US20040110999A1 - Integrated dimerization process - Google Patents
Integrated dimerization process Download PDFInfo
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- US20040110999A1 US20040110999A1 US10/314,567 US31456702A US2004110999A1 US 20040110999 A1 US20040110999 A1 US 20040110999A1 US 31456702 A US31456702 A US 31456702A US 2004110999 A1 US2004110999 A1 US 2004110999A1
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- olefins
- dimerization
- vinyl
- product mixture
- chain growth
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- 238000000034 method Methods 0.000 title claims abstract description 56
- 230000008569 process Effects 0.000 title claims abstract description 49
- 238000006471 dimerization reaction Methods 0.000 title claims description 52
- -1 vinyl olefins Chemical class 0.000 claims abstract description 119
- 229920002554 vinyl polymer Polymers 0.000 claims abstract description 109
- 230000000447 dimerizing effect Effects 0.000 claims abstract description 11
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 claims description 54
- 239000000203 mixture Substances 0.000 claims description 48
- 238000006073 displacement reaction Methods 0.000 claims description 43
- 150000001336 alkenes Chemical class 0.000 claims description 41
- 229910052782 aluminium Inorganic materials 0.000 claims description 39
- 125000002573 ethenylidene group Chemical group [*]=C=C([H])[H] 0.000 claims description 34
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims description 33
- 239000005977 Ethylene Substances 0.000 claims description 33
- GGQQNYXPYWCUHG-RMTFUQJTSA-N (3e,6e)-deca-3,6-diene Chemical compound CCC\C=C\C\C=C\CC GGQQNYXPYWCUHG-RMTFUQJTSA-N 0.000 claims description 32
- 239000003054 catalyst Substances 0.000 claims description 29
- 238000006243 chemical reaction Methods 0.000 claims description 28
- 125000005234 alkyl aluminium group Chemical group 0.000 claims description 18
- 230000015572 biosynthetic process Effects 0.000 claims description 15
- 125000000217 alkyl group Chemical group 0.000 claims description 14
- 125000004432 carbon atom Chemical group C* 0.000 claims description 14
- 239000007788 liquid Substances 0.000 claims description 11
- 238000004519 manufacturing process Methods 0.000 claims description 10
- 230000006872 improvement Effects 0.000 claims description 3
- 239000000047 product Substances 0.000 description 59
- 235000010210 aluminium Nutrition 0.000 description 40
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 20
- 239000000539 dimer Substances 0.000 description 20
- KWKAKUADMBZCLK-UHFFFAOYSA-N 1-octene Chemical compound CCCCCCC=C KWKAKUADMBZCLK-UHFFFAOYSA-N 0.000 description 16
- AFFLGGQVNFXPEV-UHFFFAOYSA-N 1-decene Chemical compound CCCCCCCCC=C AFFLGGQVNFXPEV-UHFFFAOYSA-N 0.000 description 8
- TVMXDCGIABBOFY-UHFFFAOYSA-N n-Octanol Natural products CCCCCCCC TVMXDCGIABBOFY-UHFFFAOYSA-N 0.000 description 8
- VOITXYVAKOUIBA-UHFFFAOYSA-N triethylaluminium Chemical compound CC[Al](CC)CC VOITXYVAKOUIBA-UHFFFAOYSA-N 0.000 description 7
- 239000000178 monomer Substances 0.000 description 6
- 230000035484 reaction time Effects 0.000 description 6
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 6
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 5
- 229910052799 carbon Inorganic materials 0.000 description 5
- 238000006317 isomerization reaction Methods 0.000 description 5
- LFXVBWRMVZPLFK-UHFFFAOYSA-N trioctylalumane Chemical compound CCCCCCCC[Al](CCCCCCCC)CCCCCCCC LFXVBWRMVZPLFK-UHFFFAOYSA-N 0.000 description 5
- LIKMAJRDDDTEIG-UHFFFAOYSA-N 1-hexene Chemical compound CCCCC=C LIKMAJRDDDTEIG-UHFFFAOYSA-N 0.000 description 4
- HFDVRLIODXPAHB-UHFFFAOYSA-N 1-tetradecene Chemical compound CCCCCCCCCCCCC=C HFDVRLIODXPAHB-UHFFFAOYSA-N 0.000 description 4
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 4
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical compound [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 description 4
- SQBBHCOIQXKPHL-UHFFFAOYSA-N tributylalumane Chemical compound CCCC[Al](CCCC)CCCC SQBBHCOIQXKPHL-UHFFFAOYSA-N 0.000 description 4
- 0 *C([1*])=C Chemical compound *C([1*])=C 0.000 description 3
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 3
- 150000001875 compounds Chemical class 0.000 description 3
- 238000004821 distillation Methods 0.000 description 3
- 239000001257 hydrogen Substances 0.000 description 3
- 229910052739 hydrogen Inorganic materials 0.000 description 3
- 239000000314 lubricant Substances 0.000 description 3
- 239000011541 reaction mixture Substances 0.000 description 3
- 125000000383 tetramethylene group Chemical group [H]C([H])([*:1])C([H])([H])C([H])([H])C([H])([H])[*:2] 0.000 description 3
- MCULRUJILOGHCJ-UHFFFAOYSA-N triisobutylaluminium Chemical compound CC(C)C[Al](CC(C)C)CC(C)C MCULRUJILOGHCJ-UHFFFAOYSA-N 0.000 description 3
- VXNZUUAINFGPBY-UHFFFAOYSA-N 1-Butene Chemical compound CCC=C VXNZUUAINFGPBY-UHFFFAOYSA-N 0.000 description 2
- ZGEGCLOFRBLKSE-UHFFFAOYSA-N 1-Heptene Chemical compound CCCCCC=C ZGEGCLOFRBLKSE-UHFFFAOYSA-N 0.000 description 2
- CRSBERNSMYQZNG-UHFFFAOYSA-N 1-dodecene Chemical compound CCCCCCCCCCC=C CRSBERNSMYQZNG-UHFFFAOYSA-N 0.000 description 2
- GQEZCXVZFLOKMC-UHFFFAOYSA-N 1-hexadecene Chemical compound CCCCCCCCCCCCCCC=C GQEZCXVZFLOKMC-UHFFFAOYSA-N 0.000 description 2
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 230000002411 adverse Effects 0.000 description 2
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- 238000005094 computer simulation Methods 0.000 description 2
- 230000010354 integration Effects 0.000 description 2
- 229910052757 nitrogen Inorganic materials 0.000 description 2
- 239000003921 oil Substances 0.000 description 2
- YWAKXRMUMFPDSH-UHFFFAOYSA-N pentene Chemical compound CCCC=C YWAKXRMUMFPDSH-UHFFFAOYSA-N 0.000 description 2
- USJZIJNMRRNDPO-UHFFFAOYSA-N tris-decylalumane Chemical compound CCCCCCCCCC[Al](CCCCCCCCCC)CCCCCCCCCC USJZIJNMRRNDPO-UHFFFAOYSA-N 0.000 description 2
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 2
- 239000004711 α-olefin Substances 0.000 description 2
- GNFTZDOKVXKIBK-UHFFFAOYSA-N 3-(2-methoxyethoxy)benzohydrazide Chemical compound COCCOC1=CC=CC(C(=O)NN)=C1 GNFTZDOKVXKIBK-UHFFFAOYSA-N 0.000 description 1
- FGUUSXIOTUKUDN-IBGZPJMESA-N C1(=CC=CC=C1)N1C2=C(NC([C@H](C1)NC=1OC(=NN=1)C1=CC=CC=C1)=O)C=CC=C2 Chemical compound C1(=CC=CC=C1)N1C2=C(NC([C@H](C1)NC=1OC(=NN=1)C1=CC=CC=C1)=O)C=CC=C2 FGUUSXIOTUKUDN-IBGZPJMESA-N 0.000 description 1
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- 239000004435 Oxo alcohol Substances 0.000 description 1
- 239000003905 agrochemical Substances 0.000 description 1
- 150000001298 alcohols Chemical group 0.000 description 1
- 125000001931 aliphatic group Chemical group 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
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- 230000003197 catalytic effect Effects 0.000 description 1
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- 239000003599 detergent Substances 0.000 description 1
- 229940069096 dodecene Drugs 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 230000009977 dual effect Effects 0.000 description 1
- 125000001495 ethyl group Chemical group [H]C([H])([H])C([H])([H])* 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000002816 fuel additive Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 150000004678 hydrides Chemical class 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 125000001183 hydrocarbyl group Chemical group 0.000 description 1
- 125000004435 hydrogen atom Chemical group [H]* 0.000 description 1
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 1
- 239000003879 lubricant additive Substances 0.000 description 1
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- SFMJNHNUOVADRW-UHFFFAOYSA-N n-[5-[9-[4-(methanesulfonamido)phenyl]-2-oxobenzo[h][1,6]naphthyridin-1-yl]-2-methylphenyl]prop-2-enamide Chemical compound C1=C(NC(=O)C=C)C(C)=CC=C1N1C(=O)C=CC2=C1C1=CC(C=3C=CC(NS(C)(=O)=O)=CC=3)=CC=C1N=C2 SFMJNHNUOVADRW-UHFFFAOYSA-N 0.000 description 1
- 229910052754 neon Inorganic materials 0.000 description 1
- GKAOGPIIYCISHV-UHFFFAOYSA-N neon atom Chemical compound [Ne] GKAOGPIIYCISHV-UHFFFAOYSA-N 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 238000006772 olefination reaction Methods 0.000 description 1
- 238000006384 oligomerization reaction Methods 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
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- 125000006238 prop-1-en-1-yl group Chemical group [H]\C(*)=C(/[H])C([H])([H])[H] 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
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- 239000004094 surface-active agent Substances 0.000 description 1
- JVIKNVRZMNQFFL-UHFFFAOYSA-N tri(tetradecyl)alumane Chemical compound CCCCCCCCCCCCCC[Al](CCCCCCCCCCCCCC)CCCCCCCCCCCCCC JVIKNVRZMNQFFL-UHFFFAOYSA-N 0.000 description 1
- XBEXIHMRFRFRAM-UHFFFAOYSA-N tridodecylalumane Chemical compound CCCCCCCCCCCC[Al](CCCCCCCCCCCC)CCCCCCCCCCCC XBEXIHMRFRFRAM-UHFFFAOYSA-N 0.000 description 1
- RFRNCCDBLKNKEQ-UHFFFAOYSA-N triethylalumane;tris(2-methylpropyl)alumane Chemical compound CC[Al](CC)CC.CC(C)C[Al](CC(C)C)CC(C)C RFRNCCDBLKNKEQ-UHFFFAOYSA-N 0.000 description 1
- ORYGRKHDLWYTKX-UHFFFAOYSA-N trihexylalumane Chemical compound CCCCCC[Al](CCCCCC)CCCCCC ORYGRKHDLWYTKX-UHFFFAOYSA-N 0.000 description 1
- 239000013638 trimer Substances 0.000 description 1
- JLTRXTDYQLMHGR-UHFFFAOYSA-N trimethylaluminium Chemical compound C[Al](C)C JLTRXTDYQLMHGR-UHFFFAOYSA-N 0.000 description 1
- 229930195735 unsaturated hydrocarbon Natural products 0.000 description 1
- 238000004457 water analysis Methods 0.000 description 1
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C11/00—Aliphatic unsaturated hydrocarbons
- C07C11/02—Alkenes
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C2/00—Preparation of hydrocarbons from hydrocarbons containing a smaller number of carbon atoms
- C07C2/86—Preparation of hydrocarbons from hydrocarbons containing a smaller number of carbon atoms by condensation between a hydrocarbon and a non-hydrocarbon
- C07C2/88—Growth and elimination reactions
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C2531/00—Catalysts comprising hydrides, coordination complexes or organic compounds
- C07C2531/02—Catalysts comprising hydrides, coordination complexes or organic compounds containing organic compounds or metal hydrides
- C07C2531/12—Catalysts comprising hydrides, coordination complexes or organic compounds containing organic compounds or metal hydrides containing organo-metallic compounds or metal hydrides
- C07C2531/14—Catalysts comprising hydrides, coordination complexes or organic compounds containing organic compounds or metal hydrides containing organo-metallic compounds or metal hydrides of aluminium or boron
Definitions
- the present invention relates to a process for dimerizing vinyl olefins and more particularly relates to such a dimerization process which is fully integrated into a process for manufacturing vinyl olefins.
- Vinylidene olefins are of commercial importance as raw materials for use in producing double tailed oxo alcohols and other functionalized derivatives, used in the manufacture of detergents, surfactants, specialty agricultural chemicals, and fuel or lubricant additives.
- Vinylidenes may also dimerized using a Friedel Crafts catalyst to form valuable synthetic lubricants as described in Shubkin, U.S. Pat. No. 4,172,855.
- Vinylidenes can be produced by dimerizing vinyl olefins. As described in Ziegler, U.S. Pat. No.
- vinyl olefins can be dimerized using an alkyl aluminum catalyst to form vinylidenes primarily and a much smaller amount of a non-vinylidene dimer referred to herein as a “deep internal dimer.” Vinylolefins can also be dimerized to form “deep internal olefin dimers” primarily using a catalyst such as a Friedel Crafts catalyst (for example, BF 3 ). The present invention is not concerned with such Friedel Crafts catalyzed dimerizations.
- Lin et al. U.S. Pat. No. 4,973,788 (Nov. 27, 1990) describes a process for dimerizing a vinyl olefin monomer at a selectivity of at least 85 mole percent. This is accomplished by the use of a catalyst which consists essentially of 0.001-0.04 mole of trialkylaluminum per mole of vinyl olefin, and conducting the reaction at a temperature in the range of about 100°-140° C. for a time sufficient to convert at least 80 mole percent of the initial vinyl olefin to a different product.
- the reaction rate under these conditions is quite slow, and thus a long reaction time is required. For example, it is pointed out that the time required for 90 percent conversion at 120° C.
- Lin et al. U.S. Pat. No. 5,625,105 (Apr. 29, 1997) discloses that vinyl olefins can be dimerized to vinylidenes in good yield and in shorter reaction periods than those reported in the aforesaid Lin et al. U.S. Pat. No. 4,973,788 by using a trialkyl aluminum catalyst in the range of 0.001 to 0.05 mole of catalyst per mole of initial vinyl olefin at a temperature of 140° to 170° C.
- Krzystowczyk et al. U.S. Pat. No. 5,663,469 (Sep. 2, 1997), discloses the formation of vinylidene olefins in good yield and high selectivity and in shorter reaction periods through the use of 0.001 to 0.5 mole of trialkyl aluminum catalyst per mole of the initial vinyl olefin, at a temperature of 100° to 200° C., provided that the reaction mixture is in direct contact with a nickel-containing metal alloy surface for at least one hour at a temperature above about 50° C. and that at least one acetylenic hydrocarbon is added to the reaction mixture prior to such contact in an amount that is at least sufficient to inhibit double bond isomerization in the reaction mixture but insufficient to inhibit formation.
- the present invention is an improvement in a process for manufacturing vinyl olefins containing from 4 to 30 carbon atoms, comprising: (1) reacting ethylene in a chain growth reaction in the presence of an alkyl aluminum chain growth catalyst in at least one chain growth step (2) displacing the alkyl moieties of the resulting alkyl aluminum chain growth product to form a displacement product mixture comprising the corresponding vinyl olefins formed from the alkyl moieties in at least one displacement step; (3) fractionating the displacement product mixture from at least one aforesaid displacement step to separate a liquid fraction comprising vinyl olefins containing from 4 to 30 carbon atoms; and (4) fractionating the resulting liquid fraction to separate therefrom a lower molecular weight fraction comprising the aforesaid vinyl olefins.
- the improvement comprises: (5) dimerizing vinyl olefins to form vinylidenes and deep internal olefins in the presence of a dimerization catalyst comprising alkyl aluminum at a initial molar ratio of alkyl aluminum to vinyl olefin of from about 0.01:1 to about 1.5:1 and at a temperature in the range of from 200° C. to about 288° C.
- a dimerization catalyst comprising alkyl aluminum at a initial molar ratio of alkyl aluminum to vinyl olefin of from about 0.01:1 to about 1.5:1 and at a temperature in the range of from 200° C. to about 288° C.
- FIG. 1 is a plot of the selectivities for the formation of vinylidenes from the dimerization of vinyl olefin versus reaction temperatures at each of five different initial mole ratios of dimerization catalyst to the vinyl olefin and at a reaction time of 30 minutes derived from a computer simulation of the dimerization.
- FIG. 2 is a schematic illustration of several preferred embodiments of the integration of the process for dimerizing vinyl olefins with a process for producing vinyl olefins and introducing into the process for producing vinyl olefins the entire dimerization product mixture.
- FIG. 3 is a schematic illustration of additional preferred embodiments of the integration of the process for dimerizing vinyl olefins with a process for producing vinyl olefins and introducing into the process for producing vinyl olefins a heavier fraction of the dimerization product mixture.
- olefins are referred to as “vinyl olefins” or R—CH ⁇ CH 2 ; “vinylidene olefins” or
- R, R 1 , R 2 and R 3 represent a hydrocarbyl group.
- Internal olefins are also classified as “beta-internal olefins” in which the double bond is connected to the beta-carbon atom as in:
- R 1′ and R 2′ are different by two or four carbon numbers and are aliphatic hydrocarbon groups containing two or more carbon atoms.
- the “beta-internal olefins” referred to herein are monomeric. This means they contain the same number of carbon atoms as the initial vinyl-olefins from which they are formed but the olefinic double bond has moved toward the center of the molecule, by just one carbon number (i.e., the double bond is at the second carbon number).
- the “deep internal olefins” referred to herein are dimers of the initial vinyl olefins from which they are formed.
- a deep internal dimer of 1-octene contains 16 carbon atoms. They differ from vinylidene dimers in that their olefinic double bond is in the linear chain near the center of the molecule.
- the vinylidene olefins are useful when oligomerized as oils. Depending on their viscosity, different applications for such oils are known, for example, as lubricants. These materials are mixtures of different percentages of dimer, trimer, tetramer, pentamer and higher oligomers which oligomers ae produced in different proportions in the oligomerization process. Due to the increasing use of dimers, both vinylidenes and the aforesaid “deep internal olefins,” in applications such as low temperature lubricants and drilling fluids, methods for the preferential production of both types of dimers are of interest.
- the olefins that are dimerized to make such dimers are predominately (at least 50 mole percent) C 4 to C 20 straight- or branched-chain monoolefinically unsaturated hydrocarbon (but not less than 5 mole percent) in which the olefinic unsaturation occurs at the 1- or alpha-position of the carbon chain. Typically they have the following formula
- R 2 is hydrogen or alkyl, that is, C 1 to C 16 linear or branched alkyl, preferably C 1 to C 6 linear or branched alkyl, most preferably C 1 to C 4 linear or branched alkyl, for example, methyl, ethyl and the like, and m is an integer from 0 to 18.
- Linear alpha-olefins are commercially available and can be made by the well-known Ziegler ethylene chain growth and displacement on trialkyl aluminum. Individual olefins may be used as well as mixtures of such olefins. Examples of suitable olefins are 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, 1-dodecene, 1-hexadecene and 1-tetradecene. The more preferred normal alpha-olefin monomers are those containing about 6-18 carbon atoms.
- the vinyl olefins used in the process will contain in the range of about 3 to about 30 or more carbon atoms per molecule.
- the initial vinyl olefin will contain preferably in the range of 4 to 20, and more preferably in the range of 6 to 18 carbon atoms per molecule.
- mixtures of vinyl olefins are entirely suitable. In such case co-dimerization takes place.
- any straight chain or branched chain trialkylaluminum compound can used as the catalytic component charged to the dimerization reaction zone in the practice of this invention.
- a trialkyaluminum catalyst is employed for both the chain growth and dimerization steps.
- the alkyl groups will contain from 1 to 30 carbon atoms, and preferably in the range of 2 to about 18 carbon atoms each.
- trialkyaluminum compounds such as triethylaluminum tri-isobutyl aluminum, tributylaluminum, trihexylaluminum, trioctylaluminum, tris(decyl)aluminum, tris(tetradecyl) aluminum, and the like.
- Mixtures of aluminum trialkyls can be also used if desired.
- the hydride content, if any, of the aluminum trialkyl should be quite low, for example, the aluminum trialkyl should have a maximum aluminum hydride equivalent of not more than about 0.8 weight percent.
- the aluminum trialkyl as fed to the process is essentially hydride-free, that is, the trialkylaluminum product contains, if any, a maximum of 0.10 weight percent of aluminum hydride equivalent, and more preferably a maximum of 0.05 weight percent of aluminum hydride equivalent, because the aluminum hydride bond can cause isomerization of 1-olefins to internal olefins.
- the preferred aluminum alkyls are the tri-C 1-12 alkyl aluminum such as trimethyl aluminum, triethyl aluminum, tributyl aluminum, tri-isobutyl aluminum, trioctyl aluminum, tridecyl aluminum, tridodecyl aluminum and the like including mixtures thereof.
- the more preferred aluminum alkyls are the higher aluminum alkyl such as the tri-C 4-10 alkyl aluminum.
- the alkyls bonded to aluminum have the same or close to the same number of carbon atoms as the vinyl olefin starting material.
- tri-n-octyl aluminum is the most preferred catalyst for dimerizing 1-octene.
- the reaction should be conducted in an environment that is essentially anhydrous and substantially free of oxygen and air.
- Aluminum trialkyls can react violently with water or compounds containing hydroxyl groups such as alcohols. Thus even a small amount of water, alcohol, or the like, in the system will inactivate some of the aluminum trialkyl.
- the amount of aluminum alkyl catalyst can be increased in order to compensate for the water or other active hydrogen component such as alcohol whereby the proper amount of active aluminum trialkyl catalyst remains in the system even after part of the initial aluminum alkyl has been destroyed by the water or other active hydrogen compound.
- the olefin feed can be pretreated to remove water or alcohol contamination.
- the process should be conducted under a dry inert atmosphere, for example, nitrogen, argon, neon, or the like, to prevent catalyst destruction.
- the dimerization is performed at an initial mole ratio of aluminum alkyl to vinyl olefin in the range of from about 0.01:1, preferably from about 0.6:1, to about 1.5:1, preferably to about 1.0:1, at a temperature in the range of from about 200° C., to about 288° C., preferably to about 260° C., more preferably to about 232° C. and for the period of time in the range of from about 30 to about 120 minutes.
- the conditions are selected to convert initial vinyl olefins at a selectivity for the formation of the combination of vinylidenes and deep internal olefins of at least 50 mole percent, preferably at least 70 mole percent, more preferably at least 80 mole percent.
- FIG. 1 contains plots from a computer simulation of the conversion of 1-octene to vinylidenes and deep internal olefins having 16 or 18 carbon atoms versus reaction temperature and at a reaction time of 30 minutes at each of 5 different initial mole ratios of aluminum alkyl to vinyl olefin.
- the plots illustrate that the maximum selectivities for the formation of the combination of C 16-18 vinylidenes and deep internal olefins are in the range of from about 80 to about 86 weight percent of initial vinyl olefin converted to the combination of C 16-18 vinylidenes and deep internal olefins, that this maximum conversion to the combination of C 16-18 vinylidenes and deep internal olefins takes place at a temperature in the range of 205° C. to 260° C., and that the temperature for this maximum conversion decreases within this range as the initial mole ratio of aluminum alkyl to vinyl olefin increases.
- the dimerization product mixture comprises dimers (both vinylidenes and deep internal olefins), unreacted vinyl olefins, and internal monomeric olefins that are isomers of the initial vinyl olefins. Part or all of the mixture is introduced to the process for making vinyl olefins in the method of this invention.
- the high rate of the dimerization reaction and the high yield of the combination of C 16-18 vinylidenes and deep internal olefins under the conditions employed in the present invention permit the use of smaller vessels and shorter holdup times for the dimerization reaction and thereby permits the dimerization to be incorporated as a step into the process for manufacturing vinyl olefins.
- the product mixture from the dimerization step comprises dimer products (both vinylidenes and deep internal olefins) unreacted vinyl olefins and deep internal olefins, of which all or part is incorporated into the feed to some step of the process for making vinyl olefins.
- dimer products both vinylidenes and deep internal olefins
- unreacted vinyl olefins and deep internal olefins
- ethylene is oligomerized on a trialkyl aluminum, typically triethylaluminum, in a continuous stoichiometric chain growth reactor at 120-150° C. and 14-21 MPa (140-210 atmospheres) for about an hour.
- Unreacted ethylene and other light olefins then separated by flashing and aluminum alkyl products are passed to a displacement step in which a low molecular weight alkene, typically ethylene or butylene, is used to displace the alkyl groups on the aluminum alkyl products, and the initial trialkyl aluminum, typically triethyl aluminum, is regenerated.
- This displacement step is performed at 280-320° C. and 1.0 MPa (10 atmospheres) with a minimum contact time.
- the alkyl groups on the aluminum alkyl products are displaced in this step primarily as vinyl olefins with small amounts of internal olefins that are monomeric isomers of the vinyl olefins.
- the aforesaid vinyl olefins can be separated from trialkyl aluminum and recovered at various stages in the process. If not removed at this juncture, the vinyl olefins can be treated in a second chain growth step and thereby converted to longer chain alkyl groups in higher molecular weight aluminum alkyl products. After removal of unreacted ethylene and other light olefins, these higher molecular weight aluminum alkyl products can then be treated in second displacement step, as described above, whereby the longer chain alkyl groups are displaced as longer chain vinyl olefins. These longer chain vinyl olefins can be separated from trialkyl aluminum and recovered or can be treated in another chain growth step. Thus, vinyl olefins produced in this process can be removed and recovered before or after one or more additional chain growth steps.
- step a triethyl aluminum and ethylene are fed to a first ethylene chain growth reaction zone maintained under ethylene chain growth conditions to form a first chain growth product. Unreacted ethylene is separated (step b) from the first chain growth product mixture to form an ethylene-depleted first chain growth product, which is then distilled (step c), whereby C 4-14 vinyl olefins are distilled from the ethylene-depleted first chain growth product leaving a bottoms fraction or stream comprising mainly poisson distributed tri-C 2-20+ alkyl aluminum and C 14+ vinyl olefins.
- At least part of the bottom fraction or stream is then conveyed (step d) to an ethylene or C 4-8 olefin displacement zone maintained under displacement conditions and feeding ethylene or C 4-8 olefins, to the displacement zone thereby forming an ethylene- or C 4-8 olefin-displaced product, respectively, comprising mainly triethyl or tri-C 4-8 alkyl aluminum, ethylene and C 4-20 vinyl olefins.
- the resulting ethylene- or C 4-8 olefin displaced product is next conveyed (step e) to a second ethylene chain growth reaction zone maintained under chain growth conditions and feeding ethylene to the second ethylene chain growth reaction zone to thereby form a second chain growth product comprising mainly ethylene, C 4-20 vinyl olefins and poisson distributed tri-C 4-20 alkyl aluminums.
- Ethylene is then (step f) vaporized from the second chain growth product forming an ethylene-depleted second chain growth product, which is then (step g) distilled to separate C 4-14 vinyl olefins as overhead and leaving a bottoms fraction or stream comprising mainly poisson distributed tri-C 2-20+ alkyl aluminum and C 14+ vinyl olefins.
- Another preferred embodiment of the process for making vinyl olefins in the method of the present invention includes both a C 4-8 olefin displacement loop and an ethylene displacement loop.
- any C 4-8 olefin formed in either loop can be used as feed olefin to a C 4-8 olefin displacement reactor.
- This dual loop process includes steps (a) through (g) as stated above and also includes the additional steps (h), (i) and (j).
- step (h) a portion of the bottoms stream from step (c) is charged to an ethylene displacement zone maintained under displacement conditions, and ethylene is fed to this displacement zone thereby forming an ethylene-displaced product comprising mainly triethyl aluminum, ethylene and C 4-20+ vinyl olefins.
- step (i) C 2-12 vinyl olefins are distilled from the ethylene-displaced product forming a bottoms fraction or stream comprising mainly triethyl aluminum and C 14+ vinyl olefins.
- this bottoms fraction or stream is recycled to the first ethylene chain growth reaction zone as described above.
- ethylene and chain growth catalyst are introduced through lines 11 and 12 , respectively, into the chain growth reactor 13 from which the chain growth product mixture comprising chain growth product and unreacted ethylene is withdrawn through line 14 .
- Unreacted ethylene is separated from the chain growth product mixture using a conventional separator 15 such as a distillation column and removed through line 16 .
- the ethylene-depleted chain growth product mixture comprising mainly poisson distributed alkyl aluminum chain growth product is then passed through line 17 to a displacement reactor 18 which is maintained under displacement conditions.
- This displacement product mixture is withdrawn from the displacement reactor 18 through line 20 .
- Ethylene, butylene and other light olefins are then removed from the displacement reactor mixture using a separator 21 , typically a distillation column, and withdrawn through line 22 .
- the remaining displacement product mixture is fed through line 23 to a gas liquid separator 24 wherein a gaseous fraction comprising trialkyl aluminums is separated and withdrawn through line 25 .
- the liquid fraction comprising the desired vinyl olefin products in withdrawn through line 26 to a distillation column 27 where they are separated into lighter and heavier fractions.
- the lighter fraction comprising vinyl olefins is withdrawn through line 28 and a heavier fraction is withdrawn through line 29 .
- Vinyl olefin and dimerization catalyst are introduced through lines 30 and 31 into dimerization reactor 32 from which the dimerization product mixture comprising dimeric vinylidenes, dimeric deep internal olefins, monomeric internal olefins and monomeric unreacted vinyl olefins is withdrawn through line 34 .
- the dimerization product mixture is then fed in its entirety (a) through line 35 to and combined in line 11 with the feed to the chain growth reaction 13 , (b) through line 36 to and combined in line 14 with the chain growth product (c) through line 37 to and combined in line 17 with the feed to the displacement reactor 18 , or (d) through line 38 to and combined in line 20 with the displacement product mixture.
- These alternatives are indicated by broken lines 35 , 36 , 37 and 38 .
- FIG. 3 illustrates another series of alternatives in which the dimerization product mixture is conducted from the dimerization reactor 32 through line 34 and introduced into a vapor/liquid separator 40 , from which the vapor fraction is withdrawn through line 41 and the liquid fraction which comprises olefin dimers and aluminum alkyls is withdrawn through line 42 and (a 1 ) conducted through line 43 to and combined in line 11 with the feed to the chain growth reactor 13 , (b 1 ) conducted throught line 44 to and combined in line 14 with the chain growth product, (c 1 ) through line 45 to and combined in line 17 with the feed to the displacement reactor 18 , or (d 1 ) through line 46 to and combined in line 20 with the displacement product mixture.
- These alternatives are indicated by broken lines 43 , 44 , 45 and 46 . All processing elements in FIG. 3 which correspond to processing elements in FIG. 2 are identified by the same numerals and perform the same function,
- either all or at least the liquid fraction of the dimerization product mixture is combined with either (1) the feed to or (2) product mixture from the chain growth reactor or (3) the feed to or (4) product mixture form the displacement reactor.
- the entire dimerization product mixture is recovered, and much of the recovered amount is utilized in the process for manufacturing vinyl olefins.
- the chain length of at least some components of the dimerization product mixture can be altered in the chain growth or displacement step, and/or the combination of the dimerization product mixture with the particular stream in the vinyl olefin manufacturing process can afford the desired carbon number distribution.
- Such combination also permits the maximum dimerization operating temperatures and dimer production rates to be used because they are no loner limited by the amount of by-product olefins as a result of the unreacted vinyl olefins from the dimerization step.
- the dimers are withdrawn from the process through line 29 .
- a glass pressure vessel was dried and purged with nitrogen and then charged with varying amounts of one or more vinyl olefins and of one or more trialkyl aluminums and heated at various temperatures in excess of 200° C. for varying periods of time.
- the amounts of vinyl olefins and trialkyl aluminum and the reaction temperatures and times in each example are indicated in Table 1.
- the weight percent of vinyl olefin converted and the selectivities for the formation of C 16 dimer (both vinylidines and deep internal C 16 olefins combined), internal C 8 olefins, branched C 8 paraffins are also presented in Table 1.
- the selectivites are determined as the weight percent of the particular product produced per the weight percent of feed that is converted.
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Abstract
Description
- 1. Field of the Invention
- The present invention relates to a process for dimerizing vinyl olefins and more particularly relates to such a dimerization process which is fully integrated into a process for manufacturing vinyl olefins.
- 2. Discussion of the Prior Art
- Vinylidene olefins are of commercial importance as raw materials for use in producing double tailed oxo alcohols and other functionalized derivatives, used in the manufacture of detergents, surfactants, specialty agricultural chemicals, and fuel or lubricant additives. Vinylidenes may also dimerized using a Friedel Crafts catalyst to form valuable synthetic lubricants as described in Shubkin, U.S. Pat. No. 4,172,855. Vinylidenes can be produced by dimerizing vinyl olefins. As described in Ziegler, U.S. Pat. No. 2,695,327 vinyl olefins can be dimerized using an alkyl aluminum catalyst to form vinylidenes primarily and a much smaller amount of a non-vinylidene dimer referred to herein as a “deep internal dimer.” Vinylolefins can also be dimerized to form “deep internal olefin dimers” primarily using a catalyst such as a Friedel Crafts catalyst (for example, BF3). The present invention is not concerned with such Friedel Crafts catalyzed dimerizations.
- Numerous processes for dimerizing vinyl olefins to form vinylidenes have been disclosed. Shubkin et al., U.S. Pat. No. 4,172,855 (Oct. 30, 1979), discloses alkyl aluminum compounds as preferred catalysts for such dimerization and at a useful level of 0.1 to 10 weight percent based on the weight of the vinyl olefin and over a wide temperature range of about 50°-250° C. or higher depending on the particular catalyst employed. In one example, approximately 85 percent of 1-octene at an initial weight of 400 grams was converted after reacting over a weekend at 120-130° C. in the presence of 38.5 milliliters of tri-n-butyl aluminum
- Lin et al., U.S. Pat. No. 4,973,788 (Nov. 27, 1990) describes a process for dimerizing a vinyl olefin monomer at a selectivity of at least 85 mole percent. This is accomplished by the use of a catalyst which consists essentially of 0.001-0.04 mole of trialkylaluminum per mole of vinyl olefin, and conducting the reaction at a temperature in the range of about 100°-140° C. for a time sufficient to convert at least 80 mole percent of the initial vinyl olefin to a different product. The reaction rate under these conditions is quite slow, and thus a long reaction time is required. For example, it is pointed out that the time required for 90 percent conversion at 120° C. with 0.043 mole of aluminum alkyl catalyst per mole of initial vinyl olefin is about 94 hours, and that with 0.017 mole of the catalyst per mole of initial vinyl olefin the time required at 120° C. is about 192 hours. It is also shown in the patent that, although the reaction is faster at 172° C. compared to 120° C., the selectivity to vinylidene dimer is only 71 percent compared to 90 percent with the same catalyst concentration but at 120° C. Similarly the selectivity of the conversion of the vinyl olefin to form vinylidene dimer decreased sharply as the catalyst concentration was increased above 0.043 (and up to 0.67) mole of catalyst per mole of initial vinyl olefin. The patent states that the use of larger amounts of aluminum alkyls result in the formation of unacceptably large quantities of internal olefins, both monomeric and dimeric.
- In the presence of aluminum alkyl, vinyl olefins are dimerized to vinylidene olefins via the Markovnikov route. However, a competing reaction which adversely affects the yield of vinylidene olefin or the purity thereof is the isomerization of the vinylidene dimer to deep internal olefin dimer via the anti-Markovnikov route. Another undesirable competing reaction which normally tends to occur at dimerization temperatures is the isomerization of the vinyl olefin monomer to internal isomer olefin monomer via a aluminum hydride route or by other known mechanisms. Such internal olefin formation adversely affects the dimer selectivity.
- Lin et al., U.S. Pat. No. 5,625,105 (Apr. 29, 1997) discloses that vinyl olefins can be dimerized to vinylidenes in good yield and in shorter reaction periods than those reported in the aforesaid Lin et al. U.S. Pat. No. 4,973,788 by using a trialkyl aluminum catalyst in the range of 0.001 to 0.05 mole of catalyst per mole of initial vinyl olefin at a temperature of 140° to 170° C.
- Krzystowczyk et al., U.S. Pat. No. 5,663,469 (Sep. 2, 1997), discloses the formation of vinylidene olefins in good yield and high selectivity and in shorter reaction periods through the use of 0.001 to 0.5 mole of trialkyl aluminum catalyst per mole of the initial vinyl olefin, at a temperature of 100° to 200° C., provided that the reaction mixture is in direct contact with a nickel-containing metal alloy surface for at least one hour at a temperature above about 50° C. and that at least one acetylenic hydrocarbon is added to the reaction mixture prior to such contact in an amount that is at least sufficient to inhibit double bond isomerization in the reaction mixture but insufficient to inhibit formation.
- Thus far, prior art methods have been directed at suppressing competing double bond isomerization leading to the formation of internal isomer monomers and of deep internal olefin dimers and at the expense of relatively long reaction times. There has been no disclosure of any attempt to further reduce the length of the dimerization reaction to two hours or less and to incorporate the dimerization into a process that would better utilize the products of the aforesaid competing reactions.
- It is therefore a general object of the present invention to provide an improved process for dimerizing vinyl olefins that affords such benefits.
- More particularly, it is an object of the present invention to provide an improved aforesaid process that increases the rate of conversion of vinyl olefins to vinylidenes and deep internal olefins.
- It is another object of the present invention to provide an improved aforesaid process that makes efficient use of unreacted vinyl olefins and products of the aforesaid competing reactions that form deep internal olefin dimers and internal isomer olefin monomers.
- It is a related object of the present invention to provide an improved aforesaid process which is incorporated into a process for making vinyl olefins.
- Other objects and advantages of the present invention will become apparent upon reading the following attached description and appended claims.
- The present invention is an improvement in a process for manufacturing vinyl olefins containing from 4 to 30 carbon atoms, comprising: (1) reacting ethylene in a chain growth reaction in the presence of an alkyl aluminum chain growth catalyst in at least one chain growth step (2) displacing the alkyl moieties of the resulting alkyl aluminum chain growth product to form a displacement product mixture comprising the corresponding vinyl olefins formed from the alkyl moieties in at least one displacement step; (3) fractionating the displacement product mixture from at least one aforesaid displacement step to separate a liquid fraction comprising vinyl olefins containing from 4 to 30 carbon atoms; and (4) fractionating the resulting liquid fraction to separate therefrom a lower molecular weight fraction comprising the aforesaid vinyl olefins. The improvement comprises: (5) dimerizing vinyl olefins to form vinylidenes and deep internal olefins in the presence of a dimerization catalyst comprising alkyl aluminum at a initial molar ratio of alkyl aluminum to vinyl olefin of from about 0.01:1 to about 1.5:1 and at a temperature in the range of from 200° C. to about 288° C. for a period of time in a range of from about 30 to about 120 minutes at a selectivity for the formation of vinylidenes and deep internal olefins of at least 50 mole percent; and (6) treating the resulting dimerization product mixture by (a) combining it in its entirety with the feed to at least one aforesaid chain growth step (1) or the feed to at least one aforesaid displacement step (2); or (b) combining it in its entirety with the product mixture from at least one aforesaid chain growth step (1) or with the product mixture from at least one aforesaid displacement step (2); or (c) fractionating it to separate a light olefin fraction and a heavier fraction comprising vinylidenes and deep internal olefins which heavier fraction is then treated as in step (a) or (b); such that the resulting displacement product mixture comprises vinylidenes and deep internal olefins from the dimerization product mixture or chain growth products of such vinylidenes and deep internal olefins which are separated with the aforesaid vinyl olefins in the liquid fraction separated in step (3) and are subsequently separated as the higher molecular weight fraction from the vinyl olefins in step (4).
- For a more complete understanding of this invention, reference should now be made to the embodiments illustrated in greater detail in the accompanying drawings and described below by way of examples of the invention. In the drawings:
- FIG. 1 is a plot of the selectivities for the formation of vinylidenes from the dimerization of vinyl olefin versus reaction temperatures at each of five different initial mole ratios of dimerization catalyst to the vinyl olefin and at a reaction time of 30 minutes derived from a computer simulation of the dimerization.
- FIG. 2 is a schematic illustration of several preferred embodiments of the integration of the process for dimerizing vinyl olefins with a process for producing vinyl olefins and introducing into the process for producing vinyl olefins the entire dimerization product mixture.
- FIG. 3 is a schematic illustration of additional preferred embodiments of the integration of the process for dimerizing vinyl olefins with a process for producing vinyl olefins and introducing into the process for producing vinyl olefins a heavier fraction of the dimerization product mixture.
- It should be understood, of course, that the invention is not necessarily limited to the particular embodiment illustrated in the drawings.
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- wherein R, R1, R2 and R3 represent a hydrocarbyl group. Internal olefins are also classified as “beta-internal olefins” in which the double bond is connected to the beta-carbon atom as in:
- R—CH═CH—CH3
- and “deep internal olefins” which are di-substituted olefins in which the double bond is further towards the center of the olefin as in:
- R1—CH═CH—R2
- wherein R1′ and R2′ are different by two or four carbon numbers and are aliphatic hydrocarbon groups containing two or more carbon atoms.
- The “beta-internal olefins” referred to herein are monomeric. This means they contain the same number of carbon atoms as the initial vinyl-olefins from which they are formed but the olefinic double bond has moved toward the center of the molecule, by just one carbon number (i.e., the double bond is at the second carbon number).
- The “deep internal olefins” referred to herein are dimers of the initial vinyl olefins from which they are formed. For example, a deep internal dimer of 1-octene contains 16 carbon atoms. They differ from vinylidene dimers in that their olefinic double bond is in the linear chain near the center of the molecule.
- The vinylidene olefins are useful when oligomerized as oils. Depending on their viscosity, different applications for such oils are known, for example, as lubricants. These materials are mixtures of different percentages of dimer, trimer, tetramer, pentamer and higher oligomers which oligomers ae produced in different proportions in the oligomerization process. Due to the increasing use of dimers, both vinylidenes and the aforesaid “deep internal olefins,” in applications such as low temperature lubricants and drilling fluids, methods for the preferential production of both types of dimers are of interest.
- The olefins that are dimerized to make such dimers are predominately (at least 50 mole percent) C4 to C20 straight- or branched-chain monoolefinically unsaturated hydrocarbon (but not less than 5 mole percent) in which the olefinic unsaturation occurs at the 1- or alpha-position of the carbon chain. Typically they have the following formula
- R2—(CH2)m—CH═CH2
- where R2 is hydrogen or alkyl, that is, C1 to C16 linear or branched alkyl, preferably C1 to C6 linear or branched alkyl, most preferably C1 to C4 linear or branched alkyl, for example, methyl, ethyl and the like, and m is an integer from 0 to 18.
- Linear alpha-olefins are commercially available and can be made by the well-known Ziegler ethylene chain growth and displacement on trialkyl aluminum. Individual olefins may be used as well as mixtures of such olefins. Examples of suitable olefins are 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, 1-dodecene, 1-hexadecene and 1-tetradecene. The more preferred normal alpha-olefin monomers are those containing about 6-18 carbon atoms.
- Typically the vinyl olefins used in the process will contain in the range of about 3 to about 30 or more carbon atoms per molecule. The initial vinyl olefin will contain preferably in the range of 4 to 20, and more preferably in the range of 6 to 18 carbon atoms per molecule. For some end use applications, it is desirable to use a substantially pure single vinyl olefin, such as 1-butene, 1-pentene, 1-hexene, 1-octene, 1-decene, or 1-tetradecene. For other end use applications mixtures of vinyl olefins are entirely suitable. In such case co-dimerization takes place.
- Any straight chain or branched chain trialkylaluminum compound can used as the catalytic component charged to the dimerization reaction zone in the practice of this invention. However, it is a critical future of the method of this invention that a trialkyaluminum catalyst is employed for both the chain growth and dimerization steps. Typically the alkyl groups will contain from 1 to 30 carbon atoms, and preferably in the range of 2 to about 18 carbon atoms each. Most preferred as trialkyaluminum compounds such as triethylaluminum tri-isobutyl aluminum, tributylaluminum, trihexylaluminum, trioctylaluminum, tris(decyl)aluminum, tris(tetradecyl) aluminum, and the like. Mixtures of aluminum trialkyls can be also used if desired. The hydride content, if any, of the aluminum trialkyl should be quite low, for example, the aluminum trialkyl should have a maximum aluminum hydride equivalent of not more than about 0.8 weight percent. In preferred embodiments the aluminum trialkyl as fed to the process is essentially hydride-free, that is, the trialkylaluminum product contains, if any, a maximum of 0.10 weight percent of aluminum hydride equivalent, and more preferably a maximum of 0.05 weight percent of aluminum hydride equivalent, because the aluminum hydride bond can cause isomerization of 1-olefins to internal olefins.
- The preferred aluminum alkyls are the tri-C1-12 alkyl aluminum such as trimethyl aluminum, triethyl aluminum, tributyl aluminum, tri-isobutyl aluminum, trioctyl aluminum, tridecyl aluminum, tridodecyl aluminum and the like including mixtures thereof. The more preferred aluminum alkyls are the higher aluminum alkyl such as the tri-C4-10 alkyl aluminum. Most preferably the alkyls bonded to aluminum have the same or close to the same number of carbon atoms as the vinyl olefin starting material. For example, tri-n-octyl aluminum is the most preferred catalyst for dimerizing 1-octene.
- The reaction should be conducted in an environment that is essentially anhydrous and substantially free of oxygen and air. Aluminum trialkyls can react violently with water or compounds containing hydroxyl groups such as alcohols. Thus even a small amount of water, alcohol, or the like, in the system will inactivate some of the aluminum trialkyl. If it known that some water is present in the vinyl olefin, by use of analysis such as Karl Fischer water analysis, the amount of aluminum alkyl catalyst can be increased in order to compensate for the water or other active hydrogen component such as alcohol whereby the proper amount of active aluminum trialkyl catalyst remains in the system even after part of the initial aluminum alkyl has been destroyed by the water or other active hydrogen compound. Alternatively, the olefin feed can be pretreated to remove water or alcohol contamination. Likewise the process should be conducted under a dry inert atmosphere, for example, nitrogen, argon, neon, or the like, to prevent catalyst destruction.
- The dimerization is performed at an initial mole ratio of aluminum alkyl to vinyl olefin in the range of from about 0.01:1, preferably from about 0.6:1, to about 1.5:1, preferably to about 1.0:1, at a temperature in the range of from about 200° C., to about 288° C., preferably to about 260° C., more preferably to about 232° C. and for the period of time in the range of from about 30 to about 120 minutes. Within these ranges the conditions are selected to convert initial vinyl olefins at a selectivity for the formation of the combination of vinylidenes and deep internal olefins of at least 50 mole percent, preferably at least 70 mole percent, more preferably at least 80 mole percent.
- FIG. 1 contains plots from a computer simulation of the conversion of 1-octene to vinylidenes and deep internal olefins having 16 or 18 carbon atoms versus reaction temperature and at a reaction time of 30 minutes at each of 5 different initial mole ratios of aluminum alkyl to vinyl olefin. The plots illustrate that the maximum selectivities for the formation of the combination of C16-18 vinylidenes and deep internal olefins are in the range of from about 80 to about 86 weight percent of initial vinyl olefin converted to the combination of C16-18 vinylidenes and deep internal olefins, that this maximum conversion to the combination of C16-18 vinylidenes and deep internal olefins takes place at a temperature in the range of 205° C. to 260° C., and that the temperature for this maximum conversion decreases within this range as the initial mole ratio of aluminum alkyl to vinyl olefin increases.
- The dimerization product mixture comprises dimers (both vinylidenes and deep internal olefins), unreacted vinyl olefins, and internal monomeric olefins that are isomers of the initial vinyl olefins. Part or all of the mixture is introduced to the process for making vinyl olefins in the method of this invention. The high rate of the dimerization reaction and the high yield of the combination of C16-18 vinylidenes and deep internal olefins under the conditions employed in the present invention permit the use of smaller vessels and shorter holdup times for the dimerization reaction and thereby permits the dimerization to be incorporated as a step into the process for manufacturing vinyl olefins.
- The product mixture from the dimerization step comprises dimer products (both vinylidenes and deep internal olefins) unreacted vinyl olefins and deep internal olefins, of which all or part is incorporated into the feed to some step of the process for making vinyl olefins. In general, in the process for making vinyl olefins employed in the method of the present invention, ethylene is oligomerized on a trialkyl aluminum, typically triethylaluminum, in a continuous stoichiometric chain growth reactor at 120-150° C. and 14-21 MPa (140-210 atmospheres) for about an hour. Unreacted ethylene and other light olefins then separated by flashing and aluminum alkyl products are passed to a displacement step in which a low molecular weight alkene, typically ethylene or butylene, is used to displace the alkyl groups on the aluminum alkyl products, and the initial trialkyl aluminum, typically triethyl aluminum, is regenerated. This displacement step is performed at 280-320° C. and 1.0 MPa (10 atmospheres) with a minimum contact time. The alkyl groups on the aluminum alkyl products are displaced in this step primarily as vinyl olefins with small amounts of internal olefins that are monomeric isomers of the vinyl olefins.
- The aforesaid vinyl olefins can be separated from trialkyl aluminum and recovered at various stages in the process. If not removed at this juncture, the vinyl olefins can be treated in a second chain growth step and thereby converted to longer chain alkyl groups in higher molecular weight aluminum alkyl products. After removal of unreacted ethylene and other light olefins, these higher molecular weight aluminum alkyl products can then be treated in second displacement step, as described above, whereby the longer chain alkyl groups are displaced as longer chain vinyl olefins. These longer chain vinyl olefins can be separated from trialkyl aluminum and recovered or can be treated in another chain growth step. Thus, vinyl olefins produced in this process can be removed and recovered before or after one or more additional chain growth steps.
- In a more detailed embodiment (step a) triethyl aluminum and ethylene are fed to a first ethylene chain growth reaction zone maintained under ethylene chain growth conditions to form a first chain growth product. Unreacted ethylene is separated (step b) from the first chain growth product mixture to form an ethylene-depleted first chain growth product, which is then distilled (step c), whereby C4-14 vinyl olefins are distilled from the ethylene-depleted first chain growth product leaving a bottoms fraction or stream comprising mainly poisson distributed tri-C2-20+ alkyl aluminum and C14+ vinyl olefins. At least part of the bottom fraction or stream is then conveyed (step d) to an ethylene or C4-8 olefin displacement zone maintained under displacement conditions and feeding ethylene or C4-8 olefins, to the displacement zone thereby forming an ethylene- or C4-8 olefin-displaced product, respectively, comprising mainly triethyl or tri-C4-8 alkyl aluminum, ethylene and C4-20 vinyl olefins. The resulting ethylene- or C4-8 olefin displaced product is next conveyed (step e) to a second ethylene chain growth reaction zone maintained under chain growth conditions and feeding ethylene to the second ethylene chain growth reaction zone to thereby form a second chain growth product comprising mainly ethylene, C4-20 vinyl olefins and poisson distributed tri-C4-20 alkyl aluminums. Ethylene is then (step f) vaporized from the second chain growth product forming an ethylene-depleted second chain growth product, which is then (step g) distilled to separate C4-14 vinyl olefins as overhead and leaving a bottoms fraction or stream comprising mainly poisson distributed tri-C2-20+ alkyl aluminum and C14+ vinyl olefins.
- Another preferred embodiment of the process for making vinyl olefins in the method of the present invention includes both a C4-8 olefin displacement loop and an ethylene displacement loop. In this embodiment any C4-8 olefin formed in either loop can be used as feed olefin to a C4-8 olefin displacement reactor. This dual loop process includes steps (a) through (g) as stated above and also includes the additional steps (h), (i) and (j). In step (h) a portion of the bottoms stream from step (c) is charged to an ethylene displacement zone maintained under displacement conditions, and ethylene is fed to this displacement zone thereby forming an ethylene-displaced product comprising mainly triethyl aluminum, ethylene and C4-20+ vinyl olefins. In step (i) C2-12 vinyl olefins are distilled from the ethylene-displaced product forming a bottoms fraction or stream comprising mainly triethyl aluminum and C14+ vinyl olefins. In step (j) this bottoms fraction or stream is recycled to the first ethylene chain growth reaction zone as described above.
- As illustrated in FIGS. 2 and 3, all or part of the dimerization product mixture can be introduced into any of several steps of the aforesaid process for making vinyl olefins. In FIG. 2, ethylene and chain growth catalyst are introduced through
lines chain growth reactor 13 from which the chain growth product mixture comprising chain growth product and unreacted ethylene is withdrawn throughline 14. Unreacted ethylene is separated from the chain growth product mixture using aconventional separator 15 such as a distillation column and removed throughline 16. The ethylene-depleted chain growth product mixture comprising mainly poisson distributed alkyl aluminum chain growth product is then passed throughline 17 to adisplacement reactor 18 which is maintained under displacement conditions. A low molecular weight olefin, typically ethylene or butylene, is introduced throughline 19 into thedisplacement reactor 18 to thereby form in thedisplacement reactor 18 on ethylene- or butylene-displaced product comprising mainly vinyl olefins, triethyl or tributyl aluminum and ethylene or butylene. This displacement product mixture is withdrawn from thedisplacement reactor 18 throughline 20. Ethylene, butylene and other light olefins are then removed from the displacement reactor mixture using aseparator 21, typically a distillation column, and withdrawn throughline 22. The remaining displacement product mixture is fed throughline 23 to agas liquid separator 24 wherein a gaseous fraction comprising trialkyl aluminums is separated and withdrawn throughline 25. The liquid fraction comprising the desired vinyl olefin products in withdrawn throughline 26 to adistillation column 27 where they are separated into lighter and heavier fractions. The lighter fraction comprising vinyl olefins is withdrawn throughline 28 and a heavier fraction is withdrawn throughline 29. - Vinyl olefin and dimerization catalyst are introduced through
lines dimerization reactor 32 from which the dimerization product mixture comprising dimeric vinylidenes, dimeric deep internal olefins, monomeric internal olefins and monomeric unreacted vinyl olefins is withdrawn throughline 34. In one series of alternatives, the dimerization product mixture is then fed in its entirety (a) throughline 35 to and combined inline 11 with the feed to thechain growth reaction 13, (b) throughline 36 to and combined inline 14 with the chain growth product (c) throughline 37 to and combined inline 17 with the feed to thedisplacement reactor 18, or (d) throughline 38 to and combined inline 20 with the displacement product mixture. These alternatives are indicated bybroken lines - FIG. 3 illustrates another series of alternatives in which the dimerization product mixture is conducted from the
dimerization reactor 32 throughline 34 and introduced into a vapor/liquid separator 40, from which the vapor fraction is withdrawn throughline 41 and the liquid fraction which comprises olefin dimers and aluminum alkyls is withdrawn throughline 42 and (a1) conducted throughline 43 to and combined inline 11 with the feed to thechain growth reactor 13, (b1) conductedthrought line 44 to and combined inline 14 with the chain growth product, (c1) throughline 45 to and combined inline 17 with the feed to thedisplacement reactor 18, or (d1) throughline 46 to and combined inline 20 with the displacement product mixture. These alternatives are indicated bybroken lines - Thus, in the method of the present invention, either all or at least the liquid fraction of the dimerization product mixture is combined with either (1) the feed to or (2) product mixture from the chain growth reactor or (3) the feed to or (4) product mixture form the displacement reactor. In this way, the entire dimerization product mixture is recovered, and much of the recovered amount is utilized in the process for manufacturing vinyl olefins. For example, depending on where in the process for manufacturing vinyl olefins that at least a portion of the dimerization product is introduced, the chain length of at least some components of the dimerization product mixture can be altered in the chain growth or displacement step, and/or the combination of the dimerization product mixture with the particular stream in the vinyl olefin manufacturing process can afford the desired carbon number distribution. Such combination also permits the maximum dimerization operating temperatures and dimer production rates to be used because they are no loner limited by the amount of by-product olefins as a result of the unreacted vinyl olefins from the dimerization step. The dimers are withdrawn from the process through
line 29. - The present invention will be more clearly illustrated, but not limited, by the following specific examples.
- A glass pressure vessel was dried and purged with nitrogen and then charged with varying amounts of one or more vinyl olefins and of one or more trialkyl aluminums and heated at various temperatures in excess of 200° C. for varying periods of time. The amounts of vinyl olefins and trialkyl aluminum and the reaction temperatures and times in each example are indicated in Table 1. The weight percent of vinyl olefin converted and the selectivities for the formation of C16 dimer (both vinylidines and deep internal C16 olefins combined), internal C8 olefins, branched C8 paraffins are also presented in Table 1. The selectivites are determined as the weight percent of the particular product produced per the weight percent of feed that is converted.
- From the above description, it is apparent that the objects of the present invention have been achieved. While only certain embodiments have been set forth, alternating embodiments and various modifications will be apparent from the above description to those skilled in the art. These alternatives are considered equivalents and are within the spirit and scope of the present invention.
TABLE 1 Example No. 1 2 3 4 5 6 7 Vinyl olefin charge (g) 1- octene 30 35 35 35 35 35 35 1 -decene Trialkyl aluminum charge (g) Tri-n-octyl aluminum 4.25 1.67 3.33 5 5 1.67 5 Tri-i-butyl aluminum Initial Mole Ratio of Trialkyl 0.04 0.01 0.03 0.04 0.04 0.01 0.04 aluminum to vinyl olefin Temperature (° C.) 206 206 206 223 223 234 262 Reaction time (hr.) 2 2 2 1 0.5 2 0.5 Vinyl olefin conversion (wt. %) 93 75 95 93 65 99 98 Selectivity (wt. %) for the formation of C16 Dimers 83 89 84 83 75 70 73 Internal C8 olefins 15 9 11 15 23 19 17 Branched C8 olefins 1 0 0 1 2 0 1 Example No. 8 9 10 11 12 13 14 Vinyl olefin charge (g) 1- octene 35 35 35 35 35 27.5 27.5 1 -decene 9.5 9.5 Trialkyl aluminum charge (g) Tri-n-octyl aluminum 1.67 1.67 1.67 5 5 Tri-i-butyl aluminum 2.7 1.35 Initial Mole Ratio of Trialkyl 0.01 0.01 0.04 0.02 0.01 0.04 0.04 aluminum to vinyl olefin Temperature (° C.) 262 262 262 262 262 206 206 Reaction time (hr.) 0.5 0.5 0.5 0.5 1 1 0.5 Vinyl olefin conversion (wt. %) 41 48 99 93 96 86 63 Selectivity (wt. %) for the formation of C16 Dimers 83 83 62 68 68 83 82 Internal C8 olefins 12 15 20 19 22 11 12 Branched C8 olefins 2 2 1 1 1 — —
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US2695327A (en) | 1950-06-21 | 1954-11-23 | Ziegler Karl | Dimerization of unsaturated hydrocarbons |
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US4973788A (en) | 1989-05-05 | 1990-11-27 | Ethyl Corporation | Vinylidene dimer process |
US5663469A (en) | 1996-02-05 | 1997-09-02 | Amoco Corporation | Production of vinylidene olefins |
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