US20220081384A1 - Direct conversion of esters to carboxylates - Google Patents

Direct conversion of esters to carboxylates Download PDF

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Publication number
US20220081384A1
US20220081384A1 US17/476,752 US202117476752A US2022081384A1 US 20220081384 A1 US20220081384 A1 US 20220081384A1 US 202117476752 A US202117476752 A US 202117476752A US 2022081384 A1 US2022081384 A1 US 2022081384A1
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reaction solution
calcium
process according
compound
formula
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US17/476,752
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English (en)
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Kelly Brannen
David J. Harrigan
Donal S. Tunks
Stanley A. Sojka
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Niacet Corp
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Niacet Corp
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Priority to US17/476,752 priority Critical patent/US20220081384A1/en
Assigned to Niacet Corporation reassignment Niacet Corporation ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BRANNEN, KELLY A., HARRIGAN, DAVID J., SOJKA, STANLEY A., TUNKS, DONAL S.
Publication of US20220081384A1 publication Critical patent/US20220081384A1/en
Priority to US18/460,239 priority patent/US20230406806A1/en
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C51/00—Preparation of carboxylic acids or their salts, halides or anhydrides
    • C07C51/41—Preparation of salts of carboxylic acids
    • C07C51/412—Preparation of salts of carboxylic acids by conversion of the acids, their salts, esters or anhydrides with the same carboxylic acid part
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C51/00—Preparation of carboxylic acids or their salts, halides or anhydrides
    • C07C51/42—Separation; Purification; Stabilisation; Use of additives
    • C07C51/47—Separation; Purification; Stabilisation; Use of additives by solid-liquid treatment; by chemisorption
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C53/00—Saturated compounds having only one carboxyl group bound to an acyclic carbon atom or hydrogen
    • C07C53/08—Acetic acid
    • C07C53/10—Salts thereof
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C53/00—Saturated compounds having only one carboxyl group bound to an acyclic carbon atom or hydrogen
    • C07C53/122—Propionic acid
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C53/00—Saturated compounds having only one carboxyl group bound to an acyclic carbon atom or hydrogen
    • C07C53/124—Acids containing four carbon atoms

Definitions

  • the present invention relates to processes for the production of a calcium carboxylate directly from an ester or anhydride.
  • Calcium carboxylates are useful in the production of the corresponding carboxylic acids. Calcium carboxylates also have other beneficial applications. For example, calcium acetate is used as a thickening agent, such as in cake batters, puddings, and pie fillings, as buffers in controlling pH of food during various stages of processing as well as in the finished product, as a preservative to prevent microbial growth, and as a calcium supplement in pet products. In addition, calcium propionate is used on a large scale as a preservative in the foodstuffs sector, particularly in baked goods, and as a preservative and nutritional supplement in animal feeds.
  • Calcium carboxylates are typically prepared by the conventional methods for synthesizing carboxylic acid salts, for example by reacting a carbonate, hydroxide, or oxide with a concentrated or dilute carboxylic acid.
  • Calcium propionate for instance, is typically produced from propionic acid and calcium.
  • the invention is directed to methods of converting esters to calcium carboxylates.
  • one embodiment is a method of reacting water, calcium oxide, and a compound of formula (I):
  • R is a C 1 -C 3 alkyl and R 1 is a C 1 or C 2 alkyl, to obtain a reaction solution and heating the reaction solution to remove an amount of a co-product from the reaction solution. Further, the calcium carboxylate may be recovered in solid form from the reaction solution.
  • Another embodiment is a method for producing calcium propionate comprising reacting water and calcium oxide to obtain a slurry; reacting the slurry with methyl propionate, wherein the calcium oxide is reacted in a molar excess compared to the methyl propionate, to obtain a reaction solution; heating the reaction solution to remove an amount of methanol from the reaction solution; neutralizing the reaction solution to a pH of from 7.0 to 9.5 by adding a sufficient quantity of propionic acid; and filtering the reaction solution. Further, the calcium propionate may be recovered in solid form from the filtered reaction solution.
  • the invention is further directed to methods of converting anhydrides to calcium carboxylates.
  • FIG. 1 is an apparatus for the conversion of methyl propionate to calcium propionate.
  • the reference numbers in the FIGURES correspond to a methanol tank 8 ; an integral steam coil 12 ; a condenser 14 ; a 3-way valve 16 ; an agitator 18 ; a reactor vessel 20 ; a slurry pump 22 ; and a reflux column 30 .
  • R and R 1 are, independently, selected from H, Ph, Ar, a substituted C 1 -C 60 alkyl, and an unsubstituted C 1 -C 60 alkyl.
  • the inventors also discovered a process that directly converts anhydrides of formula (II) to calcium carboxylates according to the following reaction:
  • R and R 1 are, independently, selected from H, Ph, Ar, a substituted C 1 -C 60 alkyl, and an unsubstituted C 1 -C 60 alkyl.
  • the C 1 -C 60 alkyl may be substituted with at least one substituent selected from the group consisting of: F, Cl, Br, I, At, O, S, S(O), SO 2 , N, P, P(O), Si, Si(O), B, Al, and combinations thereof.
  • Ar is a C 6 or C 12 aryl or heteroaryl optionally substituted group where the heteroatom may be O or N and the substituent may be selected from the group consisting of H, F, Cl, Br, I, At, SO 2 , NH 2 , NHR, NR 2 and combinations thereof, where R is as defined herein.
  • the number of such substituents to be substituted on the C 1 -C 60 alkyl may be 1, 2, 3 or 4.
  • the C 1 -C 60 alkyl is substituted with at least one C 1 substituent. In yet a further embodiment, the C 1 -C 60 alkyl is substituted with two Cl substituents.
  • R and R 1 are, independently, selected from the group consisting of H and an unsubstituted C 1 -C 10 alkyl. In another embodiment, R and R 1 are, independently, selected from the group consisting of an unsubstituted C 1 -C 8 alkyl. In yet another embodiment, R and R 1 are, independently, selected from the group consisting of an unsubstituted C 1 -C 6 alkyl. In yet another embodiment, R and R 1 are, independently, selected from the group consisting of an unsubstituted C 1 -C 4 alkyl.
  • R and R 1 may each be an unsubstituted C 1 alkyl.
  • R and R 1 may each be an unsubstituted C 2 alkyl.
  • R is an unsubstituted C 2 alkyl and R 1 is an unsubstituted C 1 alkyl.
  • R is an unsubstituted C 3 alkyl and R 1 is an unsubstituted C 1 alkyl.
  • the compound of formula (I) and the compound of formula (II) may comprise fewer than ten, eight, six, five, or four carbon atoms. In one embodiment, the compound of formula (I) and the compound of formula (II) comprise fewer than six carbon atoms.
  • alkyl means, unless otherwise stated, a straight or branched chain, acyclic or cyclic hydrocarbon radical, or combination thereof, which may be fully saturated, mono- or polyunsaturated and can include di- and multi-valent radicals, having the number of carbon atoms designated (e.g., C 1-10 means one to ten carbons) and may be substituted or unsubstituted.
  • saturated hydrocarbon radicals include groups such as methyl, ethyl, n-propyl, isopropyl, n-butyl, t-butyl, isobutyl, sec-butyl, cyclohexyl, (cyclohexyl)methyl, cyclopropylmethyl, homologs and isomers of, for example, n-pentyl, n-hexyl, n-heptyl, n-octyl, and the like.
  • An unsaturated alkyl group is one having one or more double bonds or triple bonds.
  • unsaturated alkyl groups include vinyl, 2-propenyl, crotyl, 2-isopentenyl, 2-(butadienyl), 2,4-pentadienyl, 3-(1,4-pentadienyl), ethynyl, 1- and 3-propynyl, 3-butynyl, and the higher homologs and isomers.
  • the compound of formula (I) may be methyl acetate, ethyl propionate, methyl propionate, or methyl butanoate. In one embodiment, the compound of formula (I) is methyl propionate.
  • the compound of formula (II) may be acetic anhydride, propionic anhydride, butanoic anhydride, or acetic propionic anhydride. In one embodiment, the compound of formula (II) is acetic anhydride.
  • the amount of calcium oxide employed in the conversion of a compound of formula (I) can be expressed as a molar ratio of calcium oxide to the compound of formula (I).
  • a molar excess of calcium oxide compared to the compound of formula (I) may be employed.
  • the molar ratio of calcium oxide to the compound of formula (I) may be from 0.5:1 to 0.75:1.
  • a stoichiometric excess of the calcium oxide compared to the compound of formula (I), i.e. a molar ratio greater than 0.5:1 will result in an excess of the calcium oxide.
  • a molar ratio of 0.75:1 corresponds to a molar excess of 50%.
  • the molar ratio of calcium oxide to the compound of formula may be from 0.5:1 to 0.6:1 (an excess of calcium oxide up to a 20% molar excess).
  • the molar ratio of calcium oxide to the compound of formula may be about 0.505:1 to about 0.55:1 (a molar excess of 1% to 10%).
  • the amount of calcium oxide employed in the conversion of a compound of formula (II) can be expressed as a molar ratio of calcium oxide to the compound of formula (II).
  • a molar excess of calcium oxide compared to the compound of formula (II) may be employed.
  • the molar ratio of calcium oxide to the compound of formula (II) may be from 1:1 to 1.5:1.
  • a stoichiometric excess of the calcium oxide compared to the compound of formula (II), i.e. a molar ratio greater than 1:1 will result in an excess of the calcium oxide.
  • a molar ratio of 1.5:1 corresponds to a molar excess of 50%.
  • the molar ratio of calcium oxide to the compound of formula (II) may be from 1:1 to 1.2:1 (an excess of calcium oxide up to a 20% molar excess).
  • the molar ratio of calcium oxide to the compound of formula (II) may be about 1.01:1 to about 1.1:1 (a molar excess of 1% to 10%).
  • the amount of water employed in the process is the amount necessary to form a slurry; one of ordinary skill in the art is capable of adjusting the amount of water such that the amount is not too large to destroy the volumetric throughput of a reaction vessel and not too small such that the slurry would be immovable, i.e. incapable of being mixed and/or pumped.
  • the amount of calcium hydroxide formed from the reaction of water and calcium oxide is from 8% to 10% (w/w).
  • the amount of calcium hydroxide formed from the reaction of water and calcium oxide is from 10% to 30% (w/w).
  • the amount of calcium hydroxide formed from the reaction of water and calcium oxide is from 30% to 60% (w/w).
  • the calcium oxide, water, and compound of formula (I) or (II) may be reacted in any order and in one or more reaction vessels.
  • the calcium oxide and water may be reacted in a first reaction vessel, followed by reaction with the compound of formula (I) or (II) in a second reaction vessel.
  • the reaction may take place in a single reaction vessel.
  • water may be added to the single reaction vessel, followed by the calcium oxide, followed by the compound of formula (I) or (II).
  • calcium oxide may be added to the single reaction vessel, followed by the water, followed by the compound of formula (I) or (II).
  • One or more of the calcium oxide, water, and compound of formula (I) or (II) may be added over a period of time instead of in a single bolus.
  • the compound of formula (I) or (II) may be added to a reaction vessel over a period of up to three hours.
  • the compound of formula (I) or (II) is added to a reaction vessel over a period of from 30 to 120 minutes.
  • the compound of formula (I) or (II) is added to a reaction vessel over a period of 30 minutes, 45 minutes, 60 minutes, 90 minutes, or 120 minutes.
  • the process of the invention can generally be conducted at a temperature sufficient to allow the reaction to proceed.
  • the temperature of the reaction may be from 50° C. to 100° C. Temperature of the reaction may be maintained, if necessary, by conventional techniques, such as by employing a heating coil or mantle.
  • the reaction time will be the time suitable to obtain the desired conversion of the compound of formula (I) or (II) into calcium carboxylate. Generally, the reaction time will vary depending on process parameters including the reaction temperature and the compound of formula (I) or (II) used. For instance, after addition of the reactants is complete, the reaction may be allowed to proceed for from 2 to 4 hours, or from 2 to 8 hours, or from 2 to 12 hours.
  • the process of the invention can be conducted as a batch, semi-batch, or continuous process depending on the scale of the process and capital investment required.
  • the process further comprises removal of an amount of one or more co-products.
  • the co-product may be, for instance, methanol or ethanol.
  • the co-product may also be propanol or butanol.
  • an amount of a co-product can be removed by heating the reaction solution to distill the co-product overhead.
  • the temperature that the reaction solution is heated to will be any suitable temperature effective to remove the desired amount of co-product and will be readily apparent to those of ordinary skill in the art.
  • the temperature may be, for instance, from 70° C. to 100° C., or from 70° C. to 150° C.
  • the time cycle for distillation can be set depending on the distillation conditions and the desired level of residual co-product in the calcium carboxylate product, and will be readily apparent to those of ordinary skill in the art.
  • nitrogen gas may be introduced below the liquid level of the reaction solution to aid in the distillation process.
  • the distilled co-product may be sufficiently pure to be reclaimed and reused. It should be understood that it may not be possible to remove all amounts of a co-product from the reaction solution and that trace amounts of a co-product may therefore still exist in the reaction solution as an impurity.
  • substantially all of a co-product is removed from the reaction solution.
  • the amount of a co-product such as methanol, is less than 1%, or 0.1%, or 0.01%, or 0.001%, or even undetectable relative to the calcium carboxylate in the reaction solution following distillation.
  • Concentration adjustment may be needed, for instance, to ensure that all of the calcium carboxylate is in solution and/or to adjust the concentration of the calcium carboxylate if the final product is to be a solution. Concentration adjustment may be effected by, for example, adding additional water or other diluent to the reaction solution. In one embodiment, the concentration of the calcium carboxylate is adjusted to from 23% to 28% (w/w) by adding water. The concentration of the calcium carboxylate may be adjusted to, for instance, 25% or 26% (w/w) by adding water.
  • the reaction solution may be optionally neutralized and may also be optionally filtered.
  • the reaction solution may only be neutralized, only be filtered, may be both neutralized and filtered, or may not be neutralized or filtered.
  • the neutralization (pH adjustment) and filtration, if both performed, can be conducted in any order.
  • the reaction solution may be filtered using conventional equipment and techniques after the distillation to remove excess insoluble calcium oxide, as well as any other impurities that may be adsorbed onto the particle surfaces, as well as any other insoluble materials present in the reactants used, such as sand, gravel, pebbles, carbonaceous material, polymers formed during the reaction, etc.
  • the pH may be adjusted with carboxylic acid corresponding to the calcium carboxylate to neutralize soluble calcium compound (forming additional calcium carboxylate) and reach the desired pH for the product.
  • the pH may be adjusted to, for instance, from 7.0 to 9.5, from 7.0 to 8.0, or 7.5, or 10.0.
  • neutralization with carboxylic acid corresponding to the calcium carboxylate to neutralize excess calcium compound present is performed. Filtration of the neutralized reaction solution is then conducted to remove remaining insolubles.
  • the reaction solution may be subjected to further processing that is dependent on the form of the final product desired, for instance, a solution product or a solid product.
  • the calcium carboxylate product optionally has the concentration adjusted by, for example, adding water or calcium carboxylate, and may have one or more additional filtrations using, for example, a polishing filter or equivalent separation device.
  • the calcium carboxylate product may be recovered and dried. Recovery and drying can be done utilizing any conventional process known to one of ordinary skill in the art.
  • the solution may be dried directly to a powder using a spray dryer or by spraying onto dry particles in a fluid bed dryer.
  • the calcium carboxylate product may be crystallized by water evaporation, collection on a filter or centrifuge, and final drying in any conventional solids dryer used to dry wet solids.
  • the calcium carboxylate solution may be processed through an agglomerator to make a granular product.
  • the purity of the solid calcium carboxylate may be determined according to standard Ca-EDTA titration as set forth in FCC 11 (“Calcium Propionate”, Food Chemicals Codex 11, page 221, US Pharmacopeia, 2018).
  • the purity of the solid calcium carboxylate may be, for instance, greater than 95.0%, greater than 98.0%, greater than 98.5%, greater than 99.0%, or greater than 99.5%, or greater than 99.9%.
  • the temperature of the reaction solution was raised to 95° C. to distill volatile components into a receiver. A total of 575.9 g of distillate was collected over a period of 6 hr. Analysis of this distillate gave 426.4 g of water by Karl Fischer titration. The volatile organic constituents of the distillate were analyzed by gas chromatography to give 149.5 g of methanol (103% recovery). The removal of the water by distillation was calculated to ensure that the remaining contents of the round bottom flask was a 26% aqueous solution of calcium propionate. This solution was filtered through diatomaceous earth. Upon cooling, solids were precipitated, removed by filtration, and dried in an oven to give 404.3 g of calcium propionate (95.9% yield) as a white solid. Analysis by standard Ca-EDTA titration gave a purity of 99.8%.
  • a lime slurry was prepared in a 55 gallon polypropylene tank fitted with an agitator by the addition of 12.8 kg of lime (95%; Specialty Minerals, Inc) into 131.9 kg of city water. This mixed slurry was pumped into a jacketed 50 gallon glass-lined steel reactor fitted with an agitator and condenser. To this reactor was then added 36.9 kg of methyl propionate (99.95%; Lucite) over a period of 0.75 hr. After this addition was complete, the reaction solution was kept at 65° C. for 1 hr. The temperature of the reaction solution did not exceed 65° C., and the final pH was adjusted from 11.3 to 7.8 by the addition of 0.9 kg of propionic acid.
  • Nitrogen gas was introduced below the liquid level at a rate of 50 SCFH as the temperature was increased to 100° C. to distill off volatile components through the condenser and into a receiving vessel. After 6 hr of distillation, a total of 111.5 kg of distillate was collected and was analyzed as 96.4 kg of water, 13.4 kg of methanol (100% recovery), and 1.7 kg of unreacted methyl propionate. The removal of volatiles by distillation was calculated to ensure that the remaining contents of the reactor was a 25% aqueous solution of calcium propionate. This solution was filtered through diatomaceous earth. The solution was found to contain 38.8 kg of calcium propionate (99.5% yield) of 99.8% purity as determined by standard Ca-EDTA titration.
  • the reactor system of this example is shown in FIG. 1 .
  • the system comprises a 50 gallon reaction vessel 20 .
  • Water and calcium oxide are reacted in a separate vessel (not pictured) and the slurry is added to the reaction vessel 20 .
  • Slurry pump 22 and 3-way valve 16 allow for the slurry to be recirculated through and recycled back to the reaction vessel 20 to ensure complete slurry formation.
  • Methyl propionate (MEP) is fed into reaction vessel 20 .
  • the contents of the reaction vessel 20 are mixed using agitator 18 .
  • Propionic acid is added to the reaction vessel 20 in order to neutralize any remaining calcium hydroxide.
  • the reactor contents are heated using an integral steam coil 12 .
  • Water and methanol vapor generated when the contents in reaction vessel 20 are heated can be condensed at the top of a reflux column 30 and returned from condenser 14 to a methanol tank 8 .
  • the methanol and water may be recycled to the next consecutive batch.
  • the calcium propionate solution is transferred by slurry pump 22 to a drum filter.
  • the 3-way valve 16 can be turned to pump thy: reactor contents out of the reaction vessel 20 to the plant instead of being recycled to the reaction vessel 20 .

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Organic Low-Molecular-Weight Compounds And Preparation Thereof (AREA)
  • Compounds Of Alkaline-Earth Elements, Aluminum Or Rare-Earth Metals (AREA)
US17/476,752 2020-09-17 2021-09-16 Direct conversion of esters to carboxylates Abandoned US20220081384A1 (en)

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US17/476,752 US20220081384A1 (en) 2020-09-17 2021-09-16 Direct conversion of esters to carboxylates
US18/460,239 US20230406806A1 (en) 2020-09-17 2023-09-01 Direct conversion of esters to carboxylates

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US17/476,752 US20220081384A1 (en) 2020-09-17 2021-09-16 Direct conversion of esters to carboxylates

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EP (1) EP3971161A1 (fr)
JP (1) JP2023541962A (fr)
KR (1) KR20230054720A (fr)
CN (1) CN116323543A (fr)
AR (1) AR123536A1 (fr)
AU (1) AU2021343253A1 (fr)
CA (1) CA3192700A1 (fr)
CL (1) CL2023000722A1 (fr)
CO (1) CO2023004641A2 (fr)
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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2033909A (en) * 1934-12-19 1936-03-17 Niacet Chemicals Corp Manufacture of calcium levulinate
US4700000A (en) * 1982-04-28 1987-10-13 Basf Aktiengesellschaft Preparation of calcium propionate
SK279966B6 (sk) * 1994-12-13 1999-06-11 Duslo Spôsob výroby protimrazového chemického prostriedk
US20180370897A1 (en) * 2015-11-11 2018-12-27 Battelle Memorial Institute Methods of making 1,19-nonadecanediester and derivatives thereof

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19935298A1 (de) * 1999-07-27 2001-02-01 Basf Ag Verfahren zur Herstellung von Calciumpropionat und Vorrichtung zur Durchführung des Verfahrens

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2033909A (en) * 1934-12-19 1936-03-17 Niacet Chemicals Corp Manufacture of calcium levulinate
US4700000A (en) * 1982-04-28 1987-10-13 Basf Aktiengesellschaft Preparation of calcium propionate
SK279966B6 (sk) * 1994-12-13 1999-06-11 Duslo Spôsob výroby protimrazového chemického prostriedk
US20180370897A1 (en) * 2015-11-11 2018-12-27 Battelle Memorial Institute Methods of making 1,19-nonadecanediester and derivatives thereof

Non-Patent Citations (3)

* Cited by examiner, † Cited by third party
Title
Cavalli et al. (Atmospheric Oxidation Mechanism of Methyl Propionate, J. Phys. Chem. A, 104. Pp. 11310-11317, Published 2000) (Year: 2000) *
NGS (Nitrogen Gas Sparging 6 pages Published 2014) (Year: 2014) *
SK279966 translated (Year: 1996) *

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JP2023541962A (ja) 2023-10-04
WO2022058401A1 (fr) 2022-03-24
IL301043A (en) 2023-05-01
CN116323543A (zh) 2023-06-23
AR123536A1 (es) 2022-12-14
CO2023004641A2 (es) 2023-06-30
TW202219025A (zh) 2022-05-16
MX2023003185A (es) 2023-04-26
US20230406806A1 (en) 2023-12-21
EP3971161A1 (fr) 2022-03-23
CA3192700A1 (fr) 2022-03-24
KR20230054720A (ko) 2023-04-25
AU2021343253A1 (en) 2023-04-20

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