Direct process

The Direct Process, also called the Direct Synthesis, Rochow Process, and Müller-Rochow Process is the most common technology for preparing organosilicon compounds on an industrial scale. It was first reported independently by Eugene G. Rochow and Richard Müller in the 1940s. The reaction involves a copper-catalyzed reaction of alkyl halides with silicon metal, which takes place in a fluidized bed reactor. Although theoretically possible with any type of alkyl halide, the best results in terms of selectivity and yield occur with methyl chloride. Typical conditions are 300 °C and 2-5 bar. These conditions allow for 90-98% conversion for silicon and 30-90% for chloromethane. Approximately 1.4 Mton of dimethyldichlorosilane (Me₂SiCl₂) is produced annually using this process.