US20050113625A1 - Composition and method for inhibiting polymerization and polymer growth - Google Patents
Composition and method for inhibiting polymerization and polymer growth Download PDFInfo
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- US20050113625A1 US20050113625A1 US11/024,217 US2421704A US2005113625A1 US 20050113625 A1 US20050113625 A1 US 20050113625A1 US 2421704 A US2421704 A US 2421704A US 2005113625 A1 US2005113625 A1 US 2005113625A1
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- 0 C.[1*]C([2*])([3*])NC.[1*]C([2*])([3*])NOC([1*])([2*])[3*] Chemical compound C.[1*]C([2*])([3*])NC.[1*]C([2*])([3*])NOC([1*])([2*])[3*] 0.000 description 26
- KJRCHILWKQLEBC-UHFFFAOYSA-N CC1=CC([N+](=O)[O-])=C(O)C(C)=C1 Chemical compound CC1=CC([N+](=O)[O-])=C(O)C(C)=C1 KJRCHILWKQLEBC-UHFFFAOYSA-N 0.000 description 1
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K15/00—Anti-oxidant compositions; Compositions inhibiting chemical change
- C09K15/04—Anti-oxidant compositions; Compositions inhibiting chemical change containing organic compounds
- C09K15/20—Anti-oxidant compositions; Compositions inhibiting chemical change containing organic compounds containing nitrogen and oxygen
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F2/00—Processes of polymerisation
- C08F2/38—Polymerisation using regulators, e.g. chain terminating agents, e.g. telomerisation
- C08F2/40—Polymerisation using regulators, e.g. chain terminating agents, e.g. telomerisation using retarding agents
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K15/00—Anti-oxidant compositions; Compositions inhibiting chemical change
- C09K15/04—Anti-oxidant compositions; Compositions inhibiting chemical change containing organic compounds
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- 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S585/00—Chemistry of hydrocarbon compounds
- Y10S585/949—Miscellaneous considerations
- Y10S585/95—Prevention or removal of corrosion or solid deposits
Definitions
- the present invention is directed to the inhibition of polymerization and polymer growth of ethylenically unsaturated monomers by means of the addition thereto of hydrogen donors and/or electron acceptors, either alone or in combination with at least one stable nitroxide free radical compound.
- Polymerization can also result in equipment fouling, especially in the case of production of acrylic monomers.
- Such polymerization causes loss in production efficiency owing to the deposition of polymer in or on the equipment being used. These deposits must be removed from time to time, leading to additional loss in production of the monomer.
- polymerization inhibitors work in several mechanisms.
- One mode of action for polymerization inhibitors is for the inhibiting species to combine with the propagating polymer chain such that the polymerization of that polymer chain stops, i.e., a termination reaction. If such an inhibitor-terminated polymer chain is capable of participating in a dynamic equilibrium between a dormant species (the inhibitor-terminated chain) and an active polymer chain, it would be considered a “living” or quasiliving polymer.
- Ivan, Macromol. Symp. 88:201-215 (1994) describes quasiliving polymerization as a polymerization in which “ . . .
- the use of recycle can significantly increase the amount of time that the “living” polymer can remain in the purification train.
- a portion of the residual stream is added to a feed stream earlier in the purification train.
- This residual stream typically contains inhibitor, small amounts of monomer, impurities in the monomer stream that have been concentrated by the purification process, and polymer formed during the production and purification process. Recycling this polymer will allow it time to grow if it is “living” polymer and the conditions of the purification train allow the “living” polymerization mechanism to occur. If this polymer grows via the “living” polymerization mechanism, excessive polymerization would cause loss in product yield, increased waste residues from the process, and potential plugging of equipment due to excessively high molecular weight polymer in the purification stream.
- Nitroxyl radicals are known to facilitate polymerization via a “living” free radical process to give polymers of narrow polydispersity.
- the unimolecular initiators it was found that an ⁇ -methyl group is essential for “living” character, while a variety of substituents could be placed on the phenyl ring or the ⁇ -carbon atom without affecting the efficiency of the unimolecular initiator. It was found that the rate of polymerization is approximately the same for both the unimolecular and corresponding bimolecular systems; however, the unimolecular initiators afforded better control over molecular weight and polydispersity.
- Hindered nitroxyl compounds are known to be very active inhibitors of free radical polymerizations of unsaturated monomers such as styrene, acrylic acid, methacrylic acid, and the like. Nitrophenols, nitrosophenols, phenylenediamines (PDA's), hydroxylamines, quinones and hydroquinones are also known to have a similar capacity.
- U.S. Pat. No. 2,304,728 discloses that a vinyl aromatic compound may effectively be stabilized against polymerization by dissolving therein a monohydric halo-nitrophenol having the general formula: wherein one X represents a halogen and the other X represents a member of the group consisting of hydrogen and halogen and nitro substituents.
- U.S. Pat. No. 3,163,677 discloses a process for the preparation of N,N,O-trisubstituted hydroxylamines and N,N-disubstituted nitroxides of the formulae: wherein R 1 , R 2 , and R 3 are each an alkyl radical having 1 to 15 carbon atoms.
- N—O* denotes a stable free radical wherein the asterisk is an unpaired electron.
- the N,N,O-trisubstituted hydroxylamines can be used to make the N,N-disubstituted nitroxides, which are stable free radicals and are said to be useful as polymerization inhibitors.
- nitroxides can be prepared from the corresponding heterocyclic amine wherein the nitrogen atom of the nitroxide group is attached to other than a tertiary carbon of an aliphatic group (i.e., the nitrogen atom forms a part of a heterocyclic nucleus). These nitroxides are said to have useful properties similar to those described for the N,N-disubstituted nitroxides of U.S. Pat. No. 3,163,677.
- U.S. Pat. No. 3,372,182 discloses that a great variety of N,N-disubstituted, stable, free radical nitroxides not otherwise readily available can be prepared by a simple and convenient process that comprises pyrolyzing in an inert reaction medium virtually any hydroxylamine that is susceptible to cleavage of the O—C bond, e.g., tri-t-butylhydroxylamine.
- U.S. Pat. No. 3,422,144 discloses stable, free radical nitroxides of the formula: wherein R is selected from the group consisting of tertiary alkyl, aryl, alkaryl, haloaryl, carboxyaryl, alkoxyaryl, alkylthioaryl, pyridyl, and dialkylaminoaryl, and R′ is tertiary alkyl.
- R is selected from the group consisting of tertiary alkyl, aryl, alkaryl, haloaryl, carboxyaryl, alkoxyaryl, alkylthioaryl, pyridyl, and dialkylaminoaryl
- R′ is tertiary alkyl.
- U.S. Pat. No. 3,494,930 discloses free radicals of the nitroxide type for use as initiators of free radical reactions, collectors of free radicals, polymerization inhibitors or antioxidants. They are constituted by nitrogenous bicyclic compounds in which one of the bridges comprises solely the nitroxide radical group and, in particular, by aza-9-bicyclo (3,3,1) nonanone-3-oxyl-9, and by aza-9-bicyclo(3,3,1) nonane oxyl-9.
- U.S. Pat. No. 3,873,564 discloses compounds and a method for assaying enzymes by adding to a medium containing an enzyme a stable free radical compound having a stable free radical functionality which, when subjected to an enzyme-catalyzed reaction, changes the environment of the free radical functionality. By following the change in the electron spin resonance spectrum as affected by the change in environment, the type of enzyme and the activity of the enzyme can be determined.
- the compounds found useful are normally stable nitroxide radicals with an enzyme labile functionality.
- Other compounds include two cyclic nitroxide containing rings joined by a chain having an enzyme labile functionality.
- U.S. Pat. No. 3,966,711 teaches that 2,2,7,7-tetraalkyl- and 2,7-dispiroalkylene-5-oxo-1,4-diazacycloheptanes substituted in the 4-position by mono- or tetravalent radicals are powerful light-stabilizers for organic polymers. They are said to possess higher compatibility than their 4-unsubstituted homologues, from which they can be synthesized by reactions known for N-alkylation. Preferred substituents in the 4-position are alkyl, alkylene, alkenyl, aralkyl, and esteralkyl groups.
- the 1-nitroxyls derived from the imidazolidines by oxidation with hydrogen peroxide or percarboxylic acids are also said to be good light stabilizers.
- U.S. Pat. No. 4,105,506 discloses a process for the distillation of readily polymerizable vinyl aromatic compounds and a polymerization inhibitor therefor.
- the process comprises subjecting a vinyl aromatic compound to elevated temperatures in a distillation system in the presence of a polymerization inhibitor comprising 2,6-dinitro-p-cresol.
- U.S. Pat. Nos. 4,252,615 and 4,469,558 disclose a process for the distillation of readily polymerizable vinyl aromatic compounds and a polymerization inhibitor therefor.
- the process comprises subjecting a vinyl aromatic compound to elevated temperatures in a distillation system in the presence of a polymerization inhibitor comprising 2,6-dinitro-p-cresol. Also disclosed is a distillation method and apparatus for use with this inhibitor.
- U.S. Pat. No. 4,434,307 discloses the stabilization of vinyl aromatic compounds against undesired polymerization by adding to the vinyl aromatic compounds small amounts of at least one N,N-diarylhydroxylamine and at least one mono- or ditertiary alkyl catechol and/or at least one mono- or ditertiary alkylhydroquinone.
- U.S. Pat. No. 4,439,278 discloses an improvement in methods for preparing and processing ethylenically unsaturated aromatic monomer.
- the improvement comprises employing 3,5-dinitrosalicylic acid or a derivative or isomer thereof as a process inhibitor.
- the process inhibitor is present in a concentration of about 50 to 3000 ppm, preferably about 250 to 2,000 ppm, and most preferably about 500 to 1,000 ppm.
- U.S. Pat. No. 4,466,904 discloses a compound and a process for utilizing the compound to prevent the polymerization of vinyl aromatic compounds, such as styrene, during heating.
- the compound includes effective amounts of phenothiazine, 4-tert-butylcatechol and 2,6-dinitro-p-cresol respectively, as a polymerization inhibitor system in the presence of oxygen resulting in a less viscous polymer tar and in the effective inhibition of polymerization to temperatures as high as 150° C.
- U.S. Pat. Nos. 4,466,905 and 4,468,343 disclose a compound and a process for utilizing the compound to prevent the polymerization of vinyl aromatic compounds, such as styrene, during heating.
- the composition includes effective amounts of 2,6-dinitro-p-cresol and either a phenylenediamine or 4-tert-butylcatechol respectively, to act as a polymerization co-inhibitor system in the presence of oxygen.
- U.S. Pat. No. 4,480,116 discloses an improvement in methods for preparing and processing readily polymerizable acrylate monomers.
- the improvement comprises employing phenyl-para-benzoquinone, 2,5-di-phenyl-para-benzoquinone, and mixtures thereof as process inhibitors.
- the process inhibitors are present in a concentration of about 50 to 3000 ppm, preferably about 250 to 2000 ppm, and most preferably about 500 ppm.
- U.S. Pat. No. 4,558,169 discloses a process for preparing vinyltoluene comprising passing ethyltoluene through a dehydrogenation zone to form vaporous crude vinyltoluene, adding from about 50 to about 100 parts per million by weight of a polymerization inhibitor such as a nitrated phenol to the vaporous crude vinyltoluene at a temperature between about 200° and about 300° C., condensing the vaporous crude vinyltoluene, maintaining the pH of the aqueous phase of the condensed crude vinyltoluene at a value between about 5.5 and about 6.5 sufficient to maintain the inhibitor in the organic phase of the condensed crude vinyltoluene, adding a second portion of polymerization inhibitor to the condensed crude vinyltoluene until the inhibitor concentration totals about 500 parts per million by weight relative to the vinyltoluene content of the crude vinyltoluene, filtering the condensed crude vinyltol
- U.S. Pat. No. 4,665,185 discloses a process for the efficient preparation of nitroxyls of sterically hindered amines by the oxidation of the amine using a hydroperoxide in the presence of a small amount of a metal ion catalyst, at moderate temperature for a short period of time, to give the nitroxyl in high yield and purity.
- U.S. Pat. No. 4,692,544 discloses certain substituted diaryl amines that are used to inhibit the polymerization of ethylenically unsaturated monomers; for example, unsaturated carboxylic acids and derivatives thereof.
- U.S. Pat. No. 4,720,566 discloses compositions and methods of inhibiting acrylonitrile polymerization, particularly in quench columns of systems producing acrylonitrile, comprising adding to the acrylonitrile an effective amount for the purpose of (a) a hydroxylamine having the formula wherein R and R′ are the same or different and are hydrogen, alkyl, aryl, alkaryl or aralkyl groups, and (b) a para-phenylenediamine or derivative thereof having at least one N—H group.
- the phenylenediamine is a para-phenylenediamine having the formula wherein R 1 , R 2 , R 3 and R 4 are the same or different and are hydrogen, alkyl, aryl, alkaryl, or aralkyl groups with the proviso that at least one of R 1 , R 2 , R 3 or R 4 is hydrogen.
- U.S. Pat. No. 4,774,374 discloses a vinyl aromatic composition stabilized against polymerization comprising (a) a vinyl aromatic compound and (b) an effective amount of a stabilizer system in which the active ingredient consists essentially of an oxygenated species formed by the reaction of oxygen and an N-aryl-N′-alkyl-p-phenylenediamine.
- U.S. Pat. No. 4,797,504 discloses compositions and methods of inhibiting acrylate monomer polymerization at elevated temperatures comprising adding to the acrylate monomer an effective amount for the purpose of (a) a hydroxylamine having the formula wherein R and R′ are the same or different and are hydrogen, alkyl, aryl, alkaryl or aralkyl groups, and (b) a para-phenylenediamine or derivative thereof having at least one N—H group.
- the phenylenediamine is a para-phenylenediamine having the formula wherein R 1 , R 2 , R 3 and R 4 are the same or different and are hydrogen, alkyl, aryl, alkaryl, or aralkyl groups with the proviso that at least one of R 1 , R 2 , R 3 or R 4 is hydrogen.
- U.S. Pat. No. 4,912,247 discloses a composition and method of use for inhibiting the polymerization of acrylate esters during elevated temperature processing and during storage and handling thereafter. It comprises the combination of a Mannich reaction product, which is prepared from a substituted phenol, an aldehyde and ethylenediamine, and either phenylenediamine or derivatives thereof and/or phenothiazine or derivatives thereof.
- U.S. Pat. No. 4,929,778 discloses methods and compositions for inhibiting the polymerization of styrene monomer during elevated temperature processing thereof or during storage or shipment of styrene containing product.
- the compositions comprise a combination of (a) a phenylenediamine compound having at least one N—H bond and (b) a hindered phenol compound.
- the methods comprise adding from 1-10,000 ppm of the combination to the styrene medium, per one million parts of styrene.
- U.S. Pat. No. 5,128,022 discloses methods and compositions for inhibiting the formation of polymers in petroleum or petrochemical processes that subsequently foul heat transfer surfaces.
- the compositions comprise a combination of N-Phenyl-N′-(1,3-dimethylbutyl)-p-phenylenediamine (PDA) and an organic acid.
- the methods comprise adding from 1 to 2500 ppm PDA and 1 to 3500 ppm organic acid to the system experiencing the fouling problem.
- U.S. Pat. No. 5,254,760 teaches that the polymerization of a vinyl aromatic compound, such as styrene, is very effectively inhibited during distillation or purification by the presence of at least one stable nitroxyl compound together with at least one aromatic nitro compound.
- U.S. Pat. No. 5,446,220 discloses methods for inhibiting the polymerization of vinyl aromatic monomers in oxygen-free processing systems. These methods comprise adding from 1 to about 10,000 parts per million parts monomer of a combination of a dinitrophenol compound, a hydroxylamine compound and a phenylenediamine compound. Preferably, 2-sec-butyl-4,6-dinitrophenol or 4,6-dinitro-o-cresol are used in combination with bis-(hydroxypropyl)hydroxylamine and N,N′-di-sec-butyl-p-phenylenediamine.
- U.S. Pat. Nos. 5,545,782 and 5,545,786 disclose that nitroxyl inhibitors in combination with some oxygen reduce the premature polymerization of vinyl aromatic monomers during the manufacturing processes for such monomers. Even small quantities of air used in combination with the nitroxyl inhibitors are said to result in vastly prolonged inhibition times for the monomers.
- European Patent Application 0 178 168 A2 discloses a method for inhibiting the polymerization of an ⁇ , ⁇ -ethylenically unsaturated monocarboxylic acid during its recovery by distillation by using a nitroxide free radical.
- European Patent Application 0 325 059 A2 discloses stabilizing vinyl aromatic compounds against polymerization by the addition of an effective amount of a polymerization inhibition composition comprising (a) a phenothiazine compound; and (b) an aryl-substituted phenylenediamine compound.
- European Patent Application 0 398 633 A1 discloses a method of inhibiting acid monomer polymerization comprising adding to the monomer (a) a manganese source compound and (b) a phenylenediamine compound having at least one N—H bond therein.
- European Patent Application 0 594 341 A1 discloses methods and compositions for inhibiting the polymerization of vinyl aromatic monomers under distillation conditions.
- the compositions comprise a combination of a phenylenediamine compound and a hydroxylamine compound.
- European Patent Application 0 765 856 A1 discloses a stabilized acrylic acid composition in which the polymerization of the acrylic acid is inhibited during the distillation process for purifying or separating the acrylic acid as well as during transport and storage.
- the compositions comprise three components: (a) acrylic acid, (b) a stable nitroxyl radical, and (c) a dihetero-substituted benzene compound having at least one transferable hydrogen (e.g., a quinone derivative such as the monomethyl ether of hydroquinone (MEHQ)).
- a quinone derivative such as the monomethyl ether of hydroquinone (MEHQ)
- nitroxide free radical compounds include di-t-butylnitroxide; di-t-amylnitroxide; 2,2,6,6-tetramethyl-piperidinyloxy; 4-hydroxy-2,2,6,6-tetramethyl-piperidinyloxy; 4-oxo-2,2,6,6-tetramethyl-piperidinyloxy; 4-dimethylamino-2,2,6,6-tetramethyl-piperidinyloxy; 4-amino-2,2,6,6-tetramethyl-piperidinyloxy; 4-ethanoyloxy-2,2,6,6-tetramethyl-piperidinyloxy; 2,2,5,5-tetramethylpyrrolidinyloxy; 3-amino-2,2,5,5-tetramethylpyrrolidinyloxy; 2,2,5,5-tetramethyl-1-oxa-3-azacyclopentyl-3
- WO 97/46504 concerns substance mixtures containing: (A) monomers containing vinyl groups; and (B) an active amount of a mixture which inhibits premature polymerization of the monomers containing vinyl groups during their purification or distillation and contains: (i) between 0.05 and 4.5 wt %, relative to the total mixture (B), of at least one N-oxyl compound of a secondary amine which has no hydrogen atom at the ⁇ -C atoms; and (ii) between 99.95 and 95.5 wt % relative to the total mixture (B), of at least one nitro compound.
- the publication also discloses a process for inhibiting the premature polymerization of monomers, and the use of mixture (B) for inhibiting the premature polymerization of monomers.
- WO 98/02403 relates to inhibiting the polymerization of vinyl aromatic compounds by using a mixture of a phenol and a hydroxylamine. It is said that the process is useful in ethylbenzene dehydrogenation effluent condenser systems and styrene-water separator vent gas compressor systems and that it effectively inhibits polymerization of monomers, preventing the formation of a polymer coating on condenser and compressor equipment, thus reducing the necessity for cleaning of equipment surfaces.
- WO 98/14416 discloses that the polymerization of vinyl aromatic monomers such as styrene is inhibited by the addition of a composition of a stable hindered nitroxyl radical and an oxime compound.
- WO 98/25872 concerns substance mixtures containing: (A) compounds containing vinyl groups; (B) an active amount of a mixture which inhibits premature polymerization of the compounds containing vinyl groups and contains: (i) at least one N-oxyl compound of a secondary amine which does not carry any hydrogen atoms on the ⁇ -carbon atoms; and (ii) at least one iron compound; (C) optionally nitro compounds; and (D) optionally co-stabilizers.
- the publication also discloses a process for inhibiting the premature polymerization of compounds (A) containing vinyl groups, and the use of (B) optionally mixed with nitro compounds (C) and/or co-stabilizers (D) for inhibiting the premature polymerization of radically polymerizable compounds and stabilizing organic materials against the harmful effect of radicals.
- U.K. Patent Number 1,127,127 discloses that acrylic acid can be stabilized against polymerization by the addition thereto of a nitroxide having the essential skeletal structure: wherein R 1 , R 2 , R 3 , and R 4 are alkyl groups and no hydrogen is bound to the remaining valencies on the carbon atoms bound to the nitrogen.
- the two remaining valencies that are not satisfied by R 1 to R 4 or nitrogen can also form part of a ring (e.g., 2,2,6,6 tetramethyl-4-hydroxy-piperidine-1-oxyl).
- CS-260755 B1 is directed to the preparation of 4-substituted-2,2,6,6-tetramethylpiperidine nitroxyls as olefin stabilizers.
- SU-334845 A1 is directed to the inhibition of the radical polymerization of oligoester acrylates using iminoxyl radical inhibitors of a given formula.
- SU-478838 is directed to the inhibition of the radical polymerization of oligoester acrylates and the prevention of oligomeric peroxides using a binary polymerization inhibitor comprising quinone.
- FR 2,761,060 relates to the prevention of premature polymerization of styrene during its production by dehydrogenation of ethylbenzene by injecting into the process effluent a radical inhibitor based on an oxyl-tetramethylpiperidine derivative.
- inhibiting systems have been developed in which a component that is a hydrogen donor or electron acceptor or a combination of two or more of such components is used in the purification train, either alone or, preferably, in combination with a nitroxyl radical to prevent polymer growth via a “living” polymerization mechanism.
- a component that is a hydrogen donor or electron acceptor or a combination of two or more of such components is used in the purification train, either alone or, preferably, in combination with a nitroxyl radical to prevent polymer growth via a “living” polymerization mechanism.
- the present invention is directed to a method for inhibiting the premature polymerization and the polymer growth of ethylenically unsaturated monomers comprising adding to said monomers an effective amount of at least one inhibitor that is a hydrogen donor or an electron acceptor.
- the preferred transition metal ion is copper, especially Cu(I)naphthenate.
- the present invention is directed to a method for inhibiting the premature polymerization and the polymer growth of ethylenically unsaturated monomers comprising adding to said monomers A) an effective amount of at least one first inhibitor that is a hydrogen donor or an electron acceptor and B) at least one second inhibitor having the following structural formula:
- the present invention is directed to a composition
- a composition comprising A) at least one first inhibitor that is a hydrogen donor or an electron acceptor and B) at least one second inhibitor having the following structural formula:
- R 1 and R 4 are independently selected from the group consisting of hydrogen, alkyl, and heteroatom-substituted alkyl and R 2 and R 3 are independently selected from the group consisting of alkyl and heteroatom-substituted alkyl; and X 1 and X 2 (1) are independently selected from the group consisting of halogen, cyano, COOR 7 , —S—COR 7 , —OCOR 7 , (wherein R 7 is alkyl or aryl), amido, —S—C 6 H 5 , carbonyl, alkenyl, or alkyl of 1 to 15 carbon atoms, or (2) taken together, form a ring structure with the nitrogen, preferably of five, six, or seven members.
- the present invention is directed to inhibiting systems in which at least one hydrogen donor or electron acceptor is used in the purification train, preferably in addition to at least one nitroxyl radical, to prevent polymer growth that occurs via a “living” polymerization mechanism.
- the hydrogen donor compounds can, for example, be hydroxylamines, oximes, phenols, catechols, hydroquinones, thiols, anilines, dihydroanthracenes, and the like. Such compounds can include a metal species which facilitates the reduction/oxidation reactions that can accompany growth inhibition through deactivation of the growing radical chain. More particularly, the hydrogen donor compounds are preferably chosen from compounds having the structural formulae I through V.
- the electron accepting compounds can, for example, be quinones, quinone imines, quinone methides, and acetylenes. Such compounds can include a metal species which facilitates the reduction/oxidation reactions that can accompany growth inhibition through deactivation of the growing radical chain. More particularly, the electron accepting compounds are preferably chosen from compounds having the structural formulae VI or VII.
- alkyl (or substituted alkyl) groups preferably contain 1 to 15 carbon atoms, e.g., methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, and the like, and isomers thereof, e.g., t-butyl, 2-ethylhexyl, and the like.
- alkyl (or substituted alkyl) groups be of one to five carbon atoms (e.g., methyl, ethyl, propyl, butyl, pentyl, and isomers thereof).
- Substituents on the substituted alkyl groups can be any moiety that will not interfere with the hydrogen donating or electron receiving functions of the compounds.
- Aryl groups are preferably of from 6 to 10 carbon atoms, e.g., phenyl or naphthyl, which, in addition, may be substituted with non-interfering substituents, e.g., lower alkyl groups, halogens, and the like.
- Exemplary hydrogen donating compounds include, but are not limited to, diethylhydroxylamine, cyclohexanoneoxime, dibenzylhydroxylamine, 2,4-dinitro-6-sec-butylphenol, N-phenyl-N′-(1,4-dimethylpentyl)-para-phenylenediamine, 2,5-di-t-butylhydroquinone, 2,5-di-t-amylhydroquinone, methylhydroquinone, 4-t-butylhydroquinone, 4-t-butylcatechol, octanethiol, 2,6-di-t-butyl-4-ethylphenol/Cu(I)naphthenate, dihydroanthracene, N-t-butyl-2-benzothiazole-sulfenamide, N-methyl-4-nitroaniline, and the like.
- Exemplary electron accepting compounds include, but are not limited to, phenylacetylene, 2,5-di-t-butyl-1,4-benzoquinone, 2,6-di-t-butyl-1,4-benzoquinone, 1,4-benzoquinone, 2-methylanthraquinone, 1,4-naphthoquinone, 2,6-di-t-butyl-4-(phenylmethylene)-2,5-cyclohexadiene-1-one, 2,6-di-t-butyl-4-(phenylimino)-2,5-cyclohexadiene-1-one, ethyl 3,4-bis-(3,5-di-t-butyl-4-one-2,5-cyclohexadienylidene)-hexane-1,6-dioate, and the like.
- An effective growth inhibiting system can consist of one or more of any of the compounds described above with or without one or more nitroxyl compounds.
- the present invention is directed to a method for inhibiting the premature polymerization of ethylenically unsaturated monomers comprising adding to said monomers, in addition to at least one first inhibitor that is a hydrogen donor or an electron acceptor, an effective amount of at least one second inhibitor that is a stable hindered nitroxyl compound having the structural formula: wherein R 1 and R 4 are independently selected from the group consisting of hydrogen, alkyl, and heteroatom-substituted alkyl and R 2 and R 3 are independently selected from the group consisting of alkyl and heteroatom-substituted alkyl; and X 1 and X 2 (1) are independently selected from the group consisting of halogen, cyano, COOR 7 , —S—COR 7 , —OCOR 7 , (wherein R 7 is alkyl or aryl), amido, —S—C 6 H 5 , carbonyl, alkenyl, or alkyl of 1 to 15 carbon atoms
- the stable hindered nitroxyl compound has the structural formula: wherein R 1 and R 4 are independently selected from the group consisting of hydrogen, alkyl, and heteroatom-substituted alkyl and R 2 and R 3 are independently selected from the group consisting of alkyl and heteroatom-substituted alkyl, and the portion represents the atoms necessary to form a five-, six-, or seven-membered heterocyclic ring.
- Z 1 , Z 2 , and Z 3 are independently selected from the group consisting of oxygen, sulfur, secondary amines, tertiary amines, phosphorus of various oxidation states, and substituted or unsubstituted carbon atoms, such as >CH 2 , >CHCH 3 , >C ⁇ O, >C(CH 3 ) 2 , >CHBr, >CHCl, >CHI, >CHF, >CHOH, >CHCN, >C(OH)CN, >CHCOOH, >CHCOOCH 3 , >CHCOOC 2 H 5 , >C(OH)COOC 2 H 5 , >C(OH)COOCH 3 , >C(OH)CHOHC 2 H 5 , >CR 5 OR 6 , >CHNR 5 R 6 , >CCONR 5 R 6 , >C ⁇ NOH, >C ⁇ CH—C 6
- R 5 and/or R 6 are alkyl, it is preferred that they be a lower alkyl (i.e., one having one to five carbon atoms, e.g., methyl, ethyl, propyl, butyl, pentyl, and isomers thereof).
- R 5 and/or R 6 are aryl, it is preferred that they be aryl of from 6 to 10 carbon atoms, e.g., phenyl or naphthyl, which, in addition, may be substituted with non-interfering substituents, e.g., lower alkyl groups, halogens, and the like.
- R 5 and/or R 6 are acyl, it is preferred that they be acyl of the structure where R 19 is alkyl, aryl, OR 20 , or NR 20 R 21 , and where R 20 and R 21 , are alkyl, aryl, or where R 22 is alkyl or aryl.
- R 19 , R 20 , R 21 or R 22 are alkyl, they are preferably alkyl of from 1 to 15 carbon atoms, more preferably lower alkyl of from 1 to 5 carbon atoms, as described above.
- R 19 , R 20 , R 21 , or R 22 are aryl, they are preferably aryl of from 6 to 10 carbon atoms, as described above.
- Z 1 and Z 2 which may be the same or different, are nitrogen or substituted or unsubstituted carbon atoms, such as ⁇ C(H)—, ⁇ C(CH 3 )—, ⁇ C(COOH)—, ⁇ C(COOCH 3 )—, ⁇ C(COOC 2 H 5 )—, ⁇ C(OH)—, ⁇ C(CN)—, ⁇ C(NR 5 R 6 )—, ⁇ C(CONR 5 R 6 )—, and the like, and where Z 3 , R 5 , and R 6 are as described above.
- the cyclic nitroxides employed in the practice of the present invention can also be derived from five-membered rings. These compounds are of the structure: wherein Z 2 and Z 3 , which may be the same or different, are sulfur, oxygen, secondary amines, tertiary amines, phosphorus of various oxidation states, or substituted or unsubstituted carbon atoms, such as, >CH 2 , >CHCH 3 , >C ⁇ O, >C(CH 3 ) 2 , >CHBr, >CHCl, >CHI, >CHF, >CHOH, >CHCN, >C(OH)CN, >CHCOOH, >CHCOOCH 3 , >CHCOOC 2 H 5 , >C(OH)COOC 2 H 5 , >C(OH)COOCH 3 , >C(OH)CHOHC 2 H 5 , >CR 5 OR 6 , >CHNR 5 R 6 , >CCONR 5 R 6 , >C ⁇ NOH, >C ⁇ CH—C 6 H 5
- the cyclic nitroxides employed in the practice of the present invention can also have the structure: wherein Z 4 and Z 5 , which can be the same or different, can be nitrogen or a substituted or unsubstituted carbon atom, such as ⁇ C(H)—, ⁇ C(CH 3 )—, ⁇ C(COOH)—, ⁇ C(COOCH 3 )—, ⁇ C(COOC 2 H 5 )—, ⁇ C(OH)—, ⁇ C(CN)—, ⁇ C(NR 5 R 6 )—, ⁇ C(CONR 5 R 6 )—, and the like, where R 5 and R 6 are as described above.
- Z 2 and Z 3 which may be the same or different, are sulfur, oxygen, secondary amines, tertiary amines, or substituted or unsubstituted carbon atoms, such as, >CH 2 , >CHCH 3 , >C ⁇ O, >C(CH 3 ) 2 , >CHBr, >CHCl, >CHI, >CHF, >CHOH, >CHCN, >C(OH)CN, >CHCOOH, >CHCOOCH 3 , >CHCOOC 2 H 5 , >C(OH)COOC 2 H 5 , >C(OH)COOCH 3 , >C(OH)CHOHC 2 H 5 , >CHNR 5 R 6 , >CCONR 5 R 6 , >CR 5 OR 6 , >C ⁇ NOH, >C ⁇ CH—C 6 H 5 , CF 2 , CCl 2 , CBr 2 , CI
- two or more nitroxyl groups can be present in the same molecule, for example, by being linked through one or more of the Z-type moieties by a linking group E, as disclosed in U.S. Pat. No. 5,254,760, which is incorporated herein by reference.
- R 1 and R 4 are independently selected from the group consisting of hydrogen, alkyl, and heteroatom-substituted alkyl and R 2 and R 3 are independently selected from the group consisting of alkyl and heteroatom-substituted alkyl.
- the alkyl (or heteroatom-substituted alkyl) groups R 1 through R 4 can be the same or different and preferably contain 1 to 15 carbon atoms, e.g., methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, and the like, and isomers thereof, e.g., t-butyl, 2-ethylhexyl, and the like.
- R 1 through R 4 be independently selected lower alkyl (or heteroatom-substituted lower alkyl) of one to five carbon atoms (e.g., methyl, ethyl, propyl, butyl, pentyl, and isomers thereof).
- heteroatom substituents can, for example, include halogen, oxygen, sulfur, nitrogen, and the like. It is most preferred that all of R 1 through R 4 be methyl.
- Suitable nitroxide free radical compounds that can be used in combination with the hydrogen donor or electron acceptor in the practice of the present invention, include, but are not limited to:
- TEMPO 2,2,6,6-tetramethyl-1-piperidinyloxy.
- 4-amino-TEMPO is 4-amino-2,2,6,6-tetramethyl-1-piperidinyloxy
- 4-hydroxy-TEMPO is 4-hydroxy-2,2,6,6-tetramethyl-1-piperidinyloxy (also known in the art as HTEMPO)
- 4-oxo-TEMPO is 4-oxo-2,2,6,6-tetramethyl-1-piperidinyloxy; and so on.
- one member of the combination employed in the practice of the present invention be 4-amino-TEMPO, 4-oxo-TEMPO, 4-hydroxy-TEMPO, or TEMPO.
- Blends of two or more of the foregoing, e.g., 4-amino-TEMPO and 4-oxo-TEMPO, can also be employed.
- Such stable nitroxide free radical compounds can be prepared by known methods. (See, for example, U.S. Pat. Nos. 3,163,677; 3,334,103; 3,372,182; 3,422,144; 3,494,930; 3,502,692; 3,873,564; 3,966,711; and 4,665,185; which are incorporated herein by reference.) They are suitable for use over a wide range of temperatures, but distillation temperatures employed with the ethylenically unsaturated monomers that are stabilized by the process of the present invention typically range from about 60° C. to about 180° C., preferably from about 70° C. to about 165° C., and, more preferably, from about 80° C. to about 150° C. Such distillations are generally performed at an absolute pressure in the range of about 10 to about 1,200 mm of Hg.
- the ethylenically unsaturated monomer, the premature polymerization and polymer growth of which is an object of the present invention, can be any such monomer for which unintended polymerization and/or polymer growth during its manufacture, storage, and/or distribution is a problem.
- styrene ⁇ -methylstyrene, styrene sulfonic acid, vinyltoluene, divinylbenzenes, polyvinylbenzenes, alkylated styrene, 2-vinylpyridine, acrylonitrile, methacrylonitrile, methyl acrylate, ethyl acrylate, methyl methacrylate, ethyl methacrylate, acrylic acid, methacrylic acid, butadiene, chloroprene, isoprene, and the like.
- the ethylenically unsaturated monomers will not necessarily be stabilized indefinitely by the presence of the inhibitor(s), especially when the monomers are heated as in distillation, but they can be considered to be stabilized as long as A) there is a measurable increase in the time for which they can be heated before the onset of polymerization and/or polymer growth in a static system, B) the amount of polymer made at a constant temperature remains constant over time in a dynamic system, and/or C) the rate of polymer growth is significantly slower than when the growth inhibiting system is not present.
- free radical scavengers can also be included in the practice of the present invention.
- air or O 2 as disclosed in U.S. Pat. Nos. 5,545,782 and 5,545,786, can be added, as can the aromatic nitro compounds disclosed in U.S. Pat. No.
- the dihetero-substituted benzene compounds having at least one transferable hydrogen e.g., a quinone derivative such as the mono-methyl-ether of hydroquinone disclosed in European Patent Application 0 765 856 A1, the iron compounds disclosed in WO 98/25872, and other inhibitors, e.g., phenolics and certain inorganic salts, well-known to those skilled in the art.
- the polymerization inhibitor(s) can be introduced into the monomer to be protected by any conventional method. They can, for example, be added as a concentrated solution in suitable solvents just upstream from the point of desired application by any suitable means.
- individual inhibiting components can be injected separately into the distillation train along with the incoming feed and/or through separate and multiple entry points, provided there is an efficient distribution of the inhibiting composition. Since the inhibitors are gradually depleted during the distillation operation, it is generally advantageous to maintain the appropriate amount of them in the distillation apparatus by adding them during the course of the distillation process. Adding inhibitors can be done either on a generally continuous basis or intermittently, in order to maintain the inhibitor concentration above the minimum required level.
- the total inhibitor concentration should be from about 1 to about 2000 ppm versus the monomer being inhibited; preferably from about 5 to about 1000 ppm, depending on the conditions of use.
- the ratio of the first component, or blend A (electron acceptor or hydrogen donor compound or blend thereof) to a second component, or blend B (nitroxyl or nitroxyls), based on the total of both components is from about 1 to 100 wt % A: about 99 to 0 wt % B; preferably, about 25-75 wt % A: about 75-25 wt % B; more preferably about 50-75 wt % A: about 50-25 wt % B.
- TBC Tert-butylcatechol
- a quantity of the Feed Solution containing inhibitor or blend of inhibitors at the desired charge (stated as a wt/wt total inhibitor to styrene) is added to a round-bottom flask (the Pot).
- a known quantity of insoluble polymer capable of growing via a living mechanism is placed inside the Pot and submersed in the Feed Solution in the Pot.
- the insoluble polymer can be retained in the Pot by any suitable means.
- the insoluble polymer is securely wrapped in a piece of filter paper or wire mesh and suspended by a wire within the Pot.
- the Bottoms Stream line (as described below) can be covered with filter paper or mesh to prevent insoluble polymer from being removed from the Pot.
- the Pot is placed in a hot oil bath, and the Feed Solution in the pot is heated to the desired temperature (usually 130° C) and brought to reflux by adjusting the pressure/vacuum.
- a continuous stream of fresh Feed Solution is begun at a rate that will add the volume of the initial Pot solution to the Pot over a period of time called the “residence time” (typically one hour).
- the Bottoms Stream flow is also begun.
- the Bottoms Stream is solution in the Pot that is removed at the same rate as the fresh Feed Solution is added.
- the equal flows of Feed and Bottoms Streams causes the quantity in the Pot to remain constant over the time of the experiment while allowing continuous replenishment of inhibitor.
- the vacuum is released and, if used, the filter paper bag of polymer is removed.
- the Pot solution is filtered to recover any insoluble polymer that may have escaped from the bag. Any filtered polymer and the polymer in the filter paper bag are allowed to dry open to the atmosphere for at least 18 hours.
- the polymer can be further dried by placing it in a vacuum oven at 40-50° C. under full vacuum for 1-2 hours. The polymer is then weighed.
- TBC Tert-butylcatechol
- TBC Tert-butylcatechol
- a quantity of the Feed Solution containing inhibitor (blend) at the desired charge (stated as a wt/wt total inhibitor to styrene) is added to a round-bottom flask (the Pot) and heated to the desired temperature (usually 130° C.) and brought to reflux by adjusting the pressure/vacuum.
- the Pot contents are at temperature, a continuous stream of fresh Feed Solution is begun at a rate that will add the volume of the initial Pot solution to the Pot over a period of time called the residence time (typically, one hour).
- the Residence time typically, one hour.
- the Bottoms Stream flow is also begun.
- the Bottoms Stream is solution in the Pot that is removed at the same rate as the fresh Feed Solution is added.
- the equal flows of Feed and Bottoms Streams cause the quantity in the Pot to remain constant over the time of the experiment, while allowing continuous replenishment of inhibitor.
- This procedure simulates the way inhibitors are used in a distillation train of a plant producing vinyl monomers.
- the experiment continues with flow in and out of the Pot for a specified period of time. Typically, the First Pass runs for 10 hours, the Second Pass runs for 9 hours, the Third Pass runs for 8 hours, etc.
- Samples are collected hourly from the Bottoms Stream. These samples are analyzed for polymer content via the methanol turbidity method. The amount of polymer in the samples is an indication of effectiveness of the inhibitor system being tested. “Average Polymer Make” is the average of the polymer content values for samples taken after 4 hours running.
- the material left in the Pot at the end of the run is quickly removed and cooled, to stop any further polymerization.
- the material is then concentrated, if necessary, under reduced pressure at 40° C. until the polymer content is >5 wt %.
- a sample of this polymer solution is then analyzed by Gel Permeation Chromatography (GPC) to determine the weighted average molecular weight (M w ) of the polymer.
- the Bottoms Stream from the previous Pass is collected except for the material in the Pot at the end of the run.
- the amounts of inhibitor(s) in the First Pass Feed Solution and the Bottoms Stream from the First Pass are determined by appropriate analytical method(s), e.g., gas chromatography.
- An amount of inhibitor(s) is added to the collective Bottoms Stream from the First Pass to increase the level of inhibitor(s) in the Bottoms Stream to a level equal to that found in the First Pass Feed Solution.
- An equivalent amount of inhibitor(s) is added to the collective Bottoms Streams for subsequent Passes.
- the difference in the “Average Polymer Make” made in one Pass versus subsequent Passes is an indication of the ability of the inhibiting system to prevent or allow polymer to grow. For example, an increase in the amount of polymer made going from one Pass to the next which is roughly equivalent to the amount of polymer made during the First Pass is an indication that the inhibiting system effectively prevents polymer growth during recycle. Conversely, an increase in the amount of polymer made going from one Pass to the next that is dramatically greater (about 10 times or more) than the amount of polymer made during the First Pass is an indication that the inhibiting system does not effectively prevent polymer growth during recycle.
- the difference in the M w of the polymer made in one Pass versus subsequent Passes is an indication of the ability of the inhibiting system to prevent or allow polymer to grow. Any significant increase in M w of the polymer made in one Pass versus the previous Pass is an indication that the inhibiting system does not prevent polymer growth. The closer to zero the increase in M w , the better the growth inhibiting ability of the system.
- Tables 1 and 4 The effectiveness of hydrogen donor systems and their blends with nitroxyls is shown in Tables 1 and 4.
- Tables 2 and 3 The effectiveness of electron-accepting systems and their blends with nitroxyls is shown in Table 2.
- Examples of Synergistic Blends of Donor and Acceptor systems are shown in Table 3.
- the first two examples in each of Tables 1-3 are baseline examples of nitroxyl inhibitors used alone—conditions that are known to allow polymer growth via a “living” mechanism. Under these Polymer Growth Test baseline conditions, about 700% growth was observed. All other examples in Tables 1-3 gave less than 700% growth, indicating that those systems provided some growth inhibiting activity.
- the first example in Table 4 is also a baseline example of a nitroxyl inhibitor used alone—conditions that are known to allow polymer growth via a “living” mechanism. Under these Multi-Pass Test baseline conditions, the average polymer make increased 100-fold and the molecular weight (M w ) of the polymer made increased nearly 10-fold over three passes. The other examples in Table 4 gave minor increases in average polymer make (versus the baseline example) and essentially no change in molecular weight of the polymer over three passes, indicating that those systems provided significant growth inhibiting activity.
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US20130116486A1 (en) * | 2010-07-09 | 2013-05-09 | Nufarm Uk Limited | Retarder Composition |
US9133288B2 (en) * | 2010-07-09 | 2015-09-15 | Nufarm Uk Limited | Retarder composition |
US20150060727A1 (en) * | 2011-06-13 | 2015-03-05 | Nalco Company | Synthesis of 7-acetyleno quinone methide derivatives and their application as vinylic polymerization retarders |
US9447002B2 (en) * | 2011-06-13 | 2016-09-20 | Nalco Company | 7-acetyleno quinone methide derivatives and their application as vinylic polymerization retarders |
US20140194559A1 (en) * | 2011-08-19 | 2014-07-10 | Nufarm Uk Limited | Novel Inhibitor Compositions and Methods of Use |
US10869444B2 (en) | 2018-07-13 | 2020-12-22 | Ecolab Usa Inc. | Compositions of oxygenated amines and quinone methides as antifoulants for vinylic monomers |
US11180578B2 (en) | 2018-07-13 | 2021-11-23 | Ecolab Usa Inc. | Polymerization inhibitor and retarder compositions with amine stabilizer |
US11396629B2 (en) * | 2019-10-11 | 2022-07-26 | Ecolab Usa Inc. | Quinone methide and ammonium salt antipolymerant composition and method |
Also Published As
Publication number | Publication date |
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CA2392526A1 (en) | 2001-06-07 |
ATE370210T1 (de) | 2007-09-15 |
AR026669A1 (es) | 2003-02-19 |
ES2292487T3 (es) | 2008-03-16 |
US7943809B2 (en) | 2011-05-17 |
US20100093897A1 (en) | 2010-04-15 |
EP1235885B1 (en) | 2007-08-15 |
MXPA02005502A (es) | 2002-09-02 |
JP2003515656A (ja) | 2003-05-07 |
TWI259185B (en) | 2006-08-01 |
CA2392526C (en) | 2010-07-27 |
JP4070461B2 (ja) | 2008-04-02 |
US20050113626A1 (en) | 2005-05-26 |
EP1235885A1 (en) | 2002-09-04 |
MY144939A (en) | 2011-11-30 |
BR0016113B1 (pt) | 2011-02-22 |
BR0016113A (pt) | 2002-11-26 |
DE60036018D1 (de) | 2007-09-27 |
WO2001040404A1 (en) | 2001-06-07 |
CN1230492C (zh) | 2005-12-07 |
KR20020070303A (ko) | 2002-09-05 |
KR100763663B1 (ko) | 2007-10-04 |
DE60036018T2 (de) | 2008-04-30 |
CN1411499A (zh) | 2003-04-16 |
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