General Electric Company

David Cheney DeMoulpied

Larry Neil Lewis

Matthew David Butts

John Matthew Bablin

Michael Lee White

William Jessup Ward

Bang M Kim

Sunita Singh Baghel

Luisito A Tolentino

William Lee Gately

Ray Walton Shade

Martha Gardner

Jeffrey David Hallen

Mark Kromer Barr

Edward Francis Kennedy

Jan-Willem Goedmakers

Dialkyldihalosilane formation during direct method alkylhalosilane production is promoted by effecting reaction between alkyl halide and powdered silicon in the presence of a catalyst comprising copper, zinc, and aluminum and further comprising an amount of phosphorus and tin wherein the amount of phosphorus and tin substantially enhances the selectivity of dialkyldihalosilane formation in comparison to the selectivity of dialkyldihalosilane formation in the presence of the catalyst comprising copper, zinc, aluminum and tin without phosphorus.

Method for promoting dialkyldihalosilane formation during direct method alkylhalosilane production

A method is described for enhancing the formation of alkylhalosilane during the direct method reaction between powdered silicon and a catalyst comprising copper, zinc, tin, and phosphorus. An increase in the value of the Cu/Zn weight ratio has been found to promote the performance of the phosphorus-containing catalyst as shown by in an increase in the weight percent dimethyldichlorosilane in methylchlorosilane crude.

The instant invention provides a process for reducing chloride content from by-products generated during production of methylchlorosilanes, comprising, (a) hydrolyzing the by-products by combining the by-products with an aqueous medium, the aqueous medium optionally comprising a surfactant, at a pH of at least about 7 and at a temperature above about 0.degree. C. to yield a first phase comprising essentially solids and a second phase comprising an aqueous phase; (b) separating the first and second phase; and (c) oxidizing the solids from the first phase at a temperature of at least about 300.degree. C. for up to about 24 hours to yield a residue comprising less than about 1% by weight of chloride. The solids from the first phase may alternatively be reduced under a hydrogen flow, at a temperature of at least about 500.degree. C. for up to about 24 hours.

Process for reducing the residual chloride concentration in copper

The instant invention relates to a novel process for the hydrolysis of the by-products produced during the manufacture of methyldichlorosilanes comprising combining the by-products with an aqueous medium, optionally comprising a surfactant, at a pH range of at least about 7 and at a temperature of above about 0.degree. C. to produce a solid material in which copper and other metals are retained in a solid phase thereby resulting in a product with a high copper content.

Process for treating methylchlorosilanes by-products

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Athens, NY, United States of America

David Cheney DeMoulpied