Synthesis of diacyl peroxide in aprotic solvent

Abstract

This invention relates to a process for the synthesis of diacyl peroxide by contacting acyl halide and peroxide complex in compatible aprotic solvent substantially free of compounds oxidizable by the peroxide complex or the reaction products of organic acyl halide with peroxide complex.

What is claimed is:  
     
         1 . A process for the synthesis of diacyl peroxide comprising contacting organic acyl halide and peroxide complex in compatible aprotic solvent substantially free of compounds oxidizable by the peroxide complex or by products of the reaction of organic acid halide with peroxide complex.  
     
     
         2 . The process of  claim 1  further comprising collecting compatible aprotic solvent containing diacyl peroxide.  
     
     
         3 . The process of  claim 1  further comprising limiting the amount of water present so as to prevent formation of an aqueous phase.  
     
     
         4 . The process of  claim 1  wherein the peroxide complex is substantially insoluble in said compatible aprotic solvent and is present as a solid phase.  
     
     
         5 . The process of  claim 1  wherein the peroxide complex is selected from the group consisting of sodium percarbonate, sodium perborate, and urea/hydrogen peroxide adduct and mixtures thereof.  
     
     
         6 . The process of  claim 1  wherein the mole ratio of peroxide in the peroxide complex to organic acyl halide is at least about one-to-one.  
     
     
         7 . The process of  claim 1  wherein the process is carried out at a reaction temperature between about −40° C. and about 40° C.  
     
     
         8 . The process of  claim 1  wherein the process is carried out at a reaction temperature between about −20° C. and about 20° C.  
     
     
         9 . The process of  claim 1  wherein the process is carried out at a reaction temperature between about −10° C. and about 10° C.  
     
     
         10 . The process of  claim 1  wherein the process is carried out at a reaction temperature selected so that the reaction time is no greater than one-quarter of the diacyl peroxide half-life at the reaction temperature.  
     
     
         11 . The process of  claim 1  wherein the organic acyl halide is selected from the group consisting of fluoroorganic acyl halides.  
     
     
         12 . The process of  claim 1  wherein the organic acyl halide is selected from the group consisting of perfluoroorganic acyl halides.  
     
     
         13 . The process of  claim 1  wherein the organic acyl halide is isobutyryl halide.  
     
     
         14 . The process of  claim 1  wherein the compatible aprotic solvent is selected from the group consisting of a halocarbon, chlorofluorocarbon hydrochlorofluorocarbon, hydrochlorocarbon, hydrofluorocarbon, perfluorocarbon, halocarbon ether and mixtures thereof.  
     
     
         15 . The process of  claim 1  wherein the compatible aprotic solvent is a nonhalogenated solvent.  
     
     
         16 . The process of  claim 1  wherein the compatible aprotic solvent is liquid or supercritical carbon dioxide.  
     
     
         17 . A process for the continuous synthesis of diacyl peroxides comprising continuously contacting a feed stream comprised of organic acyl halide in compatible aprotic solvent with a bed comprised of peroxide complex to form a product stream comprised of diacyl peroxide in compatible aprotic solvent, said compatible aprotic solvent being substantially free of compounds oxidizable by peroxide complex or by products of the reaction of organic acid halide with peroxide complex.  
     
     
         18 . The process of  claim 17  further comprising collecting said product stream.  
     
     
         19 . The process of  claim 17  further comprising limiting the amount of water present so as to prevent formation of an aqueous phase.