Organic aqueous tunable solvents (OATS): a vehicle for coupling reactions and separations

In laboratory-based chemical synthesis, the choice of the solvent and the means of product purification are rarely determined by cost or environmental impact considerations. When a reaction is scaled up for industrial applications, however, these choices are critical: the separation of product from the solvent, starting materials, and byproduct usually constitutes 60-80% of the overall cost of a process. In response, researchers have developed solvents and solvent-handling methods to optimize both the reaction and the subsequent separation steps on the manufacturing scale. These include "switchable" solvents, which are designed so that their physical properties can be changed abruptly, as well as "tunable" solvents, wherein the solvent's properties change continuously through the application of an external stimulus. In this Account, we describe the organic aqueous tunable solvent (OATS) system, examining two instructive and successful areas of application of OATS as well as its clear potential for further refinement. OATS systems address the limitations of biphasic processes by optimizing reactions and separations simultaneously. The reaction is performed homogeneously in a miscible aqueous-organic solvent mixture, such as water-tetrahydrofuran (THF). The efficient product separation is conducted heterogeneously by the simple addition of modest pressures of CO(2) (50-60 bar) to the system. Under these conditions, the water-THF phase splits into two relatively immiscible phases: the organic THF phase contains the hydrophobic product, and the aqueous phase contains the hydrophilic catalyst. We take advantage of the unique properties of OATS to develop environmentally benign and cost-competitive processes relevant in industrial applications. Specifically, we describe the use of OATS for optimizing the reaction, separation, design, and recycling of (i) Rh-catalyzed hydroformylation of olefins such as 1-octene and (ii) enzyme-catalyzed hydrolysis of 2-phenylacetate. We discuss the advantages of these OATS systems over more traditional processes. We also consider future directions that can be taken with these proven systems as well as related innovations that have recently been reported, including the use of poly(ethylene glycol) (PEG) as a tunable adjunct in the solvent and the substitution of propane for CO(2) as the external stimulus. OATS systems in fact represent the ultimate goal for a sustainable process, because in an idealized setup there is only reactant coming in and product going out; in principle, there is no waste stream.