Rhodium-catalyzed carbonylation using non-acetate lithium,...

Details Rhodium-catalyzed carbonylation using non-acetate lithium,... Rhodium-catalyzed carbonylation using non-acetate lithium,...

2000-01-12

2002-05-28

Geist, Gary (Department: 1623)

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

Organic compounds

Carboxylic acids and salts thereof

C562S607000

Reexamination Certificate

active

06395928

ABSTRACT:

BACKGROUND OF THE INVENTION AND PERTINENT PRIOR ART
1. Field of the Invention
The present invention relates to an improved process for producing an organic carboxylic acid having (n+1) carbon atoms by reacting an alcohol having n carbon atoms with carbon monoxide in the presence of a rhodium catalyst system. Particularly, the present invention relates to carbonylation of methanol catalyzed by a rhodium system to produce acetic acid.
2. Description of the Prior Art
It is a well known and commercialized technology for obtaining acetic acid by carbonylation of methanol with rhodium catalysts. Comparing with the early cobalt catalysts, the rhodium catalyst system has advantages of lower reaction temperature and lower carbon monoxide partial pressure as well as faster reaction rate. Typically, carbonylation of methanol with a rhodium catalyst system proceeds in a liquid phase comprising of a rhodium catalyst as dissolved therein and a promoter including methyl iodide. Related art in regard to this can be referred to the Applied Homogeneous Catalysis with Organometallic Compounds, Vol. 1, pp. 104-138 (1997).
A technology for producing acetic acid by carbonylation of methanol has been disclosed in U.S. Pat. Nos. 3,769,329 and 4,690,912 under reaction conditions as follows: reaction temperature of 180° C., pressure of monoxide between 35-70 Kg/cm
2
, rhodium as a catalyst and methyl iodide as a promoter. It is also disclosed in these patents that the most effective solvent for producing the acetic acid is the product acetic acid per se. The main advantages of such a catalyst system are the extremely high conversion rate and selectivity (>95%). The catalyst can substantially be recycled to the reactor except some minor loss resulting from the pipe line or the pump leakage. This art can be deemed almost perfect except that for avoiding the precipitation of the rhodium catalyst and for maintaining a fairly higher reaction rate, the water content in the reaction system may have to be maintained at least 14~15 wt %. In the teachings of Hjortkjaer (Ind. Eng. Chem. Prod. Res., 1976, 15, p46), increasing the water content from 0 to 14 wt % in such a catalyst system will increase the reaction rate of methanol carbonylation correspondingly while the reaction rate is unchanged as the water content is above 14 wt %. Such a high water content will increase the expense for the separation equipment and will consume considerable energy. In recent decades, variable methods have been suggested in many patents one after another intending to enhance the solubility of the rhodium catalyst at lower water content (<14 wt %).
European Patent Publication No. 0055618 has disclosed a method for carbonylation of methanol wherein the precipitation of rhodium catalyst at lower water content is alleviated by adding organic stabilizer for the catalyst. The stabilizer as disclosed therein includes several kinds of organic compounds, alone or simultaneously, containing one or more nitrogen atoms, phosphorus atoms or carboxyl groups selected from:
(1) N,N,N
1
,N
1
-tetramethyl-O-phenylenediamine) and 2,3
1
-dipyridyl;
(2) HOOC—Y
1
—COOH and (HOOC—Y
2
)(HOOC—Y
3
)N—Y
1
—N(Y
4
—COOH)(Y
5
—COOH),Y
1-5
═(CH
2
)m;
(3) (R
1
)(R
2
)P—R
3
—P(R
4
)(R
5
),R
1-5
=alkyl group;
U.S. Pat. No. 4,733,006 has disclosed a method of utilizing an inorganic salt additive XOAc (X=Li
+
, Na
+
, Ka
+
) to alleviate the precipitation of rhodium catalyst in the reaction solution for methanol carbonylation at lower water content. However, no description regarding the influence of the inorganic salt additive to the reaction rate is mentioned through the whole patent.
It is disclosed in U.S. Pat. No. 5,001,259 that when utilizing inorganic iodide such as lithium iodide (LiI) as a stabilizer for rhodium catalyst to alleviate the precipitation of rhodium at lower water content during the carbonylation of methanol, reaction rate which is approximately comparable to the high water content (14 wt %) can be obtained. In the same patent, a kind of quaternary ammonium salt, N-methyl-picolinium iodide, is also disclosed for raising the carbonylation rate at lower water content. Unfortunately from the experiment result, it is found that the compound N-methyl-picolinium iodide forms a complex with Rh in poor solubility easily and precipitates out of the reaction solution.
The nitrogen-containing compound N-methylimidazole as disclosed in European Patent Publication No. 0153834 also forms a complex with Rh in poor solubility easily and precipitates from the reaction solution of methanol carbonylation.
In another U.S. Pat. No. 5,442,107, six kinds of heterocyclic nitrogen compounds are selected as the catalyst stabilizer for methanol carbonylation at lower water content:
(1) 2-ethyl-4-methylimidazole,
(2) 4-methylpyridine,
(3) 4-t-butyl-pyridine,
(4) 2-hydroxylpyridine,
(5) 3-hydroxylpyridine,
(6) 4-hydroxylpyridine.
However, at lower water content die influence of the additive as used therein in regard to the reaction rate is not disclosed in the whole patent. It is also disclosed in the same patent the pyridine that is wholly without the substitution of alkyl group will form a complex with Rh in poor solubility easily and will precipitate from the reaction solution of methanol carbonylation at lower water content. This circumstance is similar to what happens to the organic compounds of 4-methyl-picoline and N-methylimidazole, as disclosed in the prior arts.
The prior arts as mentioned above hint several kinds of inorganic salt additives to alleviate or avoid the precipitation of rhodium catalyst when acetic acid is formed by carbonylation of methanol at lower water content. Such kind of technology therefore can save the energy consumed in the distillation process for separation the product acetic acid as well as can reduce additional processing steps such as extraction by solvents and can avoid enlarging some process equipment for the separation.
The present invention provides several kinds of inorganic salt additives different from the ones in the prior arts to lower the precipitation of rhodium catalyst when acetic acid is formed by carbonylation of methanol at lower water content. All these catalysts can be employed in either batch process or in a continuous type reactor.
The inorganic salt additive as used in the present invention is selected from the following formula (A):
X
n
M
m
  (A)
X=Li
+
, Na
+
, K
+
;
M=CO
3
−2
, HCO
3
−
, PO
4
−3
, HPO
4
−2
, H
2
PO
4
−
, SO
4
−2
, HSO
4
−
C
2
O
4
−2
, HC
2
O
4
−
, B(C
6
Y
5
)
4
−1
;
Y=H, F or CF
3
.
Suitable amount of inorganic salt additives such as XI and XOAc (X=Li
+
, Na
+
, K
+
) for use to alleviate the precipitation of the rhodium catalyst in the carbonylation of alcohol has been disclosed in prior arts. However, inorganic salt additive having formula (A) as disclosed herein has never been applied in alleviating the precipitation of the rhodium catalyst in the carbonylation of alcohol.
DETAILED DESCRIPTION AND PREFERRED EMBODIMENTS
The present invention relates to an improved process for producing an organic carboxylic acid having (n+1) carbon atoms by reacting an alcohol having n carbon atoms with carbon monoxide in the presence of a rhodium catalyst system. Particularly, the present invention relates to a process for carbonylation of methanol by the catalysis of a rhodium system to synthesize acetic acid. This process comprises directing the alcohol and/or the ester formed by said alcohol and acid along with carbon monoxide to the carbonylation reactor. Said reactor comprises the following components: (1) a rhodium catalyst, (2) the iodide derivative corresponding to the alcohol which is being reacted, (3) the ester formed by acid and alcohol, (4) the carboxylic acid, (5) at least a finite quantity of water, (6) one or more catalyst stabilizers as shown in the following formula (A):
X
n
M
m
  (A)
X=Li
+
,

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