Title of Invention: Method and catalyst system for producing aromatic carbonates
Abstract: A method and catalyst system for producing aromatic carbonates from aromatic hydroxy compounds is disclosed. In one embodiment, the method includes the step of contacting at least one aromatic hydroxy compound with oxygen and carbon monoxide in the presence of a carbonylation catalyst system having an effective amount of an iron source as the primary catalyst component in the absence of a Group VIII B metal source. In various alternative embodiments, the carbonylation catalyst system can include at least one inorganic co-catalyst, as well as a halide composition and/or a base.
Detailed Description: Part PAC: DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Part PAR: The present invention is directed to a method and catalyst system for producing aromatic carbonates. In one embodiment, the method includes the step of contacting at least one aromatic hydroxy compound with oxygen and carbon monoxide in the presence of a carbonylation catalyst system having an effective amount of an iron source in the absence of an effective amount of a Group VIII B metal source.
Part PAR_2: For convenience, the constituents of the catalyst system described herein are called "components" irrespective of whether a reaction between specific components actually occurs either before or during the carbonylation reaction. Therefore, the catalyst system may include the components and any reaction products thereof.
Part PAR_3: Unless otherwise noted, the term "effective amount" as used herein includes that amount of a component capable of either increasing (directly or indirectly) the yield of the carbonylation product or increasing selectivity toward an aromatic carbonate. Optimum amounts of a given component can vary based on reaction conditions and the identity of other components, yet can be readily determined in light of the discrete circumstances of a given application.
Part PAR_4: Aromatic hydroxy compounds which may be used in the present process include aromatic mono or polyhydroxy compounds, such as phenol, cresol, xylenol, resorcinol, hydroquinone, and bisphenol A. Aromatic organic mono hydroxy compounds are preferred, with phenol being more preferred.
Part PAR_5: The carbonylation catalyst system contains an effective amount of an iron source as the primary catalyst component. Suitable iron sources include iron halides, nitrates, carboxylates, oxides and iron complexes containing carbon monoxide, amines, phosphines or olefins. As used herein, the term "complex" includes coordination or complex compounds containing a central ion or atom. The complexes may be nonionic, cationic, or anionic, depending on the charges carried by the central atom and the coordinated groups. Other common names for these complexes include complex ions (if electrically charged), Werner complexes, and coordination complexes. In various applications, it may be preferable to utilize iron salts of organic acids, including carboxylates with C.sub.2-6 aliphatic acids. Suitable iron sources include iron (II or III) acetylacetonate and iron (II or III) acetate, as well as iron (III) bromide anhydrous, iron (II or III) nitrate, ferrocene, acetylferrocene, tris(2,2,6,6-tetramethyl-3,5-heptanedionate) iron (III), and iron (II) methylcyclopentadienyl.
Part PAR_6: The iron source may be a non-supported iron salt or complex. As used herein, the term "non-supported" indicates the absence of industrially conventional catalyst supports based on carbon, element oxides, element carbides or element salts in various presentations. Examples of supports containing carbon are coke, graphite, carbon black and activated carbon. Examples of element oxide catalyst supports are SiO.sub.2 (natural or synthetic silicas, quartz), Al.sub.2 O.sub.3 (.alpha.-, .gamma.- Al.sub.2 O.sub.3), aluminas, natural and synthetic aluminosilicates (zeolites), TiO.sub.2 (rutile, anatase), ZrO.sub.2 and ZnO. Examples of element carbides and salts are SiC, AIPO.sub.4, BaSO.sub.4, and CaCO.sub.3.
Part PAR_7: The present iron based catalyst system does not require a component chosen from the Group VIII B metals (i.e., Ru, Pt, Pd, Rh, Os, Ir) or a compound thereof. Surprisingly, the presently disclosed catalyst system effectively catalyzes the carbonylation reaction in the absence of a costly Group VIII B metal source, thereby effectively insulating the process from the volatile market for these elements.
Part PAR_8: In various alternative embodiments, the carbonylation catalyst system can include a catalytic amount of at least one inorganic co-catalyst (IOCC). It has been discovered that IOCC's and combinations of IOCC's can effectively catalyze the carbonylation reaction in the presence of the aforementioned iron-based catalyst system. Such IOCC's and combinations include copper, lead, copper and zirconium, titanium and cerium, lead and titanium, lead and zirconium, copper and titanium, copper and lead, and titanium and zirconium. Additional IOCC's may be used in the carbonylation catalyst system, provided the additional IOCC does not deactivate (i.e. "poison") the original IOCC combination.
Part PAR_9: An IOCC can be introduced to the carbonylation reaction in various forms, including salts and complexes, such as tetradentate, pentadentate, hexadentate, or octadentate complexes. Illustrative forms may include oxides, halides, carboxylates, diketones (including beta-diketones), nitrates, complexes containing carbon monoxide or olefins, and the like. Suitable beta-diketones include those known in the art as ligands for the IOCC metals of the present system. Examples include, but are not limited to, acetylacetone, benzoylacetone, dibenzoylmethane, diisobutyrylmethane, 2,2-dimethylheptane-3,5-dione, 2,2,6-trimethylheptane-3,5-dione, dipivaloylmethane, and tetramethylheptanedione. The quantity of ligand is preferably not such that it interferes with the carbonylation reaction itself, with the isolation or purification of the product mixture, or with the recovery and reuse of catalyst components. An IOCC may be used in its elemental form if sufficient reactive surface area can be provided. It may be preferable that an IOCC is non-supported as discussed above relative to the iron source.
Part PAR_10: IOCC's are included in the carbonylation catalyst system in catalytic amounts. In this context a "catalytic amount" is an amount of IOCC (or combination of IOCC's) that increases the number of moles of aromatic carbonate produced per mole of iron utilized; increases the number of moles of aromatic carbonate produced per mole of halide composition utilized; or increases selectivity toward aromatic carbonate production beyond that obtained in the absence of the IOCC (or combination of IOCC's). Optimum amounts of an IOCC in a given application will depend on various factors, such as the identity of reactants and reaction conditions. For example, when copper is utilized as an IOCC in the reaction, the molar ratio of copper relative to iron at the initiation of the reaction is preferably between about 1 and about 100.
Part PAR_11: The carbonylation catalyst system may further contain an effective amount of a halide composition, such as an organic halide salt. In various preferred embodiments, the halide composition can be an organic bromide or chloride salt. The salt may be a quaternary ammonium or phosphonium salt, such as tetraethylammonium bromide, tetraethylammonium chloride, tetrabutylammonium chloride, or the like. To address economic or regulatory concerns, alkali metal or alkaline earth metal salts may be preferable in certain applications. In preferred embodiments, the carbonylation catalyst system can contain between about 5 and about 2000 moles of halide per mole of iron employed, and, more preferably, between about 50 and about 1000 molar equivalents of halide are used.
Part PAR_12: The carbonylation catalyst system can also include an effective amount of a base. Any desired bases or mixtures thereof, whether organic or inorganic may be used. A non-exclusive listing of suitable inorganic bases include alkali metal hydroxides and carbonates; C.sub.2 -C.sub.12 carboxylates or other salts of weak acids; and various alkali metal salts of aromatic hydroxy compounds, such as alkali metal phenolates. Hydrates of alkali metal phenolates may also be used. Examples of suitable organic bases include tertiary amines and the like. Preferably, the base used is an alkali metal salt incorporating an aromatic hydroxy compound, more preferably an alkali metal salt incorporating the aromatic hydroxy compound to be carbonylated to produce the aromatic carbonate. Suitable bases include sodium phenoxide and sodium hydroxide. In preferred embodiments, between about 5 and about 1000 molar equivalents of base are employed (relative to iron), and, more preferably, between about 50 and about 700 molar equivalents of base are used.
Part PAR_13: The carbonylation reaction can be carried out in a batch reactor or a continuous reactor system. Due in part to the low solubility of carbon monoxide in organic hydroxy compounds, such as phenol, it is preferable that the reactor vessel be pressurized. In preferred embodiments, gas can be supplied to the reactor vessel in proportions of between about 2 and about 50 mole percent oxygen, with the balance being carbon monoxide or a combination of at least one inert gas and carbon monoxide and, in any event, outside the explosion range for safety reasons. It is contemplated that oxygen can be supplied in diatomic form or from another oxygen containing source, such as peroxides and the like. Additional gases may be present in amounts that do not deleteriously affect the carbonylation reaction. The gases may be introduced separately or as a mixture. A total pressure in the range of between about 10 and about 250 atmospheres is preferred. Drying agents, typically molecular sieves, may be present in the reaction vessel. Reaction temperatures in the range of between about 60.degree. C. and about 150.degree. C. are preferred. Gas sparging or mixing can be used to aid the reaction.
Part PAR_14: In order that those skilled in the art will be better able to practice the present invention reference is made to the FIGURE, which shows an example of a continuous reactor system for producing aromatic carbonates. The symbol "V" indicates a valve and the symbol "P" indicates a pressure gauge.
Part PAR_15: The system includes a carbon monoxide gas inlet 10, an oxygen inlet 11, a manifold vent 12, and an inlet 13 for a gas, such as carbon dioxide. A reaction mixture can be fed into a low pressure reservoir 20, or a high pressure reservoir 21, which can be operated at a higher pressure than the reactor for the duration of the reaction. The system further includes a reservoir outlet 22 and a reservoir inlet 23. The gas feed pressure can be adjusted to a value greater than the desired reactor pressure with a pressure regulator 30. The gas can be purified in a scrubber 31 and then fed into a mass flow controller 32 to regulate flow rates. The reactor feed gas can be heated in a heat exchanger 33 having appropriate conduit prior to being introduced to a reaction vessel 40. The reaction vessel pressure can be controlled by a back pressure regulator 41. After passing through a condenser 25, the reactor gas effluent may be either sampled for further analysis at valve 42 or vented to the atmosphere at valve 50. The reactor liquid can be sampled at valve 43. An additional valve 44 can provide further system control, but is typically closed during the gas flow reaction.
Part PAR_16: In the practice of one embodiment of the invention, the carbonylation catalyst system and aromatic hydroxy compound are charged to the reactor system. The system is sealed. Carbon monoxide and oxygen are introduced into an appropriate reservoir until a preferred pressure (as previously defined) is achieved. Circulation of condenser water is initiated, and the temperature of the heat exchanger 33 (e.g., oil bath) can be raised to a desired operating temperature. A conduit 46 between heat exchanger 33 and reaction vessel 40 can be heated to maintain the desired operating temperature. The pressure in reaction vessel 40 can be controlled by the combination of reducing pressure regulator 30 and back pressure regulator 41. Upon reaching the desired reactor temperature, aliquots can be taken to monitor the reaction.
Part PAC_2: EXAMPLES
Part PAR_17: The following examples are included to provide additional guidance to those skilled in the art in practicing the claimed invention. The examples provided are merely representative of the work that contributes to the teaching of the present application. Accordingly, these examples are not intended to limit the invention, as defined in the appended claims, in any manner. Unless otherwise specified, all parts are by weight, and all equivalents are relative to iron. Reaction products were verified by gas chromatography. Unless otherwise noted, all reactions were carried out in a glass, batch mitchelljason@example.com. C. in an approximately 6 -9% O.sub.2 in CO atmosphere. The glass reactor was sealed with a semi-permeable membrane and placed in an autoclave containing the reaction atmosphere at a pressure of approximately 110 atmosphere (i.e., negligible pressure differential across the walls of the glass reaction vessel). Reaction time was 3 hours for each run.
Part PAR_18: In the following examples, the aromatic carbonate produced is diphenylcarbonate (DPC). For convenience, the number of moles of DPC produced per mole of iron utilized is referred to as the iron turnover number (Fe TON).
Part PAC_3: EXAMPLE 1
Part PAR_19: Diphenyl carbonate was produced by adding, at ambient conditions, a substantially homogeneous catalyst system containing iron in the form of either iron (III) acetylacetonate ("Fe(acac).sub.3 ") or iron (III) nitrate ("Fe(NO.sub.3).sub.3 "), 5 equivalents of titanium in the form of titanium (IV) oxide acetylacetonate ("TiO(acac).sub.2 "), 2 equivalents of cerium in the form of cerium (III) acetylacetonate ("Ce(acac).sub.3 "), differing amounts of halide compositions in the form of either tetraethylammonium bromide ("TEAB" ) or tetraethylammonium chloride ("TEAC"), and 50 equivalents of NaOH to a glass reaction vessel containing phenol. The components were heated to 100.degree. C. for 3 hours in a reaction atmosphere comprised of 3% oxygen, 6% nitrogen, and 91% carbon monoxide. Total pressure in the reaction zone was approximately 102 atm. The following results were observed:
Part TBL: Experiment Fe source Halide Halide Fe No. 1 mM source Equivalents TON 1 Fe(acac).sub.3 TEAC 200 2 2 Fe(NO.sub.3).sub.3 TEAB 50 3
Part PAR_20: The data show that a Fe TON at least as high as 3 can be obtained utilizing an embodiment of the present catalyst system. Based on the results of these experiments, it is evident that a catalyst system containing Fe, Ce, Ti, an onium halide, and a base can effectively catalyze the carbonylation reaction.
Part PAC_4: EXAMPLE 2
Part PAR_21: The general procedure of Example 1 was repeated with various iron sources, FE(acac).sub.3, iron (II) acetate ("Fe(OAc).sub.2 "), iron (III) bromide ("FeBr.sub.3 "), and iron (II) methylcyclopentadienyl ("Fe(Cp).sub.2 "). Various inorganic co-catalyst combinations were employed in the presence of 50 equivalents of various halide compositions, including TEAB and tetrabutylamrnonium chloride ("TBAC" ). Some experimental runs were carried out in the presence of a base. All reactions were carried out in a 7.4% oxygen in carbon monoxide atmosphere at a total pressure of approximately 109 atm. to produce the following results:
Part TBL_2:  Experiment Fe source IOCC #1 IOCC #2 NaOH Halide Fe No. 1 mM IOCC #1 Equiv. IOCC #2 Equiv. Equiv. source TON 1 Fe(acac).sub.3 Pb 5 Ti 1 50 TEAB 3 2 Fe(acac).sub.3 Pb 5 Ti 1 50 TEAB 2 3 Fe(acac).sub.3 Pb 5 Zr 5 50 TBAC 3 4 Fe(acac).sub.3 Cu 1 Ti 5 50 TEAB 3 5 Fe(acac).sub.3 Cu 5 Zr 5 50 TEAB 2 6 Fe(OAc).sub.2 Pb 1 Cu 5 -- TEAB 5 7 Fe(OAc).sub.2 Pb 5 Ti 5 50 TEAB 5 8 Fe(OAc).sub.2 Cu 1 Ti 5 50 TEAB 3 9 Fe(OAc).sub.2 Cu 5 Zr 1 -- TEAB 2 10 Fe(OAc).sub.2 Ti 5 Zr 5 50 TBAC 2 11 Fe(Cp).sub.2 Pb 5 Cu 5 50 TEAB 3 12 Fe(Cp).sub.2 Pb 5 Cu 5 50 TEAB 2 13 Fe(Cp).sub.2 Pb 1 Ti 1 50 TEAB 6 14 Fe(Cp).sub.2 Pb 1 Ti 1 50 TEAB 2 15 Fe(Cp).sub.2 Cu 5 Ti 1 50 TBAC 3 16 Fe(Cp).sub.2 Cu 5 Ti 5 50 TEAB 3 17 Fe(Cp).sub.2 Cu 5 Ti 5 50 TEAB 2 18 Fe(Cp).sub.2 Cu 5 Zr 1 50 TBAC 2 19 Fe(Cp).sub.2 Cu 5 Zr 1 50 TBAC 4 20 Fe(Cp).sub.2 Ti 1 Zr 1 50 TEAB 4 21 Fe(Cp).sub.2 Ti 1 Zr 1 50 TEAB 2 22 FeBr.sub.3 Pb 1 Cu 5 50 TBAC 3 23 FeBr.sub.3 Pb 1 Ti 5 50 TEAB 3 24 FeBr.sub.3 Pb 5 Zr 1 50 TBAC 3 25 FeBr.sub.3 Pb 5 Zr 1 50 TBAC 3 26 FeBr.sub.3 Cu 5 Ti 5 50 TEAB 3 27 FeBr.sub.3 Ti 5 Zr 1 50 TEAB 6 28 FeBr.sub.3 Ti 5 Zr 5 50 TEAB 2
Part PAR_22: The results show that various combinations of Fe, IOCC, onium halide, and base can effectively catalyze the carbonylation reaction.
Part PAC_5: EXAMPLE 3
Part PAR_23: The general procedure of Examples 1 and 2 was repeated with 1 mM of various iron sources, 100 equivalents of TEAB, and various amounts of either lead or copper. Lead was provided as lead (II) oxide ("PbO") and copper as copper (II) actylacetonate ("Cu(acac).sub.2 "). Iron sources used for these experimental runs include FE(acac).sub.3 FE(OAc).sub.2, FeBr.sub.3, ferrocene ("Fe(C.sub.5 H.sub.5).sub.2 "), and iron (II) nitrate ("FE(NO.sub.3).sub.2 " . Reactions were carried out in a 7.8% oxygen in carbon monoxide atmosphere at approximately 110 atm. total pressure. The following results were observed:
Part TBL_3:  Experiment Fe source Cu(acac).sub.2 PbO TEAB Fe No. 1 mM Equivalents Equivalents Equiv. TON 1 Fe(acac).sub.3 5 -- 100 4 2 Fe(OAc).sub.2 5 -- 100 3 3 Fe(OAc).sub.2 5 -- 100 6 4 FeBr.sub.3 5 -- 100 3 5 FeBr.sub.3 5 -- 100 5 6 Fe(C.sub.5 H.sub.5).sub.2 5 -- 100 6 7 Fe(acac).sub.3 -- 10 100 3 8 Fe(OAc).sub.2 -- 10 100 5 9 FeBr.sub.3 -- 10 100 4 10 FeBr.sub.3 -- 10 100 11 11 Fe(C.sub.5 H.sub.5).sub.2 -- 10 100 4 12 Fe(C.sub.5 H.sub.5).sub.2 -- 10 100 3 13 Fe(NO.sub.3).sub.2 -- 10 100 11 14 Fe(NO.sub.3).sub.2 -- -- -- 16
Part PAR_24: The results show that various combinations of Fe alone, as well as in combination with an IOCC and onium bromide can effectively catalyze the carbonylation reaction.
Part PAC_6: EXAMPLE 4
Part PAR_25: The general procedure of Examples 1-3 was repeated with 1 mM of various iron sources 100 equivalents of either TEAB or TBAC, and various amounts of either PbO or Cu(acac).sub.2. Reactions were carried out in a 7.8% oxygen in carbon monoxide atmosphere at approximately 56 atm. total pressure. The following results were observed:
Part TBL_4:  Experiment Fe source Cu(acac).sub.2 PbO Halide Fe No. 1 mM Equivalents Equivalents 100 eq. TON 1 Fe(acac).sub.3 -- 10 TEAB 2 2 Fe(OAc).sub.2 -- 10 TEAB 4 3 Fe(acac).sub.3 5 -- TBAC 4 4 FeBr.sub.3 5 -- TBAC 4 5 Fe(NO.sub.3).sub.2 5 -- TBAC 3 6 Fe(NO.sub.3).sub.2 5 -- TBAC 3
Part PAR_26: The results show that various combinations of Fe, IOCC, and onium halide can effectively catalyze the carbonylation reaction at lower pressures.
Part PAC_7: EXAMPLE 5
Part PAR_27: The general procedure of Examples 1-4 was repeated with various iron source, various inorganic co-catalyst combinations, and 100 equivalents of either TEAC or TEAB. IOCC sources included TiO(acac).sub.2, PbO, Zr(OBu).sub.4, and Cu(acac).sub.2. Some experimental runs were carried out in the presence of a base. All reactions were carried out in a 9% oxygen in carbon monoxide atmosphere at a total pressure of approximately 102 atm. to produce the following results:
Part TBL_5:  Experiment Fe source IOCC #1 IOCC #2 NaOH Halide Fe No. 1 mM IOCC #1 Equiv. IOCC #2 Equiv. Equiv. source TON 1 FeBr.sub.3 Ti 2 Pb 2 50 TEAC 2 2 FeBr.sub.3 Ti 2 Pb 2 50 TEAC 2 3 Fe(Cp).sub.2 Zr 5 Pb 2 -- TBAB 2 4 Fe(Cp).sub.2 Zr 5 Pb 2 -- TEAB 2 5 Fe(Cp).sub.2 Cu 5 Ti 5 -- TEAB 2 6 Fe(OAc).sub.3 Pb 2 Cu 5 50 TEAB 3 7 Fe(OAc).sub.3 Pb 2 Cu 5 50 TEAB 2 8 Fe(acac).sub.3 Cu 5 Ti 2 50 TEAB 1 9 Fe(acac).sub.3 Pb 5 Cu 2 -- TEAC 2
Part PAR_28: The results show that various combinations of Fe, IOCC, onium halide, and base can effectively catalyze the carbonylation reaction.
Part PAC_8: EXAMPLE 6
Part PAR_29: The general procedure of Examples 1-5 was repeated with an iron source selected from either acetylferrocene ("CH.sub.3 COC.sub.5 H.sub.4 FeC.sub.5 H.sub.5 ") or tris(2,2,6,6-tetramethyl-3,5-heptanedionate) iron (III) ("Fe(TMHD).sub.3 "). The remainder of the catlyst system included TEAB, and either Cu(acac).sub.2 or PbO. Reactions were carried out at approximately 107 atm. in a 7.79% oxygen in CO atmosphere to produce the results:
Part TBL_6:  Experi- PbO ment Cu(acac).sub.2 Equiva- TEAB Fe No. Iron source Equivalents lents Equiv. TON 1 CH.sub.3 COC.sub.5 H.sub.4 FeC.sub.5 H.sub.5 5 -- 75 2 2 CH.sub.3 COC.sub.5 H.sub.4 FeC.sub.5 H.sub.5 -- 5 75 3 3 Fe(TMHD).sub.3 -- 5 75 3 4 Fe(TMHD).sub.3 -- 5 75 4
Part PAR_30: The results show that various combinations of Fe, IOCC, and onium bromide can effectively catalyze the carbonylation reaction.
Part PAR_31: It will be understood that each of the elements described above, or two or more together, may also find utility in applications differing from the types described herin. While the invention has been illustrated and described as embodied in a method and catalyst system for producing aromatic carbonates, it is not intended to be limited to the details shown, since various modifications and substitutions can be made without departing in any way from the spirit of the present invention. For example, additional effective IOCC compounds can be added to the reaction. As such, further modifications and equivalents of the invention herein disclosed may occur to person skilled in the art using no more than routine experimentation, and all such modifications and equivalents are believed to be within the spirit and scope of the invention as defined by the following claims.


{'bibliographic_information': "{'Patent Number': '061879428', 'Series Code': '9', 'Application Number': '5170001', 'Application Type': '1', 'Art unit': '166', 'Application Filing Date': '20000301', 'Title of Invention': 'Method and catalyst system for producing aromatic carbonates', 'Issue Date': '20010213', 'Number of Claims': '18', 'Exemplary Claim Number(s)': '1', 'Primary Examiner': 'Ambrose; Michael G.', 'Number of Drawing Sheets': '1', 'Number of figures': '1'}", 'source_file': './grant/2001/pftaps20010213_wk07.txt', 'source_data': 'USPTO-Grant'}