Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J27/00—Catalysts comprising the elements or compounds of halogens, sulfur, selenium, tellurium, phosphorus or nitrogen; Catalysts comprising carbon compounds
  • B01J27/24—Nitrogen compounds
  • B01J27/26—Cyanides
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G65/00—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule
  • C08G65/02—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from cyclic ethers by opening of the heterocyclic ring
  • C08G65/04—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from cyclic ethers by opening of the heterocyclic ring from cyclic ethers only
  • C08G65/06—Cyclic ethers having no atoms other than carbon and hydrogen outside the ring
  • C08G65/08—Saturated oxiranes
  • C08G65/10—Saturated oxiranes characterised by the catalysts used
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G65/00—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule
  • C08G65/02—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from cyclic ethers by opening of the heterocyclic ring
  • C08G65/26—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from cyclic ethers by opening of the heterocyclic ring from cyclic ethers and other compounds
  • C08G65/2642—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from cyclic ethers by opening of the heterocyclic ring from cyclic ethers and other compounds characterised by the catalyst used
  • C08G65/2645—Metals or compounds thereof, e.g. salts
  • C08G65/2663—Metal cyanide catalysts, i.e. DMC's

Definitions

• Double metal cyanide catalysts for the production of polyether polyols Double metal cyanide catalysts for the production of polyether polyols
• the invention relates to new double metal cyanide (DMC) catalysts for the production of polyether polyols by polyaddition of alkylene oxides to active ones
• Double metal cyanide (DMC) catalysts for the polyaddition of alkylene oxides to starter compounds having active hydrogen atoms are known (see, for example, US Pat. Nos. 3,404,109, 3,829,505, 3,941,849 and 5,158,922).
• DMC Double metal cyanide
• DMC catalysts for the production of polyether polyols results in particular in a reduction in the proportion of monofunctional polyethers with terminal double bonds, so-called monools, compared to the conventional production of polyether polyols using alkali catalysts, such as alkali metal hydroxides.
• the polyether polyols thus obtained can be processed into high-quality polyurethanes (e.g. elastomers, foams, coatings).
• DMC catalysts are usually obtained by combining an aqueous solution of a metal salt with the aqueous solution of a metal cyanide salt in the presence of an organic complex ligand, e.g. of an ether.
• aqueous solutions of zinc chloride in a typical catalyst preparation, for example, aqueous solutions of zinc chloride (in
• DMC catalysts which by using tert-butanol as organic complex ligand (alone or in combination with a polyether (EP 700 949, EP 761 708, WO 97/40086)) further reduce the proportion of monofunctional polyethers with terminal double bonds in the production of polyether polyols.
• tert-butanol organic complex ligand
• the use of these DMC catalysts reduces the induction time in the polyaddition reaction of the alkylene oxides with corresponding starter compounds and increases the catalyst activity.
• Ligand combinations of tert-butanol and polyalkylene glycols are preferably used.
• the object of the present invention was to provide further improved DMC catalysts for the polyaddition of alkylene oxides to corresponding starter compounds which have increased catalyst activity in relation to the types of catalysts known hitherto. This is done by shortening the
• the catalyst can then be used in such low concentrations (25 ppm or less) that the very complex separation of the catalyst from the product is no longer necessary and the product can be used directly for the production of polyurethane.
• DMC catalysts which contain a complex ligand which is formed by introducing a glycidyl ether into the catalyst have greatly increased activity in the production of polyether polyol.
• the present invention therefore relates to a double metal cyanide (DMC) catalyst comprising
• d) water, preferably 1 to 10% by weight and / or e) one or more water-soluble metal salts, preferably 5 to 25% by weight, of the formula (I) M (X) n from the Preparation of the double metal cyanide compounds a) may be included.
• M is selected from the metals Zn (II), Fe (II), Ni (II), Mn (II), Co (II), Sn (II), Pb (II), Fe (III) , Mo (IV), Mo (VI), AI (III), V (V), V (IV), Sr (II), W (IV), W (VI), Cu (II) and Cr (III) .
• Zn (II), Fe (II), Co (II) and Ni (II) are particularly preferred.
• X are the same or different, preferably the same and an anion, preferably selected from the group of halides, hydroxides, sulfates, carbonates, cyanates, thiocyanates, isocyanates, isothiocyanates, carboxylates, oxalates or nitrates.
• the value for n is 1, 2, or 3.
• the double metal cyanide compounds a) contained in the catalysts according to the invention are the reaction products of water-soluble metal salts and water-soluble metal cyanide salts.
• Water-soluble metal salts suitable for the preparation of double metal cyanide compounds a) preferably have the general formula (I) M (X) n , where M is selected from the metals Zn (II), Fe (II), Ni (II), Mn (II), Co (II), Sn (II), Pb
• X are the same or different, preferably the same and an anion, preferably selected from the group of halides, hydroxides, sulfates, carbonates, cyanates, thiocyanates, isocyanates, isothiocyanates, carboxylates, oxalates or nitrates. The value for n is
• water-soluble metal salts examples include zinc chloride, zinc bromide, zinc acetate, zinc acetylacetonate, zinc benzoate, zinc nitrate, iron (II) sulfate, iron (II) bromide, iron (II) chloride, cobalt (II) chloride, cobalt (II) thiocyanate, nickel ( II) chloride and nickel (II) nitrate. Mixtures of different water-soluble ones can also be used
• Water-soluble metal cyanide salts suitable for the preparation of double metal cyanide compounds a) preferably have the general formula (II) (Y) a M '(CN) b (A) c , where M 1 is selected from the metals Fe (II), Fe (III ), Co (II), Co (III), Cr (II),
• M ' is particularly preferably selected from the metals Co (II), Co (III), Fe (II), Fe (III), Cr (III), Ir (III) and Ni (II).
• the water-soluble metal cyanide salt can contain one or more of these metals.
• Y are the same or different, preferably the same, and an alkali metal ion or an alkaline earth metal ion.
• A are the same or different, preferably the same, and an anion selected from the group of halides, hydroxides, sulfates, carbonates, cyanates, thiocyanates, isocyanates, isothiocyanates, carboxylates, oxalates or nitrates.
• Both a, and b and c are integers, the values for a, b and c being chosen so that the electroneutrality of the metal cyanide salt is given; a is preferably 1, 2, 3 or 4; b is preferably 4, 5 or 6; c preferably has the value 0.
• Suitable water-soluble metal cyanide salts are potassium hexacyanocobaltate (III), potassium hexacyanoferrate (II), potassium hexacyanoferrate (III), calcium hexacyanocobaltate (III) and lithium hexacyanocobaltate (III).
• Preferred double metal cyanide compounds a) used in the invention are Preferred double metal cyanide compounds a) used in the invention.
• Containing catalysts are compounds of the general formula (III)
• M ' is as defined in formula (II), and x, x ', y and z are integers and are chosen so that the electron neutrality of the double metal cyanide compound is given.
• Suitable double metal cyanide compounds a) are zinc hexacyanocobalate (III), zinc hexacyanoiridate (II), zinc hexacyanoferrate (III) and cobalt (II) hexacyano cobaltate (III). Further examples of suitable double metal cyanide compounds are e.g. US 5 158 922 (column 8, lines 29-66). Zinc hexacyanocobaltate (III) is particularly preferably used.
• organic complex ligands b) contained in the DMC catalysts according to the invention are known in principle and are described in detail in the prior art (see, for example, US Pat. No. 5,158,922, in particular column 6, lines 9-65, US Pat. No. 3,404,109, US Pat. No. 3,829,505). US 3 941 849, EP 700 949, EP 761 708, JP 4 145 123, US 5 470 813, EP 743 093 and WO 97/40086).
• Preferred organic complex ligands are water-soluble organic compounds with heteroatoms, such as oxygen,
• Suitable organic complex ligands are e.g. Alcohols, aldehydes, ketones, ethers, esters, amides, ureas, nitriles, sulfides and their mixtures.
• Preferred organic complex ligands are water-soluble aliphatic alcohols, such as ethanol, isopropanol, n-butanol, iso-butanol, sec.
• Butanol and tert-butanol are particularly preferred.
• Tert-butanol is particularly preferred.
• the organic complex ligand is either added during the catalyst preparation or immediately after the precipitation of the double metal cyanide compound a).
• the organic complex ligand is usually used in excess.
• the DMC catalysts according to the invention contain the double metal cyanide compounds a) in amounts of 20 to 90% by weight, preferably 25 to 80% by weight, based on the amount of the finished catalyst, and the organic complex ligands b) in amounts from 0.5 to 30, preferably 1 to 25 wt .-%, based on the amount of the finished catalyst.
• the DMC catalysts according to the invention usually contain 5 to 80% by weight, preferably 10 to 60% by weight, based on the amount of the finished catalyst, of complex ligands c) which have been formed by introducing a glycidyl ether into the catalyst.
• Suitable for the production of the catalysts according to the invention are e.g.
• Glycidyl ethers of mono-, di-, tri-, tetra- or polyfunctional aliphatic alcohols such as butanol, hexanol, octanol, decanol, dodecanol, tetradecanol, ethanediol, 1,2-propanediol, 1,3-propanediol, 1,4- Butanediol, 2,2-dimethyl-l, 3-propanediol, 1,2,3-propanetriol, 1,6-hexanediol, l, l, l-tris (hydroxymethyl) ethane, 1,1,1-tris ( hydroxymethyl) propane, tetrakis (hydroxymethyl) methane, sorbitol, polyethylene glycol and polypropylene glycol, both mono-, di-, tri-,
• glycidyl ethers are generally converted into the corresponding chlorohydrins by subsequent reaction of mono-, di-, tri-, tetra- or polyfunctional alcohols with epichlorohydrin in the presence of a Lewis acid such as tin tetrachloride or boron trifluoride and subsequent dehydrohalogenation with base (eg sodium hydroxide ) receive.
• a Lewis acid such as tin tetrachloride or boron trifluoride
• base eg sodium hydroxide
• the glycidyl ether used to prepare the catalyst according to the invention can be present in the finished catalyst in the form originally used or in chemically modified, e.g. hydrolyzed form.
• the analysis of the catalyst composition is usually carried out by means of elemental analysis and thermogravimetry or extractive removal of the complex ligand, which was formed by introducing a glycidyl ether into the catalyst, with subsequent gravimetric determination.
• the catalysts of the invention can be crystalline, semi-crystalline or amorphous.
• the crystallinity is usually analyzed by powder X-ray diffractometry.
• the DMC catalysts according to the invention are usually prepared in aqueous solution by reacting ⁇ ) metal salts, in particular of the formula (I), with metal cyanide salts, in particular of the formula (II), .beta.) Organic complex ligands b) which are different from glycidyl ether and ⁇ ) Glycidyl ether.
• aqueous solutions of the metal salt e.g.
• Zinc chloride used in a stoichiometric excess (at least 50 mol% based on the metal cyanide salt)) and the metal cyanide salt (for example potassium hexacyanocobaltate) in the presence of the organic complex ligand b) (for example tert-butanol), a suspension being formed which comprises the double metal cyanide - Compound a) (eg zinc hexacyanocobaltate), water d), excess metal salt e), and the organic complex ligand b).
• the metal cyanide salt for example potassium hexacyanocobaltate
• the organic complex ligand b) for example tert-butanol
• the organic complex ligand b) can be present in the aqueous solution of the metal salt and / or the metal cyanide salt, or it is added directly to the suspension obtained after precipitation of the double metal cyanide compound a). It has proven to be advantageous to mix the aqueous solutions and the organic complex ligand b) with vigorous stirring. The suspension formed is then usually treated with the glycidyl ether. The glycidyl ether is preferably used in a mixture with water and organic complex ligand b).
• the catalyst is then isolated from the suspension by known techniques, such as centrifugation or filtration.
• the isolated catalyst is then washed with an aqueous solution of the organic complex ligand b) (for example by resuspending and then isolating again by filtration or centrifugation).
• an aqueous solution of the organic complex ligand b) for example by resuspending and then isolating again by filtration or centrifugation.
• water-soluble by-products such as potassium chloride can be removed from the catalyst according to the invention.
• the amount of the organic complex ligand b) in the aqueous washing solution is preferably between 40 and 80% by weight, based on the total solution.
• glycidyl ether to the aqueous washing solution, preferably in the range between 0.5 and 5% by weight, based on the total solution.
• the washed catalyst is then dried, if appropriate after pulverization, at temperatures of generally 20-100 ° C. and at pressures generally from 0.1 mbar to normal pressure (1013 mbar).
• Another object of the present invention is the use of the DMC catalysts according to the invention in a process for the production of
• Polyether polyols by polyaddition of alkylene oxides to starter compounds having active hydrogen atoms.
• Preferred alkylene oxides are ethylene oxide, propylene oxide, butylene oxide and mixtures thereof.
• Alkoxylation can, for example, only be carried out with one monomeric epoxide or also statistically or in blocks with 2 or 3 different monomeric epoxides. More details can be found in "Ullmann's Encyclopedia of Industrial Chemistry", English edition, 1992, Volume A21, pages 670 - 671.
• Compounds having molecular weights of 18 to 2000 and 1 to 8 hydroxyl groups are preferably used as starter compounds having active hydrogen atoms. Examples include: ethylene glycol, diethylene glycol, triethylene glycol, 1,2-propylene glycol, 1,4-butanediol, hexamethylene glycol, bisphenol A, trimethylolpropane, glycerol, pentaerythritol, sorbitol,
• starter compounds containing active hydrogen atoms are used which e.g. were prepared by conventional alkali analysis from the aforementioned low-molecular starters and are oligomeric alkoxylation products with molecular weights of 200 to 2000.
• the polyaddition of alkylene oxides to starter compounds having active hydrogen atoms which is catalyzed by the catalysts according to the invention, generally takes place at temperatures from 20 to 200 ° C., preferably in the range from 40 to 180 ° C., particularly preferably at temperatures from 50 to 150 ° C.
• the reaction can be carried out at total pressures of 0 to 20 bar.
• the polyaddition kami can be carried out in bulk or in an inert organic solvent, such as toluene and / or THF.
• the amount of solvent is usually 10 to 30% by weight, based on the amount of the polyether polyol to be prepared.
• the catalyst concentration is chosen so that good control of the polyaddition reaction is possible under the given reaction conditions.
• the catalyst concentration is generally in the range from 0.0005% by weight
• 1% by weight preferably in the range from 0.001% by weight to 0.1% by weight, particularly preferably in the range from 0.001 to 0.0025% by weight, based on the amount of the polyether polyol to be prepared.
• Polyether polyols are in the range from 500 to 100,000 g / mol, preferably in the range from 1000 to 50,000 g / mol, particularly preferably in the range from 2000 to 20,000 g / mol.
• the polyaddition can be continuous or discontinuous, e.g. be carried out in a batch or semi-batch process.
• the alkoxylation times in polyether polyol production are typically reduced by 70-75% compared to previously known DMC catalysts with tert-butanol and polyalkylene glycols as ligands.
• the catalysts according to the invention can be used in very low concentrations (25 ppm and less, based on the amount of the polyether polyol to be prepared). If the polyether polyols prepared in the presence of the catalysts according to the invention are used for the production of polyurethanes (Kunststoff Handbuch, Vol. 7, Polyurethane, 3rd edition, 1993, pp. 25-32 and 57-67), the catalyst can be removed from the polyether polyol be dispensed with without adversely affecting the product qualities of the polyurethane obtained.
• Example 2 The procedure was as in Example 1, except that the glycidyl ether used was a polypropylene glycol bis (2,3-epoxypropyl ether) with a number average molecular weight of 380 (from Aldrich) instead of the polypropylene glycol bis (2,3-epoxypropyl ether) from Example 1 used.
• the glycidyl ether used was a polypropylene glycol bis (2,3-epoxypropyl ether) with a number average molecular weight of 380 (from Aldrich) instead of the polypropylene glycol bis (2,3-epoxypropyl ether) from Example 1 used.
• Example 1 The procedure was as in Example 1, but the glycidyl ether used was poly (oxyethylene) bis (glycidyl ether) with a number-average molecular weight of 3350 (Sigma) instead of the polypropylene glycol bis (2,3-epoxypropyl ether) from Example 1.
• poly (oxyethylene) bis (glycidyl ether) with a number-average molecular weight of 3350 (Sigma) instead of the polypropylene glycol bis (2,3-epoxypropyl ether) from Example 1.
• the mixture is stirred again for 10 minutes with a mixture of 100 g of tert-butanol and 0.5 g of the above polypropylene glycol (10,000 rpm). After filtration, the catalyst is dried to constant weight at 50 ° C. and normal pressure.
• the polyether polyols obtained were characterized by determining the OH numbers, the double bond contents and the viscosities.
• Polyether polyol OH number (mg KOH / g): 30.0
• Polyether polyol OH number (mg KOH / g): 30.4
• Polyether polyol OH number (mg KOH / g): 29.0

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