Abstract: A process for preparing a product including a monohydrogentrihalosilane is disclosed. The process includes the steps of: 1) initially charging a reactor with a contact mass including both fresh silicon and recycled contact mass, where the recycled contact mass is obtained from during or after a production phase of an inorganic Direct Process reaction for production of a monohydrogentrihalosilane; and thereafter 2) feeding to the reactor a hydrogen halide and additional fresh silicon, thereby forming the product.

Abstract: 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.

Abstract: The present invention is directed to a process for the synthesis of organohalosilane monomers, comprising the steps of (1) forming a slurry of cyclone fines, ultra fines and/or spent contact mass in a thermally stable solvent and reacting the agitated slurry with an organohalide of the formula R1X in the presence of an additive for a time and at a temperature sufficient to produce organohalosilane monomers having the formulae R1SiHX2, R12SiHX, R13SiX, R1SiX3, and R12SiX2; wherein R1 is a saturated or unsaturated aromatic group, a saturated or unsaturated aliphatic group, alkaryl group, or cycloaliphatic hydrocarbyl group, and X is a halogen; and (2) recovering said organohalosilane monomers.

Abstract: Pneumatic conveying of fine solids in the direct synthesis of alkylchlorosilanes conveying gas containing at least 50% by volume of alkyl chloride. The conveying apparatus preferably contains a means for switching conveying gas in the pneumatic conveying of fine solids.

Abstract: Provided herein are cyclosiloxane-substituted polysiloxane compounds, compositions that include the polysiloxane compounds, and methods for preparation and use of the polysiloxane compounds. Provided are mechanical lubricant compositions, hydraulic fluid compositions, anti-foam compositions, water repellant agent compositions, release agent compositions, personal care compositions, cosmetic compositions, household care compositions and drug delivery compositions that include one or more of the cyclosiloxane-substituted polysiloxane compounds provided herein.

Abstract: The present invention relates to a method for preparing SiH(OR3)-type trialkoxysilane (wherein, R is a C1-C3 methyl, ethyl, propyl or isopropyl group), and more specifically, the method comprises the steps of: preventing the oxidation of a silicon surface by pulverizing raw silicon material in a solvent environment without contact with the air so that the initial induction period of the direct synthesis of trialkoxysilane is dramatically reduced; and removing impurities from a reaction environment by continuously selecting a part of the solvent through a membrane filter provided in a reactor body.

Abstract: The present invention is directed to a process for the synthesis of organohalosilane monomers, comprising the steps of (1) forming a slurry of cyclone fines, ultra fines and/or spent contact mass in a thermally stable solvent and reacting the agitated slurry with an organohalide of the formula R1X in the presence of an additive for a time and at a temperature sufficient to produce organohalosilane monomers having the formulae R1SiHX2, R12SiHX, R13SiX, R1SiX3, and R12SiX2; wherein R1 is a saturated or unsaturated aromatic group, a saturated or unsaturated aliphatic group, alkaryl group, or cycloaliphatic hydrocarbyl group, and X is a halogen; and (2) recovering said organohalosilane monomers.

Abstract: The invention pertains to a process for the preparation of organohalosilanes. The process comprises contacting a first finely-divided silicon comprising from 0.08 to 0.25% (w/w) of aluminum with an organohalide in a reactor at a temperature of from 250 to 350° C. in the presence of a Direct Process catalyst comprising copper, and a promotor; and introducing a second finely-divided silicon into the reactor comprising from 0.001 to <0.10% (w/w) of aluminum into the reactor as needed in an amount sufficient to maintain an aluminum concentration of from 0.08 to 0.2% (w/w), based on a weight of unreacted silicon and aluminum.

Abstract: Production of polycrystalline silicon in substantially closed-loop processes and systems is disclosed. The processes and systems generally involve disproportionation of trichlorosilane to produce silane or dichlorosilane and thermal decomposition of silane or dichlorosilane to produce polycrystalline silicon.

Abstract: An improved industrial method for the direct synthesis of alkylhalogenosilanes is described. Specifically, a method is described for preparing alkylhalogenosilanes by reacting, in a fluidized bed reactor, and alkyl halogenide, preferably CH3Cl, with a solid body, which is referred to as a contact body and which includes powdered silicon and a catalytic system including at least one copper catalyst and ?1 and ?2 promoter activities.

Abstract: Palladium intermetallic compounds, such as palladium silicides, e.g., PdSi and/or Pd2Si, can be selectively prepared in a two step process including the steps of (1) vacuum impregnating silicon with a metal halide comprising a palladium halide, and (2) ball milling the product of step (1). A method of preparing organohalosilanes may be performed combining an organohalide having the formula RX, where R is a hydrocarbyl group having 1 to 10 carbon atoms and X is a halogen atom, with a contact mass comprising at least 2% of the palladium intermetallic compound.

Abstract: The present invention relates to a method for preparing SiH(OR3)-type trialkoxysilane (wherein, R is a C1-C3 methyl, ethyl, propyl or isopropyl group), and more specifically, the method comprises the steps of: preventing the oxidation of a silicon surface by pulverizing raw silicon material in a solvent environment without contact with the air so that the initial induction period of the direct synthesis of trialkoxysilane is dramatically reduced; and removing impurities from a reaction environment by continuously selecting a part of the solvent through a membrane filter provided in a reactor body.

Abstract: The invention relates to a method for the direct synthesis of methylchlorosilanes by reacting chloromethane with a contact mass containing silicon, copper catalyst and at least 120 ppm by weight of manganese.

Abstract: A method of preparing a diorganodihalosilane, the method comprising the following separate and consecutive steps: (a) treating a metal catalyst comprising a metal selected from the groups consisting of i) gold, ii) gold and copper, iii) gold, copper and magnesium, iv) copper, rhodium and gold, v) copper, rhodium, and rhenium, vi) rhenium and palladium, vii) copper, and viii) copper and magnesium with a mixture comprising hydrogen gas and an organotrihalosilane at a temperature from 500 to 1400° C. to form a silicon-containing metal intermediate; and (b) reacting the silicon-containing metal intermediate with an organohalide according to the formula RX, wherein R is C1-C10 hydrocarbyl and X is halo, at a temperature from 100 to 600° C. to form a diorganodihalosilane and a depleted silicon-containing metal intermediate.

Abstract: A method of preparing a diorganodihalosilane comprising the separate and consecutive steps of (i) contacting a copper catalyst with a mixture comprising hydrogen gas and a silicon tetrahalide at a temperature of from 500 to 1400° C. to form a silicon-containing copper catalyst comprising at least 0.1% (w/w) of silicon, wherein the copper catalyst is selected from copper and a mixture comprising copper and at least one element selected from gold, magnesium, calcium, cesium, tin, and sulfur; and (ii) contacting the silicon-containing copper catalyst with an organohalide at a temperature of from 100 to 600° C. to form at least one diorganodihalosilane.

Abstract: The invention relates to silicon dioxide powder which is present in the form of aggregated primary particles having an average diameter of at least 40 nm and a ratio of the BET surface area to the STSA surface area of at least 3.5. The invention also relates to a toner composition containing said silicon dioxide powder.

Abstract: The invention pertains to a method of producing organohalohydrosilanes by treating a silicon metal with a halogen-containing compound, wherein the halogen-containing compound has a formula selected from RdSiX4-d (II) and RX (III), combining a catalyst and a promoter with the treated silicon metal, and contacting the combination with hydrogen gas and an organohalide. The invention also pertains to a method of producing organohalohydrosilanes by contacting an organohalide and hydrogen gas with a combination of silicon metal, a catalyst, a promoter and a hydrogen storage material. The invention also pertains to a method of producing organohalohydrosilanes by contacting an organohalide and hydrogen gas with a combination of a silicon metal, a catalyst, a promoter and a hydrogenation catalyst. The invention also pertains to a method of producing organohalohydrosilanes by contacting an organohalide and hydrogen gas with a reaction mass residue and optionally a hydrogenation catalyst.

Abstract: Methods and systems for producing silane that use electrolysis to regenerate reactive components therein are disclosed. The methods and systems may be substantially closed-loop with respect to halogen, an alkali or alkaline earth metal and/or hydrogen.

Abstract: The invention pertains to a process for the preparation of organohalosilanes. The process comprises contacting a first finely-divided silicon comprising from 0.08 to 0.25% (w/w) of aluminum with an organohalide in a reactor at a temperature of from 250 to 350° C. in the presence of a Direct Process catalyst comprising copper, and a promotor; and introducing a second finely-divided silicon into the reactor comprising from 0.001 to <0.10% (w/w) of aluminum into the reactor as needed in an amount sufficient to maintain an aluminum concentration of from 0.08 to 0.2% (w/w), based on a weight of unreacted silicon and aluminum.

Abstract: The invention pertains to a method of producing organohalohydrosilanes by treating a silicon metal with a halogen-containing compound, wherein the halogen-containing compound has a formula selected from RdSiX4-d (II) and RX (III), combining a catalyst and a promoter with the treated silicon metal, and contacting the combination with hydrogen gas and an organohalide. The invention also pertains to a method of producing organohalohydrosilanes by contacting an organohalide and hydrogen gas with a combination of silicon metal, a catalyst, a promoter and a hydrogen storage material. The invention also pertains to a method of producing organohalohydrosilanes by contacting an organohalide and hydrogen gas with a combination of a silicon metal, a catalyst, a promoter and a hydrogenation catalyst. The invention also pertains to a method of producing organohalohydrosilanes by contacting an organohalide and hydrogen gas with a reaction mass residue and optionally a hydrogenation catalyst.

Abstract: Process for preparing alkylhalosilanes are provided. The process involve reacting an alkyl halide with a solid body formed of silicon and a catalytic system.

Abstract: A semi-continuous process for producing organohalosilanes or halosilanes in a fluidised bed reactor, from silicon-containing contact mass, comprising removing silicon-containing contact mass that has been used in said reactor by: (i) elutriation in an unreacted organohalide or hydrogen halide stream and/or an organohalosilane or halosilane product stream and (ii) direct removal using gravitational or pressure differential methods and returning removed silicon-containing contact mass to the fluidised bed reactor and/or fresh silicon-containing contact mass. When used for producing organohalosilanes (e.g. alkylhalosilanes) the silicon-containing contact mass may contain catalysts and promoters in addition to silicon.

Abstract: Process for the preparation of alkylhalosilanes by reaction of an alkyl halide, preferably CH3Cl, with a solid body, referred to as contact body, formed of silicon and of a catalytic system comprising (?) a copper catalyst and (?) a group of promoting additives comprising: an additive ?1 chosen from metallic zinc, a zinc-based compound and a mixture of these entities, an additive ?2 chosen from tin, a tin-based compound and a mixture of these entities, optionally an additive ?3 chosen from cesium, potassium, rubidium, a compound derived from these metals and a mixture of these entities, said direct synthesis process being characterized by the following points, taken in combination: the copper catalyst (?) is in the form of metallic copper. of a copper halide or of a mixture of these entities, the contact body additionally includes a supplementary promoting additive ?4 chosen from a derivative of an acid of phosphorus and a mixture of these entities.

Abstract: Chemical grade silicon metalloid having improved performance in the direct process for making organohalosilanes is selected by (A) measuring the temperature of each batch of silicon metalloid during both the refining and the casting of the silicon metalloid; (B) measuring the elemental impurity levels in each batch of the silicon metalloid after refining of the silicon metalloid; (C) predicting the properties of the slag phase produced during refining of the silicon metalloid based on equilibrium calculations using the elemental impurity levels and the measured temperatures of each batch of silicon metalloid; and (D) selecting a chemical grade silicon metalloid for use in the direct process for making organohalosilanes based upon the predicted slag properties; such that the slag density, the viscosity, and the melting point of the slag, are within acceptable and predetermined ranges for each individual batch.

Abstract: The invention relates to a process for the direct synthesis of methylchlorosilanes by reaction of chloromethane with a contact composition comprising silicon and copper catalyst, wherein the concentration of oxygen in the chloromethane used is reduced by mixing a) chloromethane which contains oxygen, and b) chloromethane which contains a gaseous boron compound.

Abstract: Organohalosilanes are prepared by charging a reactor with a contact mass comprising metallic silicon and a catalyst and feeding an organohalide-containing gas to the reactor. The contact mass is prepared by premixing metallic silicon and a tin compound and heat treating the premix at 300-600° C. in an inert gas atmosphere.

Abstract: A container for forming an electrode that can be used in electric reduction furnaces. The container comprises a cylindrical casing. Within the cylindrical casing is a plurality of ribs attached along the inner surface of the casing lengthwise of the cylindrical casing. At least one of the ribs in the container is made of a material comprising copper.

Abstract: This invention discloses a process to improve reaction stability in the Direct Synthesis of trialkoxysilanes. The process is particularly effective in the Direct Synthesis of triethoxysilane and its higher alkyl cognates providing improved triethoxysilane yields.

Abstract: Organohalosilanes are prepared by charging a reactor with a contact mass of metallic silicon and a catalyst and feeding an organohalide-containing gas to the reactor. Tin or a tin compound is used as the catalyst. Then organohalosilanes can be produced quite efficiently at a high reaction rate while maintaining a low T/D ratio and minimizing the deposition of by-products and carbon.

Abstract: The invention relates to a process for the direct synthesis of methylchlorosilanes by reaction of chloromethane with a contact composition comprising silicon and copper catalyst, wherein the concentration of oxygen in the chloromethane used is reduced by mixing a) chloromethane which contains oxygen, and b) chloromethane which contains a gaseous boron compound.

Abstract: The present invention provides a catalyst that may be used to facilitate the formation of dimethylchlorosilanes. A catalyst in which copper oxide and zinc oxide are in intimate contact and form agglomerated particles allows for the increased selectively of the production of dimethylchlorosilanes.

Abstract: This invention discloses a process to improve reaction stability in the Direct Synthesis of trialkoxysilanes. The process is particularly effective in the Direct Synthesis of triethoxysilane and its higher alkyl cognates providing improved triethoxysilane yields.

Abstract: Organohalosilanes are prepared by reacting metallic silicon particles with an organohalide in the presence of a copper catalyst. A contact mass composed of metallic silicon and copper catalyst contains an effective amount of a catalyst powder obtained by mechanical surface treatment of a powder mixture of tin powder and another metal, typically copper powder, on a ball mill, stamp mill, jet mill, mechanofusion device or the like.

Abstract: Silanes containing halogen which is bound to silicon are prepared using microwave energy. Silicon is reacted with mixtures of elements or compounds selected from the group consisting of halogen or halogen and organohalogen compounds or halogen and hydrogen or halogen and halogen hydrogen or organohalogen compounds or organohalogen compounds and hydrogen or organohalogen compounds and halogen hydrogen or halogen hydrogen or fluorosilanes and hydrogen, or fluorosilanes and halogen hydrogen or hydrogen containing chlorosilanes and hydrogen or hydrogen containing chlorosilanes and halogen hydrogen or organohalogensilanes and hydrogen or organohalogensilanes and halogen hydrogen or hydro-carbons and halogen hydro-carbons.

Abstract: The alkylhalosilanes are directly synthesized while diminishing the formation of coke by reacting an alkyl halide with silicon in the presence of a catalytically effective amount of (?) a copper metal or a copper-based compound catalyst and (?) a catalyst promoter intermixture therefor which comprises an effective minor amount of an additive ?1 selected from the group consisting of tin, a tin-based compound and mixture thereof, optionally, an effective minor amount of an additive ?2 selected from the group consisting of zinc metal, a zinc-based compound and mixture thereof, an effective minor amount of an additive ?3 selected from the group consisting of cesium, potassium and rubidium, and compound and mixture thereof, and, optionally, an effective minor amount of an additive ?4 selected from the group consisting of the element phosphorus, a phosphorus-based compound and mixture thereof.

Abstract: A process for the direct synthesis of methylchlorosilanes by reaction of chloromethane with a contact composition comprising silicon, copper catalyst and from 10 to 90 ppm of strontium leads to increased selectivity and higher production rate.

Abstract: The alkylhalosilanes are directly synthesized by reacting an alkyl halide with silicon in the presence of a catalytically effective amount of (?) a copper metal or a copper-based compound catalyst and (?) a catalyst promoter intermixture therefor which comprises an effective minor amount of an additive ?1 selected from the group consisting of tin, a tin-based compound and mixture thereof, an effective minor amount of an additive ?2 selected from the group consisting of cesium, potassium and rubidium, and compound and mixture thereof, and an effective minor amount of an additive ?3 selected from the group consisting of the element phosphorus, a phosphorus-based compound and mixture thereof.

Abstract: Organohalosilanes are prepared by reacting metallic silicon particles with an organohalide in the presence of a copper catalyst. A contact mass composed of the metallic silicon and the copper catalyst contains an effective amount of a catalyst alloy containing 0.2–8 wt % of tin and 4–20 wt % of phosphorus which is powdered by atomization.

Abstract: A Direct Synthesis of making organohalosilanes with greater selectivity to the dialkyldihalosilane is disclosed herein. By using nanosized copper catalyst precursors, and preferably nanosized promoters as well, D/T values of greater than 10, and preferably greater than 15, are obtainable with silicon conversions in excess of 80 wt. %. Shorter induction times are realized using the nanosized copper catalysts in the Direct Synthesis. The nanosized copper catalyst precursors most preferably have an average particle size of less than 100 nanometers.

Abstract: The invention concerns a silicon powder for making alkyl- or aryl-halogenosilanes, with particle-size distribution less than 350 ?m, and containing less than 3% and preferably less than 2% of particles having a size less than 5 ?m. Said powder enables to improve efficiency of synthesis reaction.

Abstract: In a Rochow process, organohalosilanes are prepared by reacting metallic silicon particles with an organohalide in the presence of a copper catalyst and a co-catalyst. The invention uses as the co-catalyst a powder of co-catalyst active element-copper alloy containing substantial strain energy because this co-catalyst can reduce the activation time taken until a steady state is reached, which has been an outstanding problem in Rochow reaction, maintain the steady state over time and increase the selectivity of desired diorganodihalosilane for eventually increasing the yield based on the starting silicon.

Abstract: A method for preparing alkyldichlorosilanes having a Si—H bond by directly reacting metallic silicon with a mixture of alkyl chloride and (i) hydrogen chloride, or (ii) an alkyl chloride which can generate hydrogen chloride at a reaction temperature in the presence of copper catalyst.

Abstract: In an industrial process for preparing organohalosilanes by reacting metallic silicon particles with an organohalide in the presence of a copper catalyst, a contact mass composed of the metallic silicon and the catalyst further contains an effective amount of a phosphine chalcogenide compound. The invention drastically increases the silane formation rate and the utilization of silicon without lowering the selectivity of useful silane.

Abstract: When oganohalosilanes are prepared by charging a reactor with a contact mass containing metallic silicon and a copper catalyst, and introducing an organohalide-containing gas feed into the reactor, the partial pressure of organohalide gas in the gas feed is manipulated so as to keep the temperature within the reactor substantially constant. The precise control of reactor internal temperature ensures that organohalosilanes with a higher useful silane content are produced in a safe and inexpensive manner and in high yields from the contact mass having perpetually changing reactivity.

Abstract: In an industrial process for preparing organohalosilanes by reacting metallic silicon particles with an organohalide in the presence of a copper catalyst, a contact mass composed of the metallic silicon and the catalyst further contains an effective amount of a phosphonium compound having on the molecule at least one group of the formula: [R2R3R4P—]+Y− wherein R2, R3 and R4 each are a monovalent hydrocarbon group and Y is a halogen atom or acid group. The invention drastically increases the silane formation rate and the utilization of silicon without lowering the selectivity of useful silane.

Abstract: A method for making alkylhalosilanes is provided comprising reacting an alkyl halide and silicon in the presence of a copper catalyst comprising copper powder, particulated copper, copper flake, or combinations thereof and at least one co-catalyst.

Abstract: A method for making alkylhalosilanes is provided comprising reacting an alkyl halide and silicon in the presence of a copper catalyst comprising copper powder, particulated copper, copper flake, or combinations thereof and at least one co-catalyst.

Abstract: In the synthesis of organohalosilanes by the direct process of reacting an organic halogen with metallic silicon powder, a metallic copper catalyst in the form of a thermally active metallic copper powder having large strain energy is used.

Abstract: Process for the production of alkoxysilanes of the formula HSi(OR)3, where R is an alkyl group containing 1 to 6 carbon atoms, and/or alkyl orthosilicates of the formula Si(OR)4, where R is an alkyl group containing 1 to 6 carbon atoms. In a preferred embodiment, the process comprises reacting silicon metal with an alcohol in a suitable solvent in the presence of a cupric bis(diorganophosphate) catalyst. A polymeric form of ethyl orthosilicate, a by-product of the reaction, is the preferred solvent. The production of triethoxysilane and tetraethyl orthosilicate is preferred, with triethoxysilane being particularly preferred.

Abstract: In an industrial process for preparing organohalosilanes by reacting metallic silicon particles with an organohalide in the presence of a copper catalyst, a contact mass composed of the metallic silicon and the catalyst further contains an effective amount of a phosphine chalcogenide compound. The invention drastically increases the silane formation rate and the utilization of silicon without lowering the selectivity of useful silane.