Novel mesoporous solid superacidic catalysts: activity and selectivity in the synthesis of thymol by isopropylation of m-cresol with 2-propanol over UDCaT-4, -5, and -6.

The alkylation of m-cresol with isopropyl alcohol in the presence of novel superacidic catalysts named as UDCaT-4, UDCaT-5, and UDCaT-6 was investigated. The catalysts are modified versions of zirconia showing high catalytic activity, stability, and reusability in the presence of water as compared to conventional sulfated zirconia. The objective of the present investigation was to explore the potential of these catalysts in this alkylation of m-cresol with isopropyl alcohol to thymol, which has widescale applications. The reactions were conducted in liquid phase in the temperature range of 433-473 K. Both, O- and C-alkylated products were obtained at lower temperatures, while at higher temperatures, thymol was the main product of the reaction. The catalytic activity increases in the order UDCaT-5 > UDCaT-6 >UDCaT-4 > sulfated zirconia. Thymol could be efficiently obtained with selectivity reaching up to 79% at an isopropyl alcohol conversion of 92% with UDCaT-5. This process can be a replacement for the existing process based on zeolites where high temperature and pressure are required. Synergistic effects of very high sulfur content present (9% S) and preservation of the tetragonal phase in UDCaT-5, in comparison with sulfated zirconia (4% S), were responsible for higher catalytic activity. A systematic investigation of the effects of various operating parameters was accomplished, and a mathematical model is developed to describe the reaction pathway and validated with experimental results. The reaction was carried out without using solvent, and the process subscribes to the principles of green chemistry.