactones had a significant effect on the yield of methyl acrylate. Nickel ligated with
TMEDA or dppe gave the best yield of around 40%. To overcome the high reaction
barriers of b-H elimination, a large excess of methyl iodide is necessary. With the
same bidentate ligand, the yield only increased by 20% when the amount of MeI
was increased from 10 to 100 equiv. For a mixture of nickelalactone and 100 equiv
MeI, a kinetic study was performed by monitoring the shift in the n(C=O) bond
stretch with attenuated total reflectance-Fourier transform-infrared (ATR-FT-IR)
spectroscopy. A new IR band was observed at around n = 1,680 cm1, representing
complex B, which was in accord with the calculated value (1,720 G 30 cm1)
(Scheme 8). A slightly lower IR band of 1,672 cm1 was observed after 3 hr, indicating
the formation of p-bonded h2-methyl acrylate (C).
In contrast to the TMEDA complex that studied by Lee et al.,38 Plessow et al.39
proposed an alternative mechanism for MeI-assisted NiO bond cleavage of the
1,2-bis(di-tert-butylphosphino)ethane (dtbpe) ligated nickelalactone complex. This
Ph Ph
H
Ph2P P
Ni
P O Ph Ph
Ph2P O Ph2P PPh2
Ph Ph Ph Ph P
Ph2P PPh2
Ph2P P Ni Ni
Ni
P O O O O PPh2
Ph2P Ph2P
Ph Ph Ph Ph Ph
Ph PPh2
P P
bis(dppm)nickelalactone Ni (isolated)
P P PPh2
Ph Ph Ph Ph + Ph2PMe
(isolated) (detected)
difference in mechanism again indicated that the ligand plays a crucial role in
determining the kinetic profile of the reaction. In a pathway similar to that pro-
posed by Lee et al., the transition state corresponding to the addition of MeI to
dtbpe-nickelalactone complex was too high in energy (DG = 271 kJ/mol) and was
considered less likely to be a major pathway for the methylation step (Scheme 9).
Instead, methylation via SN2 methylation of the carbonyl followed by ring opening
by the iodide should be the most probable pathway (DG = 73 kJ/mol). Methylation
on the oxygen of the NiO bond is not likely either because the activation energy
(DG = 111 kJ/mol) is much higher than the methylation of the carbonyl group.
A B
In 2012, the Limbach group at Heidelberg University and researchers at BASF devel-
oped the first Ni-catalyzed acrylate formation reaction.40 Assisted by DFT-computed
DG values, they targeted the formation of sodium acrylate instead of free acrylic
acid, because the first energy barrier (nickelalactone formation) was reduced
(+101 versus +122 kJ/mol), and the overall process is exothermic for sodium acrylate
synthesis (DG = 59 kJ/mol). With dtbpe as the optimal ligand, the rate-determining
step was identified as base-facilitated deprotonation elimination at the a carbon of
the nickelalactone, rendering the p complex (Scheme 11). A strong base such as
t
BuONa was necessary to promote the a deprotonation. At 40 bar of CO2 and
5 bar of ethylene, a landmark turnover number (TON) of greater than 10 was
achieved. Limbach also discovered that the cation and the aggregation state of
the base play a crucial role in this reaction, as an appropriate cation could effectively
activate the carbonyl. Although the TON was nowhere near being applicable, it rep-
resents the first effective catalytic reaction, and a giant leap toward realizing an
industrially relevant process.
Because of the inherent incompatibility of strong bases (e.g., tBuONa) with CO2 or
carbonyl-activating reagents (e.g., Lewis acids),14 seeking less basic conditions to
adapt to the CO2 atmosphere was strongly desirable. In their follow-up research,
Huguet et al.41 replaced sodium alcoholates with weak bases such as substituted
sodium phenoxides, where sodium 2-fluorophenoxide was found to be the optimal
base. The dtbpe ligand in their previous catalytic system was replaced by the P-chi-
rogenic ligand BenzP*. An increased TON of 39 was achieved, and the pressure of
CO2 was reduced to as low as 10 bar, whereas in the Ni(dtbpe)-catalyzed reaction
it was three times higher (40 bar) (Scheme 12). Interestingly, it was found that a
greater amount of phenoxide and the addition of finely powdered zinc both further
increased the TON. A TON of 107 was realized with the addition of excessive zinc
(Zn/Ni = 100). Although the mechanism was not fully elucidated, it is suspected
that zinc reduces the Ni(II) intermediate species, thus facilitating the overall rate of
the reaction. Practically speaking, the necessity of excessive zinc is suitable for a
proof of concept but might not be industrially relevant and should preferably be
avoided.
In 1991, Hoberg et al.43 found that the addition of a Lewis acid promoter such as
BeCl2 greatly facilitated ring contraction from 5-membered to 4-membered metal-
alactone, which readily underwent a second olefin insertion. Recently, Jin et al.44 re-
ported the distinct effect of sodium tetrakis[3,5-bis(trifluoromethyl)phenyl]borate
(NaBFAr4) with the diphosphine-ligated nickelalactone. It was found by DFT calcula-
tion (M06-L with LANL2DZ for Ni and 6-31G++(d,p) for other atoms) that ring
contraction of the five-membered nickelalactone (g-to-b isomerization) with sodium
coordination was much faster and almost 40 kJ/mol lower in activation energy than
the sodium-free reaction (Scheme 14). In a recent study, Plessow et al.45 also
concluded that the sodium cation might stabilize the five- and four-membered nick-
elalactone. However, it is believed that the use of Lewis acids will not necessarily
facilitate the formation of acrylic acid species unless a base is used.
For non-metal Lewis acids, Jin et al.46 reported the acceleration effect by tris(penta-
fluorophenyl)borane. Under ambient conditions, the borane was able to rapidly pro-
mote b-hydride elimination nickelalactone ligated with 1,10 -bis(diphenylphosphino)
ferrocene (dppf) to release the acrylate-borane salt (Scheme 15).
Interest in developing Mo and W catalysts has been regained recently: the Bern-
skoetter group at Brown University has reported a Mo complex based on the use
of the tridentate phosphine ligand.51 A zerovalent molybdenum pincer complex,
[(Ph2PCH2CH2)2PPh]Mo(C2H4) (N2)2, was found to facilitate the coupling of CO2
and ethylene to afford a molybdenum(II) acrylate hydride complex (Scheme 16).
Through kinetic isotope effect experiments, the substantial rate-determining step
was identified to be the oxidative addition of CO2 and ethylene to the Mo center,
whereas b-hydride elimination from the metallacylic complex and subsequent
dimerization were fast and not rate limiting. This observation was in strong contrast
with all Ni-, Ti-, Zr-, and Pd-catalyzed reactions, in which the rate-determining step
was the b-hydride elimination of metallalactone.
Zhang et al.52 later discovered that a Mo-tetrahydride complex was also capable of
inducing CO2-ethylene coupling. The structure was confirmed by NMR and X-ray
analysis. The formation of a new C–C bond of formate (formed with a mixed gas
rich in CO2), acrylate, and/or propionate (formed in the presence of H2) was
observed by in situ 1H and 31P NMR (Scheme 17).
In 2012, Wolfe and Bernskoetter53 discovered that the oxidative addition of CO2
and ethylene could be feasibly achieved at ambient temperature with the use
of trans-tetrakis(trimethylphosphite)tungsten bis(ethylene). This zero valent W
complex was prepared by sodium amalgam reduction of tungsten tetrachloride in
the presence of 2 bar of ethylene and 4 equiv of trimethylphosphite (Scheme 18).
The oxidative addition led to two isomeric intermediates k2-O,O and k3-C,C,O
with a rapid interconversion rate in solution. The structure and equilibration of the
two isomers were studied intensively by NMR analysis.
Eventually, the acrylate could be released from the W complex via treatment with
5 equiv of MeI to afford methyl acrylate in 31% yield (based per W) (Scheme 19).
F F
Ph Ph F B Ph Ph
P O
F F 3 P
Fe Ni Fe Ni
P O P OBFAr3
H
Ph Ph O Ph Ph
PhMe2P O PMe2Ph
O PMe2Ph
Figure 2. Resulting Complexes in the Early Study of Mo- and W-Assisted CO2-Ethylene Coupling
Reactions
Iron-Mediated Reactions
Iron is an economic and environmentally friendly catalyst source in comparison
with most other transition metals. However, potential catalytic ability of iron com-
plexes has not garnered wide exploration for CO2-ethylene coupling. In 1986,
Hoberg et al.54 reported the addition of butadiene and CO2 to the Fe complex,
in which a seven-membered ring was formed. Later, they found that the addi-
tion between CO2 and [(PEt3)2Fe(C2H4)2] could take place at a low temperature
of 78 C and under 1 bar of CO2.55 The resultant five-membered metallalactone
was able to undergo a variety of reactions depending on the ligand used. When
PMe3 was used, an Fe-acrylate complex was formed, which isomerized to four-
membered metallalactone and underwent a second CO2 insertion (Scheme 20).
Methylation of the dicarbonylated complex with the use of MeOH/HCl afforded
methyl methylmalonate. However, if dcpe (1,2-bis(dicyclohexylphosphino)ethane)
was used as the ligand, no ring contraction took place and dimethyl succinate
was produced.
Palladium-Mediated Reactions
Palladium complexes have also been explored as a potential class of catalyst for
CO2-ethylene coupling. Reactions of CO2 with other olefinic compounds such as
Me
Ph O O O O
Ph
PPh3 P PPh2 H2 P PPh2
Mo Mo
P PPh3 P PPh3
Ph2 Ph2
H H
2-acrylate 2-propionate
dienes were investigated by several groups over the years. The earliest examples
were presented in a series of studies by several groups, focusing on the reaction
of butadiene. In 1976, Sasaki et al.57 reported a CO2-butadiene addition catalyzed
by 0.015 mol % of Pd(dppe) complex. The major product was (E)-octa-1,3,7-triene,
however, up to 12% yield of a g-lactone (2-ethylidenehept-5-en-4-olide) was ob-
tained, indicating that CO2 insertion had taken place. Musco et al.58 also studied
the Pd-mediated CO2-butadiene addition, which formed a complex set of products
with multiple butadiene fragments. Later in 1986, Behr et al.59 reported that two
molecules of butadiene reacted with CO2 to form a d-lactone (2-ethylidene-6-
hepten-5-olide), in the presence of a PiPr3-ligated Pd catalyst. Behr60 also found
that the presence of nitrile co-ligands was crucial to create vacant coordination sites,
thus forming the catalytically active species. In recent years, Behr’s group has been
transferring the CO2-butadiene addition reaction to a miniplant with a continuous
setup.61 As for substituted dienes, Hoberg and Minato62 reported the dimerization
of isoprene with one molecule of CO2 to form unsaturated esters with the assistance
of a stoichiometric amount of tributyltin ethoxide.
O
L = DCPE MeO
L O MeOH
Fe O O
O L Fe
L CO2 HCl O
L O
OMe
O
L = PMe3
O O
Me O MeOH MeO
L H L CO2 L
Fe Me Me
L
Fe
O O L Fe L
O HCl MeO
O O
O O
29 was realized. Note that the pressure of each gaseous component was doubled
from that in the Ni(BenzP*) system. The previously used ligand dtbpe afforded a
much lower TON (1.5).
With the same catalytic system, Stieber et al.66 were able to couple CO2 with dienes
to afford the corresponding conjugated acrylate analogs with TONs of 24–50
(Scheme 24).
Scheme 22. Proposed Mechanism of Dibenedetto and Pápai’s Ethyl Acrylate Synthesis Catalyzed
by the (dppe)Pd–H Complex
Among the transition-metal complexes with catalytic activities, nickel complexes are
still the most deeply investigated potential catalysts. Mo- and W-mediated reactions
have a unique rate-determining step, so that the difficulty of b-hydride elimination
can be avoided. However, current examples are not catalytic and are at the stage
of mechanistic study. Pd catalysis, exemplified by the ethyl acrylate synthesis
catalyzed by the Pd–H complex, enables an alternative approach and warrants
further investigation. Reactions induced by Fe, Pt, and Rh complexes are currently
underdeveloped.
1. To date, no catalytic system has been efficient enough for industrial practice as
a result of the extremely low TON.
2. Although the efficacy of several catalytic systems has been demonstrated,
the requirement for a superstoichiometric amount of a reductant (e.g., zinc)
and/or an alkylation regent (e.g., MeI) highlights the challenges of this field.
Scheme 24. Coupling of Dienes with CO2 Catalyzed by the Pd(dcpe) Complex
Even in the theoretical study, the unclear function of zinc and the variable
mechanism of methylation by MeI are still puzzles to solve.
3. Current methods produce esters and sodium salts of acrylic acid, which
are extremely valuable fine chemicals among their class. Unfortunately, no
example to date has been able to produce free acrylic acid. Therefore, it is a major
disadvantage in comparison with the traditional propylene oxidation process.
4. Strong or structurally exotic bases are often necessary, which is neither consid-
ered safe nor economically attractive.
5. Most examples require harsh reaction conditions such as high temperature
and pressure.
For the establishment of a more efficient catalytic process, ligand design is believed
by previous researchers and by the authors of this review to be the key to success
because it is the most straightforward way to modify the catalytic property of the
metal complex. We also envision the following potential solutions:
1. An amphoteric compound with both a Lewis acid part and Brønsted base part
could have the ability to stabilize carbonyl and induce ring contraction, thus
liberating free acrylic acid (instead of sodium acrylate). The acrylic acid can
either be removed from the system by separation techniques or be neutralized
with a mild and cheap base.
2. For feasible b-hydride elimination of the metalalactone, adding a methyl-
ation reagent is a popular strategy, which however often introduces unde-
gradable contaminanta such as iodide. An alternative solution would be to
use a cleaner and traceless reagent such as dimethyl carbonate (DMC).
Ideally, DMC can be generated from CO2 and methanol in situ by an orthog-
onal catalytic system, which also catalyzes the formation of acrylate in the
same reactor.
3. The inherent geometric limitation for b-hydride elimination of a 5-membered
metalalactone is one of the biggest obstacles in the existing examples. An
intriguing strategy is to avoid the formation of metalalactone. To that end,
we expect novel C–H activation methods to be developed that directly acti-
vate the C–H bond of ethylene and insert the vinyl group to CO2, thus the
problem with b-hydride elimination can be skipped.
AUTHOR CONTRIBUTIONS
X.W. proposed the topic of the review and conceptualized the article content. X.W.,
H.W., and Y.S. discussed and finalized the manuscript.