Ketene is produced on a commercial scale by thermal dehydration of acetic acid. Substituted ketenes can be prepared from acyl chlorides by an elimination reaction in which HCl is lost:
In this reaction, a base, usually triethylamine, removes the acidic proton alpha to the carbonyl group, inducing the formation of the carbon-carbon double bond and the loss of a chloride ion:
Ketenes can also be formed from α-diazoketones by the Wolff rearrangement.
Another way to generate ketenes is through flash vacuum thermolysis (FVT) with 2-pyridylamines. Plüg and Wentrup developed a method in 1997 that improved on FVT reactions to produce ketenes with a stable FVT that is moisture insensitive, using mild conditions (480 °C). The N-pyridylamines are prepared via a condensation with R-malonates with N-amino(pyridene) and DCC as the solvent.
A more robust method for preparing ketenes is the carbonylation of metal-carbenes, and in situ reaction of the thus produced highly reactive ketenes with suitable reagents such as imines, amines, or alcohols. This method is an efficient one‐pot tandem protocol of the carbonylation of α‐diazocarbonyl compounds and a variety of N‐tosylhydrazones catalysed by Co(II)–porphyrin metalloradicals leading to the formation of ketenes, which subsequently react with a variety of nucleophiles and imines to form esters, amides and β‐lactams. This system has a broad substrate scope and can be applied to various combinations of carbene precursors, nucleophiles and imines.