WO1994006739A1 - Procede d'hydroformylation d'olefines - Google Patents
Procede d'hydroformylation d'olefines Download PDFInfo
- Publication number
- WO1994006739A1 WO1994006739A1 PCT/EP1993/002512 EP9302512W WO9406739A1 WO 1994006739 A1 WO1994006739 A1 WO 1994006739A1 EP 9302512 W EP9302512 W EP 9302512W WO 9406739 A1 WO9406739 A1 WO 9406739A1
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- WO
- WIPO (PCT)
- Prior art keywords
- alcohol
- hof
- fraction
- stage
- hydrogenation
- Prior art date
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- 238000007037 hydroformylation reaction Methods 0.000 title claims abstract description 30
- 150000001336 alkenes Chemical class 0.000 title claims abstract description 26
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims abstract description 104
- 239000000203 mixture Substances 0.000 claims abstract description 71
- 238000000034 method Methods 0.000 claims abstract description 61
- 238000005984 hydrogenation reaction Methods 0.000 claims abstract description 45
- 238000004821 distillation Methods 0.000 claims abstract description 30
- 238000009835 boiling Methods 0.000 claims abstract description 17
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 claims abstract description 17
- 238000004230 steam cracking Methods 0.000 claims abstract description 11
- 230000003197 catalytic effect Effects 0.000 claims abstract description 8
- 238000009903 catalytic hydrogenation reaction Methods 0.000 claims abstract description 7
- 125000002485 formyl group Chemical class [H]C(*)=O 0.000 claims description 47
- 239000003054 catalyst Substances 0.000 claims description 35
- 238000004064 recycling Methods 0.000 claims description 14
- 238000005336 cracking Methods 0.000 claims description 13
- 150000002148 esters Chemical class 0.000 claims description 13
- 238000004519 manufacturing process Methods 0.000 claims description 11
- 229910052799 carbon Inorganic materials 0.000 claims description 9
- 229910044991 metal oxide Inorganic materials 0.000 claims description 9
- 239000004014 plasticizer Substances 0.000 claims description 9
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 7
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 6
- 230000015572 biosynthetic process Effects 0.000 claims description 6
- 239000010949 copper Substances 0.000 claims description 6
- 238000000926 separation method Methods 0.000 claims description 6
- 238000002156 mixing Methods 0.000 claims description 5
- 238000003786 synthesis reaction Methods 0.000 claims description 5
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 4
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 4
- 150000004706 metal oxides Chemical class 0.000 claims description 4
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 3
- 229910052802 copper Inorganic materials 0.000 claims description 3
- 239000000047 product Substances 0.000 description 67
- 239000002253 acid Substances 0.000 description 25
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 description 18
- 125000002915 carbonyl group Chemical group [*:2]C([*:1])=O 0.000 description 17
- 150000001298 alcohols Chemical class 0.000 description 16
- 150000001241 acetals Chemical class 0.000 description 15
- 238000006243 chemical reaction Methods 0.000 description 11
- 239000000463 material Substances 0.000 description 10
- 238000006460 hydrolysis reaction Methods 0.000 description 8
- POAOYUHQDCAZBD-UHFFFAOYSA-N 2-butoxyethanol Chemical compound CCCCOCCO POAOYUHQDCAZBD-UHFFFAOYSA-N 0.000 description 7
- DHKHKXVYLBGOIT-UHFFFAOYSA-N acetaldehyde Diethyl Acetal Natural products CCOC(C)OCC DHKHKXVYLBGOIT-UHFFFAOYSA-N 0.000 description 7
- 230000007062 hydrolysis Effects 0.000 description 7
- 150000002170 ethers Chemical class 0.000 description 6
- 239000007789 gas Substances 0.000 description 6
- 238000010992 reflux Methods 0.000 description 6
- 239000006227 byproduct Substances 0.000 description 5
- 150000001875 compounds Chemical class 0.000 description 5
- ZZUFCTLCJUWOSV-UHFFFAOYSA-N furosemide Chemical compound C1=C(Cl)C(S(=O)(=O)N)=CC(C(O)=O)=C1NCC1=CC=CO1 ZZUFCTLCJUWOSV-UHFFFAOYSA-N 0.000 description 5
- 229930195733 hydrocarbon Natural products 0.000 description 5
- 150000002430 hydrocarbons Chemical class 0.000 description 5
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 4
- 229910017052 cobalt Inorganic materials 0.000 description 4
- 239000010941 cobalt Substances 0.000 description 4
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 4
- 239000000539 dimer Substances 0.000 description 4
- -1 poly(vinyl chloride) Polymers 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 3
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 3
- 229910052739 hydrogen Inorganic materials 0.000 description 3
- 239000001257 hydrogen Substances 0.000 description 3
- 239000013638 trimer Substances 0.000 description 3
- 239000004215 Carbon black (E152) Substances 0.000 description 2
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 150000001721 carbon Chemical group 0.000 description 2
- 229910002091 carbon monoxide Inorganic materials 0.000 description 2
- 239000011651 chromium Substances 0.000 description 2
- JGDFBJMWFLXCLJ-UHFFFAOYSA-N copper chromite Chemical compound [Cu]=O.[Cu]=O.O=[Cr]O[Cr]=O JGDFBJMWFLXCLJ-UHFFFAOYSA-N 0.000 description 2
- 238000006170 formylation reaction Methods 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 229910052759 nickel Inorganic materials 0.000 description 2
- 239000012074 organic phase Substances 0.000 description 2
- 239000012188 paraffin wax Substances 0.000 description 2
- 229930195734 saturated hydrocarbon Natural products 0.000 description 2
- 239000000377 silicon dioxide Substances 0.000 description 2
- 241000331231 Amorphocerini gen. n. 1 DAD-2008 Species 0.000 description 1
- 241000905957 Channa melasoma Species 0.000 description 1
- 239000004435 Oxo alcohol Substances 0.000 description 1
- WGLPBDUCMAPZCE-UHFFFAOYSA-N Trioxochromium Chemical compound O=[Cr](=O)=O WGLPBDUCMAPZCE-UHFFFAOYSA-N 0.000 description 1
- 150000001722 carbon compounds Chemical class 0.000 description 1
- 230000006315 carbonylation Effects 0.000 description 1
- 238000005810 carbonylation reaction Methods 0.000 description 1
- 239000012018 catalyst precursor Substances 0.000 description 1
- 238000004523 catalytic cracking Methods 0.000 description 1
- 238000006555 catalytic reaction Methods 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 229910000423 chromium oxide Inorganic materials 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 230000005494 condensation Effects 0.000 description 1
- 238000006482 condensation reaction Methods 0.000 description 1
- 238000010924 continuous production Methods 0.000 description 1
- 229910000431 copper oxide Inorganic materials 0.000 description 1
- 239000012043 crude product Substances 0.000 description 1
- MWKFXSUHUHTGQN-UHFFFAOYSA-N decan-1-ol Chemical compound CCCCCCCCCCO MWKFXSUHUHTGQN-UHFFFAOYSA-N 0.000 description 1
- 238000006297 dehydration reaction Methods 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 230000001627 detrimental effect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- MQIKJSYMMJWAMP-UHFFFAOYSA-N dicobalt octacarbonyl Chemical group [Co+2].[Co+2].[O+]#[C-].[O+]#[C-].[O+]#[C-].[O+]#[C-].[O+]#[C-].[O+]#[C-].[O+]#[C-].[O+]#[C-] MQIKJSYMMJWAMP-UHFFFAOYSA-N 0.000 description 1
- 238000002845 discoloration Methods 0.000 description 1
- 238000010931 ester hydrolysis Methods 0.000 description 1
- 230000032050 esterification Effects 0.000 description 1
- 238000005886 esterification reaction Methods 0.000 description 1
- 150000004675 formic acid derivatives Chemical class 0.000 description 1
- 230000022244 formylation Effects 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 150000002576 ketones Chemical class 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 239000000178 monomer Substances 0.000 description 1
- 230000003472 neutralizing effect Effects 0.000 description 1
- 150000002894 organic compounds Chemical class 0.000 description 1
- 239000011368 organic material Substances 0.000 description 1
- 239000012071 phase Substances 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 230000000379 polymerizing effect Effects 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- 239000004800 polyvinyl chloride Substances 0.000 description 1
- 239000002243 precursor Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 150000003333 secondary alcohols Chemical class 0.000 description 1
- 238000010517 secondary reaction Methods 0.000 description 1
- 238000007086 side reaction Methods 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 241000894007 species Species 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 239000004408 titanium dioxide Substances 0.000 description 1
- JSPLKZUTYZBBKA-UHFFFAOYSA-N trioxidane Chemical compound OOO JSPLKZUTYZBBKA-UHFFFAOYSA-N 0.000 description 1
- 238000005406 washing Methods 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C45/00—Preparation of compounds having >C = O groups bound only to carbon or hydrogen atoms; Preparation of chelates of such compounds
- C07C45/49—Preparation of compounds having >C = O groups bound only to carbon or hydrogen atoms; Preparation of chelates of such compounds by reaction with carbon monoxide
- C07C45/50—Preparation of compounds having >C = O groups bound only to carbon or hydrogen atoms; Preparation of chelates of such compounds by reaction with carbon monoxide by oxo-reactions
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C29/00—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring
- C07C29/132—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of an oxygen containing functional group
- C07C29/136—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of an oxygen containing functional group of >C=O containing groups, e.g. —COOH
- C07C29/14—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of an oxygen containing functional group of >C=O containing groups, e.g. —COOH of a —CHO group
- C07C29/141—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of an oxygen containing functional group of >C=O containing groups, e.g. —COOH of a —CHO group with hydrogen or hydrogen-containing gases
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C29/00—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring
- C07C29/16—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by oxo-reaction combined with reduction
Definitions
- This invention relates to the hydroformylation of olefins to produce, inter alia, alcohols and more especially alcohols suitable for use in the manufacture of esters for use as plasticizers, for example, for poly(vinyl chloride) .
- Alcohols may conveniently be made by the oxo process, which has as a major step hydroformylation.
- Hydroformylation in general terms is a process for the preparation of oxygenated organic compounds by the reaction of carbon monoxide and hydrogen (synthesis gas) with carbon compounds containing olefinic unsaturation.
- the oxo reaction is performed under hydroformylation conditions in the presence of a carbonylation catalyst or catalyst precursor such, for example, as dicobaltoctacar- bonyl, and results in the formation of a compound, e.g., an aldehyde, which has one more carbon atom in its molecular structure than the olefin feedstock.
- a carbonylation catalyst or catalyst precursor such, for example, as dicobaltoctacar- bonyl
- the feedstock for a hydroformylation process is a commercial C 6 to C 12 olefin fraction and the desired end product is the corresponding C 7 to C 13 saturated alcohol or derived mixed product produced by hydrogenation of the aldehyde oxonation product.
- the hydroformylation reaction inevitably yields a range of products because of the numerous secondary reactions which take place.
- the main products of the hydroformyla ⁇ tion unit are aldehydes and alcohols, with side reactions in the hydroformylation, catalyst removal and hydrogena ⁇ tion stages of the process usually producing some 5 to 20 wt% of high boiling materials such as aldols, esters, ethers and acetals.
- high boiling materials which represent a serious yield loss to the alcohol producer, are collectively termed the Heavy Oxo Fraction (HOF) , and are formed in large part by condensation, esterification and dehydration reactions.
- the feedstock as described above is fed together with synthesis gas into an oxonation unit where catalytic hydroformylation takes place, using e.g., hydrocobalt-carbonyl as the active catalyst species.
- the oxonation unit product passes to a unit for removing catalyst, and then to a hydrogenation unit where it is hydrogenated to form the desired alcohol.
- the product mixture at this stage comprising the desired alcohol, the high boiling HOF and a low boiling fraction termed the Light Oxo Fraction (LOF) , is then passed to a distillation unit where LOF, HOF and desired alcohol product are physically separated.
- LPF Light Oxo Fraction
- the LOF taken off overhead is a low value product, typically containing unreacted olefin feed and paraffins.
- the HOF usually contains dimers, for example, esters, aldols and ether-alcohols (e.g. C2 0 compounds for C ⁇ Q alcohol production) and trimers, for example, acetals (e.g. C 30 compounds for C ⁇ Q alcohol production) , and heavier; although substantially alcohol- free (apart from the heavy aldols and ether-alcohols) , it may contain a minor amount of alcohol which has not been removed in the distillation stage.
- HOF is conventionally purged from the system at low value. It is desirable, therefore, to develop a more profitable use of HOF within the oxo process and which serves to increase the yield of more useful products of the process.
- U.S. 2,595,096 seeks to improve the alcohol yield of the oxo process by treating the bottoms obtained following oxonation, hydrogenation and removal of, first, unreacted hydrocarbons and then alcohols from the hydrogenated product stream.
- Such bottoms are said to contain polymerized aldehydes and ketones, principally acetals, high molecular weight ethers and secondary alcohols and polymerized hydrocarbons. It is the acetal content of these bottoms which, in this patent, is con ⁇ sidered to be useful.
- the acetal content is hydrolysed with dilute mineral acid, with water (steam) or by catalytic means, the product then being steam distilled.
- the quantities of alcohols and aldehydes collected may themselves be recycled to the hydrogenation stage.
- the product from the hydrolyser may be vacuum distilled and then hydrogenated or treated with aldehyde polymerizing agents. Further distillation gives the desired alcohol product.
- the HOF (Heavy Oxo Fraction) separated out by the distillation is subjected to catalytic steam cracking, at a temperature of from 260 to 380°C, using as catalyst an active metal oxide or pseudo-metal oxide to form a residue and a cracked mixture which are separated by distillation.
- the cracked mixture comprising a major proportion of alcohol and aldehyde, and a minor propor ⁇ tion of olefin and saturated hydrocarbon, is then recycled to the hydroformylation or hydrogenation stage of the oxo process, leading to an improved overall yield of alcohol.
- the process takes HOF as the starting material and produces certain ether/ether-alcohol rich compositions having useful properties, especially in solvent or surfactant precursor applications.
- the process involves taking the product of a hydro ⁇ formylation reaction, hydrogenating it and distilling the product to separate out a mixture of ether, ether-alcohol and acetal components (HOF) from lighter ends, then catalytically hydrogenating the mixture, at a temperature of 200 to 250°C, to form an alcohol-enriched product.
- HAF ether-alcohol and acetal components
- the ether/ether-alcohol rich fraction may then be further separated by reflux distillation into an ether- rich fraction and an ether-alcohol rich fraction.
- An optional additional step in the process is to take the distilled ether/ether-alcohol and acetal mixture (HOF) and to subject it to catalytic steam cracking at a temperature from 260°C to 380°C using as a catalyst an active metal oxide or pseudo-metal oxide to form an ether enriched heavy product mixture and lighter materials.
- the heavy product mixture then goes on to be hydrogenated and distilled. It is said in EP-A-185,477 to be possible to combine the processes of EP-A-185,477 and EP-A-183,545 to give both improved alcohol yield and ether/ether-alcohol byproducts having value - see page 18 of EP-A-185,477.
- the alcohols produced by the oxo process are often used in the manufacture of esters for use as, amongst other things, plasticizers.
- the aldehyde and acid content of alcohols used for plasticizer manufacture is required to be very low as high or moderate levels of such impurities can lead to discoloration, tackiness, and reduced UV stability when the plasticizer is incorporated in a polymer.
- the present invention provides a process including a recycling loop for producing an alcohol from an olefinic feedstock which comprises (a) hydroformylating the feedstock with synthesis gas in the presence of a hydroformylation catalyst to form a product mixture, containing aldehyde, alcohol, unreacted feed and secondary products, and removing catalyst therefrom;
- the hydroformylation conditions employed to produce the crude product mixture may be those which are well known in the art.
- the hydroformylation reaction (a) may be carried out at a temperature of from 125 to 175°C and a pressure of 15 to 30 MPa.
- the hydroformylation catalyst used may be, for example, cobalt in desired active form, preferably in a concentra ⁇ tion of from 0.05 to 3 wt% based on the olefinic feed.
- the syn gas used has a H 2 :CO volume ratio in the range 0.9:1 to 1.5:1.
- the oxo-aldehyde hydrogenation (b) is typically carried out at a temperature of 140 to 190°C and under a pressure of 5 MPa.
- a copper chrome catalyst is preferred.
- the HOF resulting from stage (c) of the invention typically has a composition comprising 0 to 35, more typically 25 to 35, wt.% alcohols, 15 to 25 wt.% ethers, 30 to 50 wt.% ether-alcohols, 2 to 10 wt.% esters, and 5 to 10 wt% acetals, with possibly extremely minor amount of other materials e.g., up to 2 wt.% heavies, depending on feedstock and selected process conditions.
- such HOF is typically the material boiling in the range 200 to 450°C at atmospheric pressure.
- the temperature at which the HOF steam cracking step (d) is performed is most preferably in the relatively high range of 290 to 360°C, and preferably at pressures of from 100 to 1000 kPa, more preferably 100 to 300 kPa. It is preferred that the hydrolysis of the HOF is performed with the weight ratio of steam and HOF in the range 0.1:1 to 2:1, more preferably 0.2:1 to 1.2:1. In general, the higher the steam ratio, the better is the selectivity to aldehyde/alcohol rich cracked HOF mixture, but for economic reasons the optimum range has been found to be from 0.15:1 to 0.5:1.
- the catalysts which may be employed in the cracking stage (d) in accordance with the invention are those which promote hydrolysis of the components of the HOF, which generally contains alcohols (assuming not all have been removed in the separation stage), ethers, esters, ether-alcohols and acetals.
- the catalyst is selected such that the hydrolysis reaction takes place under the rather severe conditions defined to yield a product mixture (the cracked HOF mixture) which is relatively enriched in higher alcohols and aldehydes.
- the catalysed reactions performed under the specified conditions may be for example acetal hydrolysis, ester hydrolysis, or ether hydrolysis.
- metal or pseudo-metal oxides in the active state such as silica, alumina or titanium dioxide, or mixed silica/alumina. It is particularly preferred to employ alumina as the hydrolysis catalyst.
- alumina as the hydrolysis catalyst.
- Such catalysts in the temperature range specified, at least partially convert the HOF components to alcohols and aldehydes.
- an active metal or pseudo-metal oxide hydrolysis catalyst in accordance with the invention particularly alumina, at 260 to 380°C, yields a cracked HOF mixture which is useful to the oxo-process operator for improving alcohol yield since it contains high . proportions of aldehyde/alcohol.
- steam cracking of HOF using an alumina catalyst at 260 to 380°C yields HOF residue and a cracked HOF mixture which may comprise up to 90% alcohol/aldehyde and some 10% olefinic hydrocarbon based on the total alcohol/aldehyde/olefin content of the mixture.
- increasing steam cracking temperature has been found to give increased overall conversion of the HOF but reduced selectivity to the alcohol/aldehyde component.
- a reduced selectivity to alcohol/aldehyde results, on recycle of the material to the hydrogenation stage (b) of the process, in an increased proportion of LOF.
- the temperature at which stage (d) is carried out is important. Too low a temperature will not give conver ⁇ sions which make the capital expenditure associated with HOF cracking worthwhile, whereas too high a temperature will increase the proportion of olefin/paraffin and hence increase LOF, if recycle is to the hydrogenation stage, and this too will be detrimental to the economics of the process.
- the steam cracking of the HOF in accordance with the invention yields, as well as the cracked HOF mixture, a HOF residue which is typically oxygenated dimers and trimers (C 2 o to C 30 + materials for a C 10 alcohol) .
- Both the cracked HOF mixture and the HOF residue may be passed to a hydrogenation unit after first passing through a water removal stage.
- the conditions for the second hydrogenation stage (e) are much more severe than those of the first hydrogenation stage (b) .
- the hydrogenation is preferably carried out at a temperature in the range 200 to 240°C and at a pressure in the range 4.5 to 6.5 MPa. Any suitable hydrogenation catalyst may be employed, but the preferred catalysts are the copper chrome (also termed Cu/Cr or copper/chromium oxide or copper-chromite) catalyst or supported nickel catalysts.
- the product mixture from the hydrogenator preferably has an acid number less than 1.0 mg KOH/g and a carbonyl number less than 1.0 mg KOH/g and will typically comprise 0 to 5 wt% olefins/paraffins, 55 to 75 wt% alcohols/aldehydes, 15 to 25 wt% ethers, 5 to 15 wt% ether-alcohols, 0 to 5 wt% esters and 0 to 5 wt% acetals.
- the product mixture may then be directly recycled back to the hydroformylation, hydrogenation or distilla ⁇ tion stages of the oxo process.
- the cracked hydrogenated product mixture is passed through a distillation stage where it is separated into a light fraction and a residue, only the light fraction, typically comprising up to 8 wt% LOF, 75 to 95% wt% alcohol and up to 20 wt% ether, being recycled.
- the acid number of the light fraction be less than 0.5 mg KOH/g and the carbonyl number less than 0.2 mg KOH/g.
- the light fraction typically boils in the temperature range 85 to 220°C (for C 6 to C 12 olefin feedstock) , however, the boiling range is of course very dependent on the carbon number of the alcohol, on the distillation conditions and on the composition of the mixture.
- the residue may be used in further processes to produce valuable by-products.
- the residue typically boils at temperatures above 200 to 300°C at atmospheric pressure although, it will be understood, the attribution of a specific boiling temperature to a complex mixture of components is not straightforward, depending amongst other things on whether distillation is on a continuous or a batch basis, the length of the distillation column and the point or phase in the column at which temperature is measured.
- the proportions of the components will depend on the carbon numbers of the feedstock and the degree of separation required by the operator.
- the boundary between the light fraction and the residue depends to an extent on the wishes of the process operator and the economics of the particular oxo-process. It is generally the case that the residue comprises substantially the dimer and trimer and even heavier components of the organic phase.
- the undistilled cracked product mixture or the light fraction from the distillation is recycled to the hydrogenation stage of the process, although it is of course possible to introduce the mixture at the hydro ⁇ formylation stage so as to provide some upgrade of its admittedly very low olefin content to aldehyde and ultimately alcohol.
- Economic considerations would usually require recycle to the hydrogenation stage, since recycle to the hydroformylation stage might result, by virtue of the major proportion of alcohol/aldehyde in the mixture, in an increased production of undesirable by ⁇ products and also an unnecessary increase in operating costs.
- recycle to the hydroformylation stage may be elected if for some reason the cracking conditions have resulted in a cracked HOF mixture containing a proportion of olefin/paraffin approaching that of alcohol/aldehyde.
- the alcohol passes through to the distillation stage (c) unconverted, any remaining aldehyde is con ⁇ verted to alcohol, and any remaining olefinic hydrocarbon is either reduced or passes through unchanged.
- recycle is to the hydroformylation stage (a) the alcohol and any remaining aldehyde may undergo reactions to generate undesirable by-products, or may pass through unconverted to the hydrogenation stage (b) . Olefinic hydrocarbons are oxonated and upgraded to the higher aldehyde/alcohol, which is then passed to the hydrogena ⁇ tion stage (b) .
- the mixture which is recycled after hydrogenation (e) is one which is substantially the monomer components of the cracked HOF organic phase, that is those compounds containing one more carbon atom in their molecules than the carbon number of the feedstock of the overall process.
- the cracked HOF mixture will contain no more than about 20 wt.% of dimers and above, whilst the residue preferably contains less than 10 wt.% of monomeric components.
- the mixture as recycled should contain alcohol/aldehyde in a proportion which corresponds to greater than about 30 or 40 wt.% of the organic material obtained following cracking of the HOF. It is particularly preferred that the amount should correspond to greater than about 75 wt.% since this helps to maximize the overall process yield of higher alcohol.
- the recycled light fraction advantageously has an acid number of less than 0.5 mg KOH/g and a carbonyl number of less than 0.2 mg KOH/g.
- the cracked and hydrogenated material produced in the process of the present invention has a sufficiently low acid content that recycling of the material does not lead to a build up of acid in the system, which as indicated above may be a major cause of the poor quality alcohol products in other systems.
- the alcohol product of the process of the present invention desirably has an acid number less than 0.05, and preferably less than 0.025, mg KOH/g.
- a further advantage of the process of the present invention is a reduction in the carbonyl number of the alcohol product.
- the severe hydrogenation conditions convert the vast majority, normally 99% (but at least 95%) of any aldehydes into alcohol before recycling. Any remaining aldehyde is normally converted as it passes through the hydrogenation (b) and/or hydrofinishing stage.
- the process according to the invention is par ⁇ ticularly suitable for use with branched olefin feedstocks, preferably those with carbon numbers Cg to C ⁇ 2 , more preferably Cg to C 10 , and results in improved yields of branched alcohol, and also in by-products having higher value.
- the HOF residue which is the product of the process has been found to be a surprisingly useful material.
- the HOF residue contains substantially dimeric, trimeric and heavier compounds based on the original feedstock, and preferably contains a minor amount e.g. less than 10 wt.%, of monomeric compounds derived from the feedstock.
- the invention further provides the alcohol product of a process according to the invention which has a carbonyl number of less than 0.20 mg KOH/g and preferably less than 0.10 mg KOH/g.
- a further aspect of the present invention is the use in the manufacture of an alcohol from an olefin by a process comprising oxonation of the olefin to form an aldehyde and hydrogenation of the aldehyde to form the desired alcohol, separating a fraction comprising desired alcohol from a higher boiling heavy oxo fraction (HOF) and cracking the HOF, of the steps comprising catalytically hydrogenating the cracked HOF and recycling at least a portion of the hydrogenated cracked HOF to a stage in the process prior to the separation of the desired alcohol from the HOF or provided that the heavy fraction has been removed therefrom mixing it with the separated desired alcohol.
- HOF oxoxo fraction
- the substantially catalyst-free oxonation product (1) is passed through a hydrogenation stage (Hydro) to give a hydrogenated product (2) .
- the product (2) is distilled in a first distillation column (Tl) and the Light Oxo Fraction (3) is separated out.
- the remaining fraction is passed to a second distillation column (T2) where the desired alcohol-rich fraction (4) is separated out, leaving a Heavy Oxo Fraction (HOF) (5) .
- the alcohol-rich fraction (4) is passed through a hydro- finishing stage to give the desired alcohol product (10) .
- the HOF (5) undergoes catalytic cracking in the cracking unit (HCU) to give a cracked product mixture (6) which is passed to the catalytic hydrogenation unit (HHU) .
- the hydrogenated cracked product mixture (7) passes to a distillation unit (T3) where it is separated into a light fraction (9) , which is recycled to the first hydrogenation step (Hydro) , and a residue (8) which may be used to produce high-value by-products.
- the hydrogenated cracked product mixture (7) may be recycled directly (via the route shown by a dotted line) to the first hydrogenation step (Hydro) without passing through the distillation step (T3) .
- Hydroformylation was performed using a feed compris ⁇ ing syn gas containing hydrogen and carbon monoxide in a molar ratio of 1.16:1 and (ii) a commercially available stream of branched nonenes including also about 2 wt% octenes and about 8 wt% decenes.
- the olefin feed was delivered at a rate of 1 tonne/hr, and the syn gas at a rate of 0.27 tonnes/hr (413 Nm 3 /hr) giving a space velocity of 1.9 vol/vol/hr.
- the reaction was carried out at a pressure of 30 MPa and a temperature of 175°C, using a cobalt catalyst at 0.3 wt% based on the feed.
- the crude oxo product containing higher aldehyde resulting from stage (1) was decobalted to less than 10 ppm cobalt in conventional manner by neutralizing the cobalt hydrocarbonyl with sodium hydroxide and washing with water.
- stage (2) The product of stage (2) was fed to a conventional hydrogenation train where, using Cu/Cr or Ni-containing catalysts, a hydrogen pressure of 5 MPa and a tempera ⁇ ture of 140 to 190°C the product containing higher aldehydes, formates and acetals was converted to a hydrogenation product mixture containing the desired higher alcohol.
- stage (3) was then distilled under vacuum to produce three fractions, a light oxo fraction (LOF) , a heavy oxo fraction (HOF) and a desired alcohol fraction (AF) as shown below:
- LPF light oxo fraction
- HAF heavy oxo fraction
- AF desired alcohol fraction
- the yield of desired alcohol (chiefly C 10 , with minor amounts of C 9 and C 1:L ) was 102 g per 100 g of feed olefin.
- the alcohol fraction was then passed to a hydrofinishing process.
- the HOF was analysed and was shown to comprise:
- the mixture was characterized by having a carbonyl number of 22.28 and an acid number of 0.91 (both expressed in mg KOH/g) .
- the HOF product separated in stage (4) was intro ⁇ quizzed in admixture with half its mass of steam into a steam cracking reactor.
- the reactor was packed with an active alumina catalyst, RHONE-POULENC A2-5, and operated at 350°C, and a pressure of 300 kPa.
- the flow of HOF through the reactor was 0.120 tonnes/hr, corresponding to a space velocity of 0.33 v/v/hr expressed as volume of HOF per volume of catalyst per hour. After cracking, any water present in the mixture was removed and recycled.
- the alcohol-enriched mixture was found to comprise 1.8 wt% olefins/paraffins, 67.5 wt% alcohol/aldehyde and 30.7 wt% heavies/HOF residue.
- the mixture had a carbonyl number of 66.00 mg KOH/g and an acid number of 5.40 mg KOH/g.
- the cracked product from (5) was passed through a catalytic hydrogenation reactor at a rate of 0.120 tonnes/hour corresponding to a space velocity of 1.5 v/v/hr.
- the pressure employed was 5.0 MPa and the hydrogenation was carried out over a copper-chromite catalyst (Girdler G22RS) at 230°C.
- the alcohol-enriched product mixture was found to have the following characteristics: 3.6 wt % olefins/paraffins
- the above hydrogenated cracked product mixture was then passed to a vacuum reflux distillation at a pressure of 2 kPa and a reflux ratio of 2.
- stage (7) The alcohol-rich light fraction of stage (7) was recycled to the hydrogenation stage (3). A flow of 0.081 tonnes/hr of light fraction was incorporated into a stream of 1.239 tonnes/hr of decobalted oxo product from stage (2) .
- the alcohol product from stage (4) was analysed and was found to have a carbonyl number of 0.21 and an acid number of 0.01.
- the acid number of 0.01 falls well below the maximum acid number, 0.05, allowed by plasticizer manufacturers and is characteristic of a high quality alcohol product.
- the remaining fraction, the HOF residue, comprised: 0.1 wt % olefins/paraffins
- the alcohol product from the distillation step (4) comprised 0.2 wt% olefins and paraffins and 99.8 wt% higher alcohol.
- the carbonyl number of the product was 0.44 and the acid number was 0.04. After hydrofinishing the carbonyl number had dropped to 0.14 the acid number remaining at 0.04.
- the acid number is very close to the maximum acid number allowed by the plasticizer manufacturers.
- the carbonyl number is also high (0.14) compared with a carbonyl number of 0.05 in Example 1.
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Abstract
Procédé de production d'un alcool à partir d'une charge oléfinique consistant à procéder à l'hydroformylation de ladite charge oléfinique, à effectuer l'hydrogénation du mélange de produits résultant et la distillation du produit hydrogéné pour séparer le mélange en (i) une fraction légère obtenue par réaction OXO (FOL) ayant une température d'ébullition inférieure, (ii) l'alcool désiré et (iii) une fraction lourde obtenue par réaction OXO ayant une température d'ébullition supérieure. Puis la fraction lourde est soumise à un procédé de vapocraquage et ensuite à un procédé d'hydrogénation catalytique, au moins une partie du mélange craqué et hydrogéné résultant étant par la suite recyclée vers une étape précédente du procédé.
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Application Number | Priority Date | Filing Date | Title |
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GB9219832.4 | 1992-09-18 | ||
GB929219832A GB9219832D0 (en) | 1992-09-18 | 1992-09-18 | Hydroformylation of olefins |
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PCT/EP1993/002512 WO1994006739A1 (fr) | 1992-09-18 | 1993-09-17 | Procede d'hydroformylation d'olefines |
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Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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WO2001070660A1 (fr) * | 2000-03-22 | 2001-09-27 | Shell Internationale Research Maatschappij B.V. | Procede de preparation d'un alcool a partir d'une olefine |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0183547A1 (fr) * | 1984-11-30 | 1986-06-04 | Exxon Research And Engineering Company | Hydroformylation d'oléfines |
EP0183545A1 (fr) * | 1984-11-30 | 1986-06-04 | Exxon Research And Engineering Company | Hydroformylation d'oléfines |
EP0185477A1 (fr) * | 1984-11-30 | 1986-06-25 | Exxon Research And Engineering Company | Préparation de compositions d'éther/éther-alcool |
-
1992
- 1992-09-18 GB GB929219832A patent/GB9219832D0/en active Pending
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1993
- 1993-09-17 WO PCT/EP1993/002512 patent/WO1994006739A1/fr active Application Filing
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0183547A1 (fr) * | 1984-11-30 | 1986-06-04 | Exxon Research And Engineering Company | Hydroformylation d'oléfines |
EP0183545A1 (fr) * | 1984-11-30 | 1986-06-04 | Exxon Research And Engineering Company | Hydroformylation d'oléfines |
EP0185477A1 (fr) * | 1984-11-30 | 1986-06-25 | Exxon Research And Engineering Company | Préparation de compositions d'éther/éther-alcool |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2001070660A1 (fr) * | 2000-03-22 | 2001-09-27 | Shell Internationale Research Maatschappij B.V. | Procede de preparation d'un alcool a partir d'une olefine |
US6762332B2 (en) | 2000-03-22 | 2004-07-13 | Shell Oil Company | Process for preparing an alcohol from an olefin |
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GB9219832D0 (en) | 1992-10-28 |
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