Siemens Reloaded: Chloride-Assisted Selective Hydrodechlorination of SiCl4 to HSiCl3.

Trichlorosilane is the key intermediate for the large-scale production of polycrystalline silicon in the Siemens and Union Carbide processes. Both processes, however, are highly inefficient, and over two thirds of the trichlorosilane employed is converted to unwanted silicon tetrachloride accumulating in millions of tons per year on a global scale. In this combined experimental and theoretical study we report an energetically and environmentally benign synthetic protocol for the highly selective conversion of SiCl4 to HSiCl3 using organohydridosilanes as recyclable hydrogen transfer reagents in combination with onium chlorides as efficient catalysts. We put the same protocol to further use demonstrating the quantitative conversion of higher oligosilane residues, which form as another unwanted and potentially hazardous byproduct of Siemens processes, to HSiCl3 in a low-temperature recycling step.

1946 and the Early History of Hydrosilylation.

Three events occurred in the second half of 1946 in three adjoining US States (NJ, NY, and PA) which marked the birth of Hydrosilylation Technology. They occurred before the landmark 1957 JACS paper and the 1958 issued US patent by Speier et al. and before Chalk and Harrod named the reaction. First, on 27 June 1946, Mackenzie et al., of Montclair Research Corp., applied for a patent to prepare addition compounds of hydridosilanes and unsaturated organic compounds. Then, on 9 October 1946, Wagner and Strother of Union Carbide Corp. applied for a patent on a process to produce organic compounds of silicon with Si-C bonds by reacting a hydridosilane and an alkene or alkyne in the presence of a catalyst metal of the platinum group. Finally, Sommer et al., submitted a paper on peroxide-catalyzed hydrosilylation to JACS on 17 December 1946. It was published in January 1947. The landmark patent interference § and priority § case law associated with the Mackenzie et al. and Wagner et al., applications is well known to patent attorneys. This presentation will retrace the origins of hydrosilylation and report events (1946-1960) in the history of the reaction that are most probably unknown to most authors and presenters of hydrosilylation investigations. George Wagner's contribution to the birth of this technology is also highlighted.

Disilane Cleavage with Selected Alkali and Alkaline Earth Metal Salts.

The industry-scale production of methylchloromonosilanes in the Müller-Rochow Direct Process is accompanied by the formation of a residue, the direct process residue (DPR), comprised of disilanes Men Si2 Cl6-n (n=1-6). Great research efforts have been devoted to the recycling of these disilanes into monosilanes to allow reintroduction into the siloxane production chain. In this work, disilane cleavage by using alkali and alkaline earth metal salts is reported. The reaction with metal hydrides, in particular lithium hydride (LiH), leads to efficient reduction of chlorine containing disilanes but also induces disproportionation into mono- and oligosilanes. Alkali and alkaline earth chlorides, formed in the course of the reduction, specifically induce disproportionation of highly chlorinated disilanes, whereas highly methylated disilanes (n>3) remain unreacted. Nearly quantitative DPR conversion into monosilanes was achieved by using concentrated HCl/ether solutions in the presence of lithium chloride.

Making Use of the Direct Process Residue: Synthesis of Bifunctional Monosilanes.

The industrial production of monosilanes Men SiCl4-n (n=1-3) through the Müller-Rochow Direct Process generates disilanes Men Si2 Cl6-n (n=2-6) as unwanted byproducts ("Direct Process Residue", DPR) by the thousands of tons annually, large quantities of which are usually disposed of by incineration. Herein we report a surprisingly facile and highly effective protocol for conversion of the DPR: hydrogenation with complex metal hydrides followed by Si-Si bond cleavage with HCl/ether solutions gives (mostly bifunctional) monosilanes in excellent yields. Competing side reactions are efficiently suppressed by the appropriate choice of reaction conditions.

Synthesis of Functional Monosilanes by Disilane Cleavage with Phosphonium Chlorides.

The Müller-Rochow direct process (DP) for the large-scale production of methylchlorosilanes Men SiCl4-n (n=1-3) generates a disilane residue (Men Si2 Cl6-n , n=1-6, DPR) in thousands of tons annually. This report is on methylchlorodisilane cleavage reactions with use of phosphonium chlorides as the cleavage catalysts and reaction partners to preferably obtain bifunctional monosilanes Mex SiHy Clz (x=2, y=z=1; x,y=1, z=2; x=z=1, y=2). Product formation is controlled by the reaction temperature, the amount of phosphonium chloride employed, the choice of substituents at the phosphorus atom, and optionally by the presence of hydrogen chloride, dissolved in ethers, in the reaction mixture. Replacement of chloro by hydrido substituents at the disilane backbone strongly increases the overall efficiency of disilane cleavage, which allows nearly quantitative silane monomer formation under comparably moderate conditions. This efficient workup of the DPR thus not only increases the economic value of the DP, but also minimizes environmental pollution.

Bis(imino)pyridine cobalt-catalyzed dehydrogenative silylation of alkenes: scope, mechanism, and origins of selective allylsilane formation.

The aryl-substituted bis(imino)pyridine cobalt methyl complex, ((Mes)PDI)CoCH3 ((Mes)PDI = 2,6-(2,4,6-Me3C6H2-N═CMe)2C5H3N), promotes the catalytic dehydrogenative silylation of linear α-olefins to selectively form the corresponding allylsilanes with commercially relevant tertiary silanes such as (Me3SiO)2MeSiH and (EtO)3SiH. Dehydrogenative silylation of internal olefins such as cis- and trans-4-octene also exclusively produces the allylsilane with the silicon located at the terminus of the hydrocarbon chain, resulting in a highly selective base-metal-catalyzed method for the remote functionalization of C-H bonds with retention of unsaturation. The cobalt-catalyzed reactions also enable inexpensive α-olefins to serve as functional equivalents of the more valuable α, ω-dienes and offer a unique method for the cross-linking of silicone fluids with well-defined carbon spacers. Stoichiometric experiments and deuterium labeling studies support activation of the cobalt alkyl precursor to form a putative cobalt silyl, which undergoes 2,1-insertion of the alkene followed by selective ß-hydrogen elimination from the carbon distal from the large tertiary silyl group and accounts for the observed selectivity for allylsilane formation.

Iron catalysts for selective anti-Markovnikov alkene hydrosilylation using tertiary silanes.

Alkene hydrosilylation, the addition of a silicon hydride (Si-H) across a carbon-carbon double bond, is one of the largest-scale industrial applications of homogeneous catalysis and is used in the commercial production of numerous consumer goods. For decades, precious metals, principally compounds of platinum and rhodium, have been used as catalysts for this reaction class. Despite their widespread application, limitations such as high and volatile catalyst costs and competing side reactions have persisted. Here, we report that well-characterized molecular iron coordination compounds promote the selective anti-Markovnikov addition of sterically hindered, tertiary silanes to alkenes under mild conditions. These Earth-abundant base-metal catalysts, coordinated by optimized bis(imino)pyridine ligands, show promise for industrial application.