The present invention relates to an integrated process for the manufacture of methylchlorohydridomonosilanes in particular, from products of the Müller-Rochow Direct Process.

The present invention relates to an integrated process for the manufacture of methylchlorohydridomonosilanes in particular, from products of the Müller-Rochow Direct Process.

A halosilane compound: R.sup.1CH.sub.2CH.sub.2SiR.sup.5.sub.2X is prepared by hydrosilylation reaction of a vinyl compound: R.sup.1CH═CH.sub.2 with a halogenodiorganosilane compound having formula: HSiR.sup.5.sub.2X in the co-presence of an iridium catalyst, an internal olefin compound, and an allyl halide. The halosilane compound is prepared on an industrial scale with the advantages of low costs, high yields, and high selectivity, using a small amount of iridium catalyst.

A halosilane compound: R.sup.1CH.sub.2CH.sub.2SiR.sup.5.sub.2X is prepared by hydrosilylation reaction of a vinyl compound: R.sup.1CH═CH.sub.2 with a halogenodiorganosilane compound having formula: HSiR.sup.5.sub.2X in the co-presence of an iridium catalyst, an internal olefin compound, and an allyl halide. The halosilane compound is prepared on an industrial scale with the advantages of low costs, high yields, and high selectivity, using a small amount of iridium catalyst.

A method of preparing an organosilicon compound via selective silylation of ethylene is disclosed. The method comrises prises reacting via silylation (A) a hydridochlorosilane compound and (B) ethylene in the presence of (C) a catalyst, thereby preparing the organosilicon compound. The silylation may be selectively conducted as a dehydrogenative coupling to prepare the organosilicon ompound as a vinylchlorosilane compound, or as a hydrosilylation to prepare the organosilicon compound as an ethylchlorosilane compound. The catalyst (C) comprises a Ru(0) complex, and may be recycled for use in subsequent silylation reactions without purification. The organosilicon compound prepared according to the method is also disclosed.

A method of preparing an organosilicon compound via selective silylation of ethylene is disclosed. The method comrises prises reacting via silylation (A) a hydridochlorosilane compound and (B) ethylene in the presence of (C) a catalyst, thereby preparing the organosilicon compound. The silylation may be selectively conducted as a dehydrogenative coupling to prepare the organosilicon ompound as a vinylchlorosilane compound, or as a hydrosilylation to prepare the organosilicon compound as an ethylchlorosilane compound. The catalyst (C) comprises a Ru(0) complex, and may be recycled for use in subsequent silylation reactions without purification. The organosilicon compound prepared according to the method is also disclosed.

A process for dehydrogenating and methylating silanes. The process includes providing methyl chloride that is reacted with a silane selected from the group consisting of SiH.sub.4, H.sub.2SiMe.sub.2, H.sub.2SiMeCl, H.sub.3SiMe, H.sub.3SiCl and HSiMe.sub.2Cl, in the presence of at least one ammonium and/or phosphonium salt at a temperature in the range of 70-350° C.

A process for dehydrogenating and methylating silanes. The process includes providing methyl chloride that is reacted with a silane selected from the group consisting of SiH.sub.4, H.sub.2SiMe.sub.2, H.sub.2SiMeCl, H.sub.3SiMe, H.sub.3SiCl and HSiMe.sub.2Cl, in the presence of at least one ammonium and/or phosphonium salt at a temperature in the range of 70-350° C.

A method for producing an organohalosilane, the method comprising: reacting an organic compound comprising a halogen-substituted or unsubstituted aromatic compound with a hydridohalosilane mixture comprising at least two different hydridohalosilanes of formula (I) R.sub.nSiH.sub.mX.sub.4-m-n, where each R is independently C.sub.1-C.sub.14 hydrocarbyl or C.sub.1-C.sub.14 hologen-substituted hydrocarbyl, X is fluoro, chloro, bromo, or iodo, n is 0, 1, or 2, m is 1, 2, or 3 and m+n is 1, 2, or 3, in the presence of a catalyst comprising one or more of the elements Sc, Y, Ti, Zr, Hf, Nb, B, Al, Ga, In, C, Si, Ge, Sn, or Pb, at a temperature greater than 100° C., and at a pressure of at least 690 kPa, to produce a crude reaction product comprising the organohalosilane, provided that when the at least two different hydridohalosilane comprise a hydridohalosilane of formula (I) where n=0 and m=1 and a hydridohalosilane of formula (I) where n=0 and m=2, the catalyst is a heterogeneous catalyst comprising an oxide of one or more of the elements Sc, Y, Ti, Zr, Hf, B, Al, Ga, In, C, Si, Ge, Sn, or Pb.

A method for producing an organohalosilane, the method comprising: reacting an organic compound comprising a halogen-substituted or unsubstituted aromatic compound with a hydridohalosilane mixture comprising at least two different hydridohalosilanes of formula (I) R.sub.nSiH.sub.mX.sub.4-m-n, where each R is independently C.sub.1-C.sub.14 hydrocarbyl or C.sub.1-C.sub.14 hologen-substituted hydrocarbyl, X is fluoro, chloro, bromo, or iodo, n is 0, 1, or 2, m is 1, 2, or 3 and m+n is 1, 2, or 3, in the presence of a catalyst comprising one or more of the elements Sc, Y, Ti, Zr, Hf, Nb, B, Al, Ga, In, C, Si, Ge, Sn, or Pb, at a temperature greater than 100° C., and at a pressure of at least 690 kPa, to produce a crude reaction product comprising the organohalosilane, provided that when the at least two different hydridohalosilane comprise a hydridohalosilane of formula (I) where n=0 and m=1 and a hydridohalosilane of formula (I) where n=0 and m=2, the catalyst is a heterogeneous catalyst comprising an oxide of one or more of the elements Sc, Y, Ti, Zr, Hf, B, Al, Ga, In, C, Si, Ge, Sn, or Pb.