CN103648640A - 用于捕集和循环卤代烷化合物生产中使用的铁催化剂的方法 - Google Patents
用于捕集和循环卤代烷化合物生产中使用的铁催化剂的方法 Download PDFInfo
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 title claims abstract description 91
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- STCOOQWBFONSKY-UHFFFAOYSA-N tributyl phosphate Chemical compound CCCCOP(=O)(OCCCC)OCCCC STCOOQWBFONSKY-UHFFFAOYSA-N 0.000 claims description 10
- 239000000203 mixture Substances 0.000 claims description 8
- 239000003426 co-catalyst Substances 0.000 claims description 4
- VZGDMQKNWNREIO-UHFFFAOYSA-N tetrachloromethane Chemical compound ClC(Cl)(Cl)Cl VZGDMQKNWNREIO-UHFFFAOYSA-N 0.000 claims description 4
- PNLQPWWBHXMFCA-UHFFFAOYSA-N 2-chloroprop-1-ene Chemical compound CC(Cl)=C PNLQPWWBHXMFCA-UHFFFAOYSA-N 0.000 claims description 2
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims description 2
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- DQWPFSLDHJDLRL-UHFFFAOYSA-N triethyl phosphate Chemical compound CCOP(=O)(OCC)OCC DQWPFSLDHJDLRL-UHFFFAOYSA-N 0.000 claims description 2
- WVLBCYQITXONBZ-UHFFFAOYSA-N trimethyl phosphate Chemical compound COP(=O)(OC)OC WVLBCYQITXONBZ-UHFFFAOYSA-N 0.000 claims description 2
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- VVWFZKBKXPXGBH-UHFFFAOYSA-N 1,1,1,3,3-pentachloropropane Chemical compound ClC(Cl)CC(Cl)(Cl)Cl VVWFZKBKXPXGBH-UHFFFAOYSA-N 0.000 abstract description 5
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- MSSNHSVIGIHOJA-UHFFFAOYSA-N pentafluoropropane Chemical compound FC(F)CC(F)(F)F MSSNHSVIGIHOJA-UHFFFAOYSA-N 0.000 description 2
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Abstract
本文公开了一种用于捕集和循环卤代烷化合物生产中所使用的铁催化剂的方法,更具体地涉及一种用于生产化合物1,1,1,3,3-五氯丙烷(HCC-240fa)的改进方法,其中使用电磁分离单元(EMSU)来促进反应。当通电时,EMSU运行而从反应器流出物中除去铁颗粒;当不通电时,可以将由EMSU捕集的铁颗粒冲洗回到反应器中以便在HCC-240fa的继续生产中重复使用。本发明也可应用于其它卤代烷化合物例如HCC-250和HCC-360的制造工艺中。
Description
相关申请的交叉引用
本申请要求2011年6月3日提交的共同所有的、共同未决的美国临时专利申请序列号61/492,907的本国优先权,其公开内容在此以引用的方式并入本文中。
技术领域
本发明涉及一种用于制造卤代烷化合物的方法,更具体地涉及一种用于生产化合物1,1,1,3,3-五氯丙烷(HCC-240fa)的改进方法。本发明也可应用于其它卤代烷化合物(例如HCC-250和HCC-360)的制造方法中。
背景技术
化合物1,1,1,3,3-五氯丙烷(HCC-240fa)是用于制造1,1,1,3,3-五氟丙烷(HFC-245fa)的原料,1,1,1,3,3-五氟丙烷是非臭氧消耗化学品并且可以用作发泡剂、能量传递介质等。用于制备有用的卤代烷(例如HCC-240fa)的加成反应在本领域中是已知的。例如,美国专利第6,313,360号教导了一种通过在催化剂混合物存在下在足以制造含有HCC-240fa的产品混合物的条件下使四氯化碳(CCl4)与氯乙烯(VCM)反应而制造HCC-240fa的方法,该催化剂混合物包含有机磷酸酯(例如磷酸三丁酯(TBP))、金属铁和三氯化铁。然后通过从反应物、催化剂和副产物中分离而回收240fa产品。也可参见美国专利5,902,914、6,187,978、6,198,010、6,235,951、6,500,993、6,720,466、7,102,041、7,112,709和7,265,082以及美国专利公开2004/0225166和2008/0091053。所有这些参考文件的公开内容在此均通过引用并入本文中。
在通过CCl4与VCM之间的偶联反应合成HCC-240fa期间,将铁粉用作主催化剂。由CCl4、TBP和240fa组成的液体介质与铁粉形成浆体。因此,反应器流出物将含有实质量的悬浮的固体,其可能会干扰下游单元的机械和化学操作。此外,因为从流出物除去了催化剂,所以反应性将收到损害,增加所需的损失铁粉的补充量。因此,对于可以将铁催化剂捕集和循环回到反应器中的装置存在着需求。本发明提供一种针对此问题的解决方案。
发明内容
本发明采用电磁分离单元(electromagnetic separation unit,EMSU),该单元构造成使得在由CCl4和VCM催化形成卤代烷化合物期间能够从反应器流出物连续除去铁颗粒并且循环所捕集的铁颗粒。
在一个实施方案中,本发明可以概括地描述成用于捕集和循环1,1,1,3,3-五氯丙烷生产中使用的铁催化剂的方法,其中使用电磁分离单元(EMSU)来促进反应。当通电时,EMSU运行以从反应器流出物中除去铁颗粒;当不通电时,可以将由EMSU捕集的铁颗粒冲洗回到反应器中再次使用。
因此,本发明的一个实施方案是一种用于在1,1,1,3,3-五氯丙烷生产期间捕集和循环铁催化剂的方法,该方法包括以下步骤:
(a)将CCl4和VCM进料到具有包含铁粉和TBP的催化剂的反应器中,以形成HCC-240fa;
(b)通过使用通电的电磁分离单元(EMSU),从HCC-240fa反应器流出物中除去铁颗粒;以及
(c)将EMSU断电并且循环铁颗粒且使铁颗粒返回到反应器中以便重新用在步骤(a)中。
本发明也可用于其它卤代烷化合物(例如HCC-250和HCC-360)的铁催化的制造方法中:
(1)可以根据以下反应,由CCl4和乙烯制造HCC-250:
CCl4+CH2=CH->CCl3CH2CH2Cl。
(2)可以根据以下反应,由CCl4和2-氯丙烯制造HCC-360:
CCl4+CH2=CClCH3->CCl3CH2CCl2CH3。
附图说明
附图示出了在连续搅拌釜反应器(continuous stirred tank reactor,CSTR)中用于在HCC-240fa和其它卤代烷化合物生产中连续除去和循环催化剂固体的工艺设置。
具体实施方式
铁被广泛被应用于许多催化剂应用中,其中其粉末形式悬浮于会由化学反应物组成的液体混合物中。通常对这些浆体进行连续处理并且可能需要仔细地控制存在的固体。有时下游设备(即,泵、阀、管道)不能处理含有大量固体物质的物流。此外,在铁存在下,可能存在不合需要的化学状况(分离、副反应)。虽然铁粉(iron powder)是优选的,但可以使用任何铁物体,例如铁球(iron balls)、铁丝(iron wire)、铁屑(iron shavings)等。
通常使用过滤器并且策略性地设置以防止固体的下游携带(carry-over)。然而,当这些过滤器被铁充满时,通常需要从使用中取出这些过滤器。因此,可能会损失昂贵的催化剂并且/或者由于对这些过滤器进行清洁和维护造成可能存在工艺停机时间。
本发明被设计成通过使用一个或多个电磁分离单元(EMSU)在由CCl4铁催化形成卤代烷化合物期间使铁携带和工艺停机时间最小化,以及在使用铁固体悬浮液的方法中使催化剂保留最大化。这种装置是市场上可买到的。一家商业制造商是Eriez of Erie,PA。
更具体地,本发明被设计成捕集(capture)和循环(recycle)1,1,1,3,3-五氯丙烷生产中所使用的铁催化剂,其中以期望的比率将CCl4和VCM连续地进料到反应器中并且可以周期性地或连续地将铁粉和助催化剂TBP添加到反应器中。在此可使用的额外助催化剂包括以下的有机磷酸酯化合物:磷酸三苯酯、磷酸三丁酯、磷酸三乙酯、磷酸三甲酯、磷酸三丙酯、或任何类似的有机磷酸酯化合物,以及这些化合物中的两种或更多种的混合物。
CCl4与VCM的反应优选地是以大约0.01小时至大约24小时、优选大约1小时至大约12小时的停留时间实施。基于高VCM效率、高HCC-240fa产率和低副产物产生,合理地选择反应条件。虽然间歇工艺可用于本发明的反应,但优选的是在本发明中采用继续制造工艺。
在连续操作中,通过浸入液态浆体中的管,连续地抽出反应器内容物。当从反应器取出浆体时,在下游处理之前将通过利用EMSU除去铁而制备物流。尽管可以用单个EMSU对该物流进行处理,但在一个优选的实施方式中,安装两个(或更多个)串联的(tandem)EMSU并且以并行的方式操作,如图1中所示。
在启动时,将阀1打开以允许进料材料经过旁路流入240fa反应器并且允许引导流出物经过EMSU“A”。在连续操作时,EMSU“A”将被通电。该通电的EMSU接收反应器流出物并且运行以捕集悬浮的铁颗粒。然后,液体部分可以在无铁的情况下继续流到下游。一旦EMSU“A”变得被铁饱和,则关闭阀1和打开阀3使得EMSU“B”可以接收反应器流出物并且开始除去铁。
当EMSU“B”运行时,将饱和的EMSU“A”断电。然后可以将反应器进料重新引导经过饱和的EMSU“A”从而将铁催化剂冲洗回到反应器中。这样的话,通过当EMSU“A”变饱和时打开阀3或者当EMSU“B”变饱和时打开阀2,通过交换各EMSU的任务,可以维持连续过程,防止铁损失到下游、使催化剂利用最大化、以及减少工艺停机时间。
在经过其中捕集铁颗粒的EMSU之后,对反应器流出物物流实施闪蒸以除去包含未反应的CCl4和VCM(如果存在)进料材料及HCC-240反应产物的“顶部”物流,而催化剂/助催化剂混合物留下。蒸馏可以在一个或多个蒸馏塔中进行,这在本领域中是公知的。
优选地,在2个步骤中实施闪蒸:首先,在低于反应温度的温度在压力下(优选地在真空下)实施闪蒸以除去任何未反应的CCl4和/或VCM,接着在更低的压力下实施另一真空闪蒸以除去HCC-240fa反应产物。将“底部”物流循环回到反应器。可将蒸馏的未反应的CCl4和VCM循环回到反应器。可实施周期性的吹洗(purges)以避免重副产物(例如HCC-470异构体)在催化剂循环物流中的积累。
在该方法的后面步骤中,本发明通过蒸馏提供对粗产物的纯化。在大约5至大约200mm Hg和大约50℃至大约150℃的温度,实施真空分馏以回收产物。已发现当在有机磷酸酯化合物(例如磷酸三丁酯)或者其它金属螯合化合物存在下实施该纯化步骤时,经纯化产物的蒸馏产率被显著改善。
虽然不希望受任何特定理论约束,但据信磷酸三丁酯的作用是防止HCC-240fa产物的分解。因此,在一个优选的实施方案中,该纯化步骤包括添加足以改善HCC-240fa产物产率的量的金属螯合化合物。优选地,使用5重量%的磷酸三丁酯。
如本文中使用的那样,除非上下文另外明确规定,否则单数形式“a”、“an”和“the”包括复数。此外,当一个数量、浓度或其他值或参数以范围、优选范围、或一系列优选上限值和优选下限值给出时,这理解为具体公开了由任意范围上限或优选值和任意范围下限或优选数值的任意一对形成的所有范围,无论范围是否是被单独公开。在本文给出数值范围的地方,除非另外说明,否则该范围意在包括其端点,以及该范围内的所有整数和分数。当定义一个范围时,不是表示本发明的范围限制在提及的具体值。
应当理解前文描述仅仅是对本发明的说明。本领域技术人员能够不脱离本发明想出各种替代和改进。因此,本发明意在包括落入所附权利要求书范围内的所有替代、改进和变动。
Claims (9)
1.一种通过采用电磁分离单元(EMSU)捕集和循环在通过使用铁催化剂和一种或多种作为助催化剂的磷酸三烷基酯化合物由四氯化碳和烯烃生产卤代烷化合物期间使用的铁催化剂的方法。
2.如权利要求1所述的方法,其中所述烯烃选自氯乙烯、乙烯和2-氯丙烯。
3.如权利要求1所述的方法,其中所述卤代烷化合物选自HCC-240fa、HCC-250和HCC-360。
4.如权利要求1所述的方法,其中所述铁催化剂具有选自铁粉、铁球、铁丝、铁屑及其混合物的形态。
5.如权利要求1所述的方法,其中所述助催化剂选自磷酸三丁酯、磷酸三甲酯、磷酸三乙酯、磷酸三丙酯、以及这些化合物中的两种或更多种的混合物。
6.如权利要求1所述的方法,所述方法是以连续操作的方式实施。
7.如权利要求1所述的方法,所述方法是以间歇操作的方式实施。
8.如权利要求1所述的方法,其中使用两个或更多个通电的电磁分离单元。
9.如权利要求8所述的方法,其中所述两个或更多个电磁分离单元是以串联的方式安装并且以并行的方式操作。
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