Abstract: Disclosed herein are compounds and methods useful as carbonylation catalysts that improve steric properties so that reaction with epoxide is improved, reaction with lactones is avoided, and polymer bonds to the metal centers are weakened, which facilitates faster ring closure, that improve stability of the carbonylation catalyst by not being susceptible to hydrolysis, which reduces side products and improves recovery yields of the carbonylation catalyst after using to make lactones, and that have improved steric and electron properties so that release time of a lactone product is minimized, which reduces side reactions.

Abstract: Disclosed are methods which comprise the preparation of beta-lactones which provide for shorter reaction times with lower by-product formation. The method comprises contacting carbon monoxide with an epoxide in the presence of a carbonylation catalyst to form a reaction mixture under conditions such that the carbon monoxide distributed throughout the reaction mixture and the reaction mixture is substantially saturated with carbon monoxide. The reaction conditions and reactor designs are chosen to distribute the carbon monoxide throughout the reaction mixture and to maintain the reaction mixture as substantially saturated with carbon monoxide. Under these conditions the formation of beta-lactones over the formation of by-products is favored.

Abstract: Disclosed herein are compounds and methods useful as carbonylation catalysts that improve steric properties so that reaction with epoxide is improved, reaction with lactones is avoided, and polymer bonds to the metal centers are weakened, which facilitates faster ring closure, that improve stability of the carbonylation catalyst by not being susceptible to hydrolysis, which reduces side products and improves recovery yields of the carbonylation catalyst after using to make lactones, and that have improved steric and electron properties so that release time of a lactone product is minimized, which reduces side reactions.

Abstract: A method including contacting a ligand complex, a metalation compound, and a metal carbonyl in a mixture to form a catalyst. The ligand complex includes one or more of phosphine, imine, and/or hydroxyl groups bound to one or more cyclic structures. The method includes separating the catalyst from the mixture. Contacting the ligand complex with a metalation compound and the metal carbonyl in the mixture to form a catalyst is conducted without isolating any intermediates, performed within a single vessel, and/or performed in a moisture, oxygen, and/or air free environment.

Abstract: A composition, comprising: a metal carbonyl anion; and a cation ionically bonded to the metal carbonyl anion. The cation includes a ligand and a metal centered compound. The ligand includes two residues of 3,5-substituted salicylaldehydes connected by an hydrocarbyl-diimine bridge that includes a nitrogen atom contacted with a carbon of an aldehyde residue at each of the two residues of the 3,5-substituted salicylaldehydes. Each of the residues of the 3,5-substituted salicylaldehydes are independently substituted at one or both of a 3 position and a 5 position by a hydrocarbyl group containing at least 5 carbons. The metal coordinated with the ligand at each hydroxyl residue the two residues of the 3,5-substituted salicylaldehydes at a 2 position and at each of the nitrogen atoms of the hydrocarbyl-diimine bridge. The composition includes two polar ligands coordinated with the metal.

Abstract: Disclosed herein are compounds and methods useful as carbonylation catalysts that improve steric properties so that reaction with epoxide is improved, reaction with lactones is avoided, and polymer bonds to the metal centers are weakened, which facilitates faster ring closure, that improve stability of the carbonylation catalyst by not being susceptible to hydrolysis, which reduces side products and improves recovery yields of the carbonylation catalyst after using to make lactones, and that have improved steric and electron properties so that release time of a lactone product is minimized, which reduces side reactions.

Abstract: Provided herein are heterogeneous catalysts suitable for use in carbonylation reactions, including the production of acrylic acid from ethylene oxide and carbon monoxide on an industrial scale. The production may involve various unit operations, including, for example: a beta-propiolactone production system configured to produce beta-propiolactone from ethylene oxide and carbon monoxide; a polypropiolactone production system configured to produce polypropiolactone from beta-propiolactone; and an acrylic acid production system configured to produce acrylic acid with a high purity by thermolysis of polypropiolactone.