Studies to aid process development for the manufacture of neopentyl glycol from isobutyraldehyde: aldol condensation followed by hydrogenation

In our present research and investigations, attempts were made to study aldol condensation of isobutyraldehyde with formaldehyde, and the subsequent hydrogenation of resultant hydroxypivaldehyde (aldol product) to neopentyl glycol. The kinetics of aldol condensation were studied using a weak basic anion‐exchange resin catalyst, Indion‐860, after screening other heterogeneous catalysts. The initial rate data were analyzed using a power‐law model to aid process design. Further, subsequent hydrogenation of resultant hydroxypivaldehyde was studied using 5% Ru/Al2O3 catalyst. The selectivity towards neopentyl glycol was > 99%. The kinetic data were analyzed using a power‐law model. A dual‐site Langmuir–Hinshelwood‐type model suggesting molecular adsorption (nondissociative) of hydrogen and surface reaction as the rate‐controlling step provided the best fit of the experimental data. The catalyst could be recycled with good selectivity.