Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
  • B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
  • B01J23/74—Iron group metals
  • B01J23/75—Cobalt
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
  • B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
  • B01J23/74—Iron group metals
  • B01J23/755—Nickel
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J25/00—Catalysts of the Raney type
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J25/00—Catalysts of the Raney type
  • B01J25/02—Raney nickel
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J25/00—Catalysts of the Raney type
  • B01J25/04—Regeneration or reactivation
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C209/00—Preparation of compounds containing amino groups bound to a carbon skeleton
  • C07C209/44—Preparation of compounds containing amino groups bound to a carbon skeleton by reduction of carboxylic acids or esters thereof in presence of ammonia or amines, or by reduction of nitriles, carboxylic acid amides, imines or imino-ethers
  • C07C209/48—Preparation of compounds containing amino groups bound to a carbon skeleton by reduction of carboxylic acids or esters thereof in presence of ammonia or amines, or by reduction of nitriles, carboxylic acid amides, imines or imino-ethers by reduction of nitriles
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
  • Y02P20/00—Technologies relating to chemical industry
  • Y02P20/50—Improvements relating to the production of bulk chemicals
  • Y02P20/584—Recycling of catalysts

Definitions

• This invention is generally related to the manufacture of dimethylaminopropylamme (DMAPA) from dimethylaminopropionitrile (DMAPN) using a hydrogenation process. More specifically, the invention is related to the use of a low-pressure diamine hydrogenation process for the preparation of dimethylaminopropylamme from dimethylaminopropionitrile with exceptionally high selectivity using a sponge (Raney®) type catalyst with an alkali metal hydroxide solution. In particular, low-pressure hydrogenation of DMAPN to DMAPA using a sponge nickel catalyst and a 50%/50% by weight mixture of sodium hydroxide and potassium hydroxide at low temperature is disclosed.
• N,N-dimethylaminopropylamine (DMAPA, N,N-dimethyl-l,3-diaminopropane, 3- dimethylaminopropylamine) is an important intermediate in the large-scale production of a variety of industrial processes.
• DMAPA is an important intermediate as a surfactant for the production of soft soaps and other products, as an intermediate for the production of betaines and fatty amine oxides.
• N,N-dimethylamino-propylamine is also used as a starting product in the production of flocculating agents (by conversion to methacrylamide), road marking paints, and polyurethanes.
• DMAPA has also been shown to inhibit corrosion in boiler water treatment, and is an intermediate for gasoline and motor oil additives. Owing to DMAPA' s wide utility, and the fact that the products it is associated with are produced at the multi-million pound per year level, there is the constant challenge to produce the N,N- dimethylaminopropylamme in high yield and selectivity, due to the high costs associated with byproduct contamination.
• U.S. Patent No. 3,821,305 describes a hydrogenation process in the liquid phase at pressures of 20-50 atmospheres and temperatures between 60° and 100 °C in the presence of a finely divided Raney® catalyst and a caustic alkali base.
• hydrogen and the nitrile are fed into a liquid medium consisting of HMD A, water, caustic alkali base, and a catalyst, wherein the content of the base is in the range of 2-130 moles per mole of caustic alkali.
• U.S. Patent No. 4,885,391 describes a process for the hydrogenation of C 4 to C 12 nitriles using a Raney® cobalt catalyst promoted with chromium in which the catalyst activity is maintained by the addition of water. The process is carried out at a temperature of about 80° to 150 °C, and at a pressure of about 400 to 2500 psig, without the use of any caustic bases.
• U.S. Patent No. 4,967,006 describes the use of ammonia in alcohol instead of caustic base in order to have lower reaction pressures.
• the use of alcohol can be problematic, as it can sometimes be difficult to remove and recycle depending upon the alcohol used, and it can result in the formation of undesirable byproducts in the reaction.
• U.S. Patent No. 5,869,653 to Johnson describes a continuous process for hydrogenating nitrites over Raney® cobalt catalysts in the absence of ammonia, and in the presence of catalytic amounts of lithium hydroxide and water.
• the reduction of nitriles to amines is carried out under a hydrogen pressure of 1 to 300 bars, and at temperatures of 60° to 160 °C.
• the catalyst is either pre-treated with lithium hydroxide in order to achieve the desired catalytic effect, or the reaction is carried out with the lithium hydroxide present in the reaction medium itself.
• Elsasser describes an industrial batch process for the hydrogenation of organic nitrites to primary amines, using an aqueous alkali metal hydroxide, at least one Raney® catalyst, water, and hydrogen at temperatures between 150° and 220 °C and at hydrogen pressures between 250 and 2500 psi.
• the improvement to the process comprises eliminating the steps of drying the charge and adding water, and reducing the required water in the system to about 0.2%.
• EP 0316,761to Kiel and Bauer teaches that DMAPA can be made essentially free of the 1,3-propanediamine (PDA) by-product by using a sponge cobalt or nickel catalyst and a small amount of either calcium or magnesium oxide and ammonia in order to control the selectivity of the reaction in favor of the desired primary amine.
• PDA 1,3-propanediamine
• This patent also suggests that the process can be carried out at temperatures between 160 °C and 180 °C at 2200 psig with batch processing.
• U.S. Patent No. 6,281,388 to Goodwin, et al. describes a method for the production of amines from nitriles using hydrogenation.
• the method includes the steps of feeding both hydrogen and a nitrile into a reactor containing a catalyst, water, and an inorganic base, and mixing the reaction medium to provide a uniform bulk concentration of nitrile in at least one direction across the reactor in order to minimize reactor volume.
• the described process can be carried out at pressures of 20-50 atmospheres and 60-120 °C, using a Raney® nickel catalyst and an inorganic base.
• US Patent Application Publication No. 2002/0058841 to Ansmann, et al. describes the activation and use of a special macroporous, shaped Raney® catalyst based on an alpha- Al 2 O 3 alloy of aluminum and at least one transition metal for use in the hydrogenation of nitriles to primary amines.
• the nitrile hydrogenation is carried out in an organic solvent such as DMF or NMP at a pressure of 10 to 300 bar.
• the present invention is directed to an improved process for the low-pressure hydrogenation manufacture of dimethylaminopropylamme from 3-(dimethylamino)propionitrile with a selectivity greater than 99.50 %.
• the basic process comprises contacting the nitrile with hydrogen in the presence of a sponge nickel catalyst under conditions suitable to effect conversion of the nitrile group to a primary amine.
• the improvement in the hydrogenation process resides in effecting the hydrogenation in the presence of a sponge nickel catalyst incorporating inexpensive caustic hydroxide at low pressures (45-500 psig) and temperatures (70 - 100 °C).
• the reaction can be carried out with the caustic hydroxide dissolved in water and dispersed in the reaction medium.
• N-N-dimethylaminopropryamine is typically produced at the multi-billion pound per year level
• Industry's challenge is to produce the product in high yield and selectivity because at these high volumes, even a few tenths of a percent represents a significant byproduct removal and disposal problem.
• these byproducts can become unmanageable and costly to dispose of unless there is a commercial use for the byproducts. Consequently, it is beneficial to develop improved and optimized technology for controlling the selectivity and yield of the primary amine product during the hydrogenation of N,N-dimethylaminopropionitrile.
• the invention is directed to the process for the production of 3- dimethylaminopropylamine, it is applicable to any amine including aliphatic and aromatic amines and their derivatives, such as hexamethylene diamine, propyl amines, butyl amines, benzyl amines, tallow amines, ethyl amines, etc., produced from a nitrile including aliphatic and aromatic nitrites and their derivatives such as proprionitrile, butyronitriles, tallow nitrites, acetonitriles, benzyl nitrites, etc., in which finely divided catalyst is suspended in the liquid reaction medium.
• a nitrile including aliphatic and aromatic nitrites and their derivatives such as proprionitrile, butyronitriles, tallow nitrites, acetonitriles, benzyl nitrites, etc.
• a process for production of 3 -dimethylaminopropylamine in high yield and selectivity may be carried out at pressures of 45-500 psig, preferably 45-150 psig, and at temperatures of 70° to 100° C, by feeding hydrogen and nitrile into a liquid reaction medium containing, along with the amine produced, water, inorganic base and a finely divided nickel or cobalt catalyst dispersed in the liquid components of the reaction medium.
• the catalyst which preferably is sponge (e.g. Raney®) nickel, with or without promoter metals such as chromium and/or iron, loses some of its activity during hydrogenation.
• a key to the effectiveness of the low pressure diamine hydrogenation process of the present invention is the incorporation of an effective amount of an inexpensive caustic hydroxide in the sponge nickel catalyst to enhance the selectivity of the reaction.
• the hydroxide is preferably a hydroxide of a Group LA ("alkali metal") element of the periodic table, selected from the group consisting of lithium, sodium, potassium, rubidium, cesium, and mixtures thereof. More preferably, the caustic alkali metal hydroxide is sodium hydroxide, potassium hydroxide, cesium hydroxide, and mixtures thereof.
• the catalyst suitable for use in the present invention is a Raney® type catalyst, also known as "skeletal" or “sponge-type” metal catalysts. While both nickel and cobalt sponge catalysts are acceptable for use, it is preferred to use a Raney® nickel catalyst with the present invention due to the higher cost associated with the use of cobalt sponge catalysts.
• the nickel catalyst used in the low-pressure hydrogenation process of the present invention is sponge nickel, or as it is often referred to, Raney® nickel.
• the catalyst is commercially available from a number of sources (W.R. Grace and Co.; Degussa; Activated Metals), or it may be manufactured using any number of methods described in the literature, for instance by Mozingo in Organic Syntheses Collected Volume 3, p. 181; and Fieser and Fieser, Reagents for Organic Synthesis, Vol. 1, pp. 723-731 and references cited therein.
• An alternative catalyst which may be used with the present invention is a cobalt catalyst.
• Such a cobalt catalyst used in the low-pressure hydrogenation process of the present invention is sponge cobalt, also known as Raney® cobalt.
• the catalyst is also available commercially from a number of sources, and may be obtained synthetically using routes described in the literature.
• promoters may be incorporated into or included with the sponge catalyst in conventional amounts known to those of skill in the art.
• Examples of such promoters suitable for incorporation into the catalyst include Group Via and Group VIII metals such as chromium, iron, molybdenum, and the like.
• the N,N-dimethylaminopropionitrile (DMAPN) which is used as the starting material (feedstock) in the present invention can be obtained commercially from a variety of sources (Acros; Aldrich Chemical Co.).
• DMAPN can be obtained synthetically by any of the processes known in the art, such as from the reaction of acrylonitrile and dimethylamine.
• a process of this type, namely the reaction of dimethylamine with acrylonitrile in a blow column reactor, is described in German Patent Specification No. 27 09 966.
• the DMAPN is obtained from a commercial supplier and is significantly free of ft-propylamine and diaminopropane.
• the hydrogenation of DMAPN to DMAPA according to the present invention is conducted under conditions such that only a minimal amount of water is required for use within the reactor.
• the liquid portion of the reaction medium comprises two phases: an aqueous solution of inorganic base, and an aqueous solution of the catalyst.
• the amount of water suitable for use with the reduction process is between about 0.1 wt. % and about 10 wt. % of the weight of the reaction mixture, preferably about 2 wt. % of the reaction mixture.
• the preferred range ratio is 0.5 to 10 moles of water to 1 mole of caustic alkali.
• the reduction of the nitrile to the amine can be carried out under hydrogen pressures from as low as about 45 psig to as high as about 500 psig.
• the hydrogenation of DMAPN to DMAPA is preferably carried out under a hydrogen pressure of from 45 to 300 psig, more preferably at a pressure from 45 to 150 psig or at a pressure from 45 to 110 psig.
• the reduction of the nitrile to the amine is preferably carried out at temperatures of between about 70 °C to about 100 °C, more preferably at temperatures between about 80 °C to about 100 °C, and still more preferably at temperatures between 85 °C and 95 °C.
• the reduction of DMAPN to DMAPA is carried out at about 100 psig and about 90 °C.
• the process described herein for the hydrogenation of N,N- dimethylaminopropionitrile to N-N-dimethylaminopropylamine has the ability to effect the conversion of the nitrile group to the primary amine in surprisingly high selectivity and yield while minimizing or avoiding secondary amine byproduct formation over the course of the reaction. Consequently, the product amine, DMAPA, is produced with a selectivity of greater than 99.90%, and is produced in a yield of at least 99% (based on starting DMAPN). As described herein, selectivity refers to the amount of DMAPA formed from DMAPN, including the formation of byproducts that can be generated during the course of the reaction.
• the process of the present invention preferably exhibits a selectivity of at least 99.60 % of DMAPN to DMAPA, more preferably exhibits a selectivity of at least 99.70 % of DMAPN to DMAPA, and still more preferably exhibits a selectivity of at least 99.90 % of DMAPN to DMAPA.
• the yield of DMAPA produced according to the present invention is preferably at least 99 % based on starting DMAPN, and can be about 99.1 %, about 99.2 %, about 99.3 %, about 99.4 %, about 99.5 %, about 99.6 %, about 99.7 %, about 99.8 %, and about 99.9 % based on the starting nitrile.
• the process of the present invention exhibits a selectivity of at least 99.98% and in a yield of at least 99% from N,N-dimethylaminopropionitrile.
• the hydrogenation can be conducted in any conventional hydrogenation equipment suitable to effect the conversion.
• suitable equipment includes, but is not limited to, a stirred tank or loop reactor, a continuous stirred tank reactor, a continuous gas lift reactor, a fixed-bed reactor, a trickle-bed reactor, a bubble-column reactor, or a sieve-tray reactor.
• Preferred methods of operation include those described in U.S. Patent No. 6,281,388, which is incorporated herein in its entirety.
• the present invention is also envisioned to be applicable to other hydrogenation processes which typically use high pressures and temperatures and sponge, or Raney® -type catalysts.
• Specific examples of such processes which are envisioned to be applicable are those processes which utilize a mixture containing Raney® nickel catalyst and a strong caustic base.
• Such processes would be expected to yield improvements similar to those described herein for the low-pressure hydrogenation of DMAPN to DMAPA.
• the low-pressure hydrogenation of adiponitrile to hexamethylenediamine would be expected to yield similarly improved results.
• Caustic preparation begins with obtaining distilled water that has been boiled to remove dissolved carbon dioxide.
• Caustic solutions are prepared in about 25 wt. % in 100 gram batches by weight.
• the caustic KOH, NaOH, etc.
• the caustic is added to the degassed water ( ⁇ 60 mL) with stirring. After complete dissolution of the caustic, additional water is added to bring the weight of the solution to a total weight of 100 grams.
• the solution is filtered, and stored in a closed container until use in order to minimize adsorption of CO 2 from the air.
• Example 2 Hydro enation procedure.
• a one-liter autoclave reactor equipped with double turbine blades, dispersimax-type agitator, a coil extending to the bottom to circulate the transfer fluid from a temperature controlled bath for temperature control, and a fritted, stainless steel metal sample port below the liquid level is used to react hydrogen with 3-(dimethylamino)propionitrile.
• Hydrogen is fed from a cylinder equipped with a pressure gauge and a regulator to add hydrogen to the reactor when the pressure drops below the set pressure. The hydrogen flows though a mass flow meter.
• the 3-(dimethylamino)propionitrile (Acros) is pumped to the autoclave with an Isco Model 500D syringe pump.
• the caustic solution is a blend containing 50 wt. % sodium hydroxide and 50 wt. % potassium hydroxide.
• the agitator is turned on, and the autoclave heated to 60 °C.
• the autoclave is then purged three times with nitrogen, and then three times with hydrogen, before being pressurized to 7.805 atm with hydrogen.
• the autoclave is then heated to 90 °C, and the pressured checked and maintained for 5 minutes.
• reaction mixture was sampled after each cycle and analyzed for purity, reaction progress, and the presence and amount of by-products (if any) formed. Analysis was by gas chromatography (HP 5890 Series II; Phenomenex Zebron ZB-1 capillary column, Phenomenex Cat. No. 7HK-G001-36) with flame ionization detection in order to quantify the by-product impurities. Analysis of the cycles and the product are given in Table 1.
• Table 1 Product analysis, per cycle.
• Table 1 shows that the amount of secondary amine remains generally at or below 300 ppm over the course of the entire reaction when DMAPN was hydrogenated utilizing a sponge nickel catalyst and a Group LA alkali metal hydroxide according to the process of the present invention.
• the product 3- (dimethylamino)propylamine results in a molar yield of 99.98 % with a purity of >99 % and no TMPDA or other secondary amine impurity and less than 300 ppm of the secondary amine present in the final product.
• Tables 1 and 2 clearly show that the use of such alkali metal hydroxides as KOH, 5 CsOH, and mixtures of KOH/NaOH allowed the reaction to proceed to a high DMAPN conversion, e.g., a low DMAPN concentration remained in the product DMAPA within a reasonable time and also maintaining a high selectivity for the primary amine.
• the use of LiOH (run 5) showed a poor improvement in the amount of side-product formation using the same catalyst as in the other tests.
• KOH, CsOH, and mixtures of KOH/NaOH are most effective as alkali metal hydroxides.

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• 2003
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