Hydroformylation process

Details Hydroformylation process Hydroformylation process

1997-10-15

2000-04-11

Kumar, Shailendra

Organic compounds -- part of the class 532-570 series

Organic compounds

Oxygen containing

568454, 568878, 568882, 568883, 560233, 560247, C07C 4500

Patent

active

06049011&

DESCRIPTION:

BRIEF SUMMARY
FIELD OF THE INVENTION

This invention relates to a process for hydroformylation of a dilute ethylene-containing feedstream.


BACKGROUND OF THE INVENTION

It has been recognized that in principle the lower unsaturated hydrocarbon component in certain hydrocarbon streams is a valuable source for higher organic molecules. Such higher organic molecules may be reached, for example, by treatment, for example hydroformylation, of unsaturated hydrocarbons, in particular those containing two carbon atoms, the unsaturated hydrocarbons being obtainable, for example, by pyrolysis of hydrocarbons, more especially their pyrolysis in the presence of steam to form a light olefin-containing mixture, or pyrolysis of methane in appropriate conditions, as described in U.S. patent application Ser. No. 375,324 of Jan. 18th, 1995, and a corresponding PCT application entitled "Direct Hydroformylation of a Multi-Component Synthesis Gas Containing Carbon Monoxide, Hydrogen, Ethylene and Acetylene", applicants Gabor Kiss et al., assigned to Exxon Research & Engineering Company, filed simultaneously with the present application, and whose entire disclosures are incorporated by reference herein.


DESCRIPTION OF THE RELATED ART

In European Patent Application No. 95.300 301.9 of Jan. 18th, 1995, and a corresponding PCT application entitled "Organic Compounds and Processes for their Manufacture", filed by the present applicants simultaneously with the present application, and whose entire disclosures are incorporated by reference herein, there are disclosed processes for the manufacture of aldehydes, primarily those containing 9 carbon atoms, and their derivatives, optionally from an unsaturated hydrocarbon containing two carbon atoms, which is in turn optionally obtained by appropriate treatment of natural gas.
In view of the desirability of being able to make the best possible economic use of the various dilute olefin sources, e.g., natural gas, stream cracking and other hydrocarbon sources, becoming available around the world, there remains a need for a hydroformylation procedure sufficiently flexible to use ethylene-containing feedstocks of a variety of compositions.
In DE-OS 2354217 (BASF AG), there is disclosed a process in which an ethylene-containing feedstream is hydroformylated. In this process, a mixture of gases resulting from thermal cracking of oil is treated to abstract pure ethylene, acetylene or butadiene, and a feedstock of the residual gases, being primarily C.sub.2 to C.sub.4 olefins, carbon monoxide and hydrogen, is contacted with a rhodium-based catalyst under hydroformylation conditions. In the examples, the hydrocarbons are methane and ethylene only, and the ethylene represents from 76 to 99% volume percent of the hydrocarbon content.
In Vol. 2 of the Proceedings of INTERPEC 91, at pp 614 to 620, Yin et al describe hydroformylation of a feedstream, resulting from fluid bed catalytic cracking, using syngas in the presence of a supported liquid phase rhodium-based catalyst. The ethylene content of the feedstream, based on total hydrocarbon content, is below 30 volume percent. The hydrocarbon content of the stream is about 50% by volume, the remainder being hydrogen, about 30%, and nitrogen, about 19%.
In Catalysis Letters, 13, (1992), 341 to 347, Green et al describe the synthesis of propanal from methane and air by oxidative coupling of a portion of the methane to ethylene, partial oxidation of another portion of the methane to syngas, and hydroformylation of the ethylene-containing feedstream by the syngas. In a proposal to use natural gas as a methane source, ethane is cryogenically separated out of the natural gas before oxidative coupling. In an example, the ethylene content of the feedstream to hydroformylation is about 10 volume percent, based on the hydrocarbon content.


BRIEF SUMMARY OF THE INVENTION

The present invention provides a process for the hydroformylation of a hydrocarbon-containing feedstream which comprises contacting a feedstream containing from 27.5 to 75 percent by weight of ethylene, b

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