Classifications

• • 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
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/08—Processes
  • C08G18/16—Catalysts
  • C08G18/18—Catalysts containing secondary or tertiary amines or salts thereof
  • C08G18/1875—Catalysts containing secondary or tertiary amines or salts thereof containing ammonium salts or mixtures of secondary of tertiary amines and acids
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07D—HETEROCYCLIC COMPOUNDS
  • C07D251/00—Heterocyclic compounds containing 1,3,5-triazine rings
  • C07D251/02—Heterocyclic compounds containing 1,3,5-triazine rings not condensed with other rings
  • C07D251/12—Heterocyclic compounds containing 1,3,5-triazine rings not condensed with other rings having three double bonds between ring members or between ring members and non-ring members
  • C07D251/26—Heterocyclic compounds containing 1,3,5-triazine rings not condensed with other rings having three double bonds between ring members or between ring members and non-ring members with only hetero atoms directly attached to ring carbon atoms
  • C07D251/30—Only oxygen atoms
  • C07D251/34—Cyanuric or isocyanuric esters
• • 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
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/02—Polymeric products of isocyanates or isothiocyanates of isocyanates or isothiocyanates only
• • 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
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/02—Polymeric products of isocyanates or isothiocyanates of isocyanates or isothiocyanates only
  • C08G18/022—Polymeric products of isocyanates or isothiocyanates of isocyanates or isothiocyanates only the polymeric products containing isocyanurate groups
• • 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
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/08—Processes
  • C08G18/09—Processes comprising oligomerisation of isocyanates or isothiocyanates involving reaction of a part of the isocyanate or isothiocyanate groups with each other in the reaction mixture
  • C08G18/092—Processes comprising oligomerisation of isocyanates or isothiocyanates involving reaction of a part of the isocyanate or isothiocyanate groups with each other in the reaction mixture oligomerisation to isocyanurate groups

Definitions

• the subject of the present invention is a process for oligomerization of isocyanates continuously.
• Many processes for preparing polyisocyanates are known and include the use of various catalysts.
• patent application EP 0 003 765 describes the partial cyclotrimerization of isophorone diisocyanate (IPDI or 1-isocyanato-3,3,5-thmethyl-5-isocyanatomethylcyclohexane) via the implementation of a process discontinuous (or batch process) using as catalyst a hydroxide of a quaternary hydroxyalkylammonium.
• IPDI isophorone diisocyanate
• 1-isocyanato-3,3,5-thmethyl-5-isocyanatomethylcyclohexane 1-isocyanato-3,3,5-thmethyl-5-isocyanatomethylcyclohexane
• the patent application DE 10 2004 060 131 describes a process for the continuous preparation of polyisocyanates comprising the use of a catalyst chosen in particular from quaternary ammonium salts. It is specified that the temperature in the reactor varies from 40O to 110O, but this temperature is not uniform inside the reactor because of the existence of different temperature zones in said reactor (preheating zones, reaction zones). and cooling). Finally, this document only mentions the use of a tubular reactor.
• the patent application EP 0 927 731 describes a process for the continuous preparation of a polyisocyanate from IPDI in the presence of quaternary ammonium hydroxide or carboxylate, and at a temperature of 40 to 120 ° C., but this temperature does not vary. It is not uniform inside the reactor due to the existence of different temperature zones in said reactor (preheating, reaction and cooling zones). Finally, this document relates to the use of a tubular reactor.
• the catalysts especially those based on a quaternary ammonium hydroxide such as choline, have a very high reactivity, which makes it difficult to control the trimerization reaction, in particular when the starting isocyanate is an aliphatic isocyanate.
• the object of the present invention is to provide a new process for the preparation of polyisocyanates by using as catalysts catalysts of very high reactivity, especially quaternary ammonium hydroxides such as choline, which is easy to implement despite the very high reactivity of the catalysts used. .
• the present invention also aims to provide such a method in which the temperature inside the reactor used is controlled.
• the object of the present invention is also to provide a new process for the preparation of polyisocyanates using as catalysts very high reactivity catalysts, especially quaternary ammonium hydroxides, such as choline, in a reactor which allows the removal of heat from the reactor. reaction.
• the present invention also aims to provide such a process for the simultaneous addition of the catalyst and the isocyanate monomer.
• the present invention relates to a process for the oligomerization of isocyanates comprising a step of continuously converting an isocyanate monomer to a polyisocyanate containing carbamate and / or allophanate groups in the presence of a catalyst, in which the conversion step is carried out.
• a reactor whose specific heat exchange coefficient is greater than or equal to about 200 kW / mVc, and is preferably about 500 kW / m Vc at about 4000 kW / m 3 / ⁇ C,
• the process of the invention is therefore characterized by its continuous character and a maintenance of the temperature in the reactor in a given range.
• the method of the invention thus makes it possible to maintain throughout the reaction a constant and controlled temperature inside the reactor by an efficient and controlled transfer of calories.
• the reactor used in the context of the present invention has a specific heat exchange coefficient of about 200 kW / m 3 / ⁇ C at about 14 000 kW / m 3 / ⁇ C.
• the process according to the invention is characterized in that the above-mentioned conversion step is advantageously carried out continuously in a reactor maintained at a temperature of about 65 ° to about 180 °, in particular from about 65O to about 130O, preferably from about 80O to about 100O, and more preferably at a temperature of about 90O to about 95O.
• the implementation of a continuous process allows a better control of the reaction compared to the implementation of a batch process (batch process), as well as a control of the conversion rate.
• This implementation of the continuous process also reduces the volume of the equipment used and to obtain a productivity gain.
• the continuous process increases driving safety.
• the reactors used in the context of the present invention have a smaller volume compared to the reactors used in the batch processes.
• the method of the present invention allows to modulate and control the rate of transformation.
• the control of the conversion rate, and more particularly its maintenance makes it possible to control the physicochemical properties of the product obtained (trimer), such as the viscosity or the rate of NCO functions.
• oligomerization refers to a process of converting a monomer, or a mixture of monomers, into an oligomer, which is a substance composed of molecules of intermediate molecular weight consisting essentially of the repetition in small numbers of atoms or groups of atoms, called “constituent units" and derived from low molecular weight molecules.
• the specific heat exchange coefficient is designated by USA /, where U represents the heat exchange coefficient, S represents the reactor surface and V represents the reactor volume.
• the coefficient U is related to the thermal conductivity of the reactor material and therefore to the nature of the reactor material, as well as to the type of process used, that is to say for example according to the agitation and the turbulence of the fluids or the nature of the fluids used.
• ⁇ TJ ( ⁇ T a - ⁇ T b ) / Ln [((T a ) e - (T b ) e ) / ((T a ) s - (T b ) s )]
• This transferred energy corresponds to: - the energy supplied by the hot fluid and which cools from ⁇ T a :
• Q and Cp being respectively the flow rate and the heat capacity of the fluids passing through the process.
• the heat transfer coefficient is calculated as indicated below, in a case where the cold fluid (or 'utility' fluid) and the hot fluid to be cooled (or 'process fluid') are both some water.
• the experiment is conducted on two plates: A 'utility' plate which receives the cold fluid and a 'process' plate which receives the hot fluid. The two plates are sealed to allow heat transfer from the hot fluid to the cold fluid.
• the process as defined above comprises the use of a catalyst chosen from the quaternary ammonium hydroxides of formula (I) below:
• R 1 represents a saturated or unsaturated alkyl group comprising from 1 to 20 carbon atoms, an aryl group comprising from 6 to 12 carbon atoms, atoms, a cycloalkyl group having 5 to 12 carbon atoms or a heterocyclic 5- or 6-membered ring system having a nitrogen atom, an oxygen atom or a sulfur atom, - R2, R3 and R 4 are independently from each other, an alkyl group, saturated or unsaturated, comprising from 1 to 20 carbon atoms, an aryl group comprising from 6 to 12 carbon atoms, said groups R2, R3 and R 4 possibly being substituted by at least one hydroxyl group or a thiol group.
• thermal control is essential in the context of the use of these quaternary ammonium hydroxides, which are sensitive to temperature, in order to avoid the degradation of these catalysts.
• the control of the temperature for the process of the invention is essential in order to be able to control the progress of the reaction. If the temperature in the reactor is below 65 °, the reaction does not proceed fast enough.
• the reaction becomes too fast and therefore not controllable. It is no longer possible to control the conversion rate related to the progress of the reaction.
• the present invention makes it possible to find a compromise between the reaction rate, which must be rapid (from 1 to 3 minutes), and the degradation of the catalyst.
• the process of the invention is characterized in that the transformation step is carried out in a reactor type reactor-plate exchanger or baffled multitubular reactor.
• a reactor type reactor-plate exchanger or baffled multitubular reactor For plate reactors, mention may be made of Alpha Laval technology as described in patent applications FR 2 823 995, US 2004/0109798, FR 2 880 967, WO 02/85511, US 2006/0159600, EP 1 562,699, and that of Chart and BRH Group with Marbond TM Hex Reactor technology (as described in applications WO 02/37047 and WO 02/58840).
• the baffled multitubular reactors one can quote the intensified reactors of the type FlexReactor of BHR Group.
• the present invention also relates to a process as defined above in which the transformation step is carried out for a period of stay in the reactor less than 1 hour, preferably less than 30 minutes, and more preferably less than 10 minutes, and preferably for about 3 minutes.
• This reduced residence time is important in order to adapt a batch-type process into a continuous process, due to the large number of calories to be evacuated. If the residence time becomes too high, then the advantage of performing the process is lost.
• the catalysts used herein must be adequate to have a limited residence time. In terms of productivity, the increase is for example about a factor of 20 compared to discontinuous processes.
• the process of the invention is characterized in that the isocyanate monomer and the catalyst are simultaneously added to the reactor.
• the process of the invention is characterized in that the isocyanate monomer is selected from the group consisting of aliphatic, cycloaliphatic and aromatic isocyanates.
• the isocyanate monomer is chosen from the group consisting of 1,6-hexamethylene diisocyanate (HDI), 1,12-dodecane diisocyanate, 1,3-cyclobutane and diisocyanate, cyclohexane-1,3 and / or 1,4-diisocyanate, 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethylcyclohexane (isophorone diisocyanate - IPDI), isocyanatomethyloctylenediisocyanate (TTI), dicyclohexyl methane-4,4'-diisocyanate, toluene diisocyanate (TDI), methylene bis-phenylisocyanate (MDI), 2,2,4-trimethyl-1,6-hexamethylene diisocyanate, 2,4,4-trimethyl- 1,6-hexamethylenediisocyanate (HDI), 1,12-dodecane diis
• the present invention also relates to a method as defined above wherein the catalyst is selected from the group consisting of tetrabutylammonium hydroxide (TBAOH) and hydroxide N 1 N 1 N thméthyl-N- (2 hydroxyethyl) ammonium (choline hydroxide).
• TAAOH tetrabutylammonium hydroxide
• the process of the invention is characterized in that the amount of catalyst used is from about 0.01% to about 0.5% by weight relative to the weight of monomer.
• the present invention also relates to a process as defined above for the preparation of hexamethylene diisocyanate trimer (HDT), comprising a step of conversion of 1,6-hexamethylene diisocyanate (HDI) in the presence of N, N, N-trimethyl -N- (2-hydroxyethyl) ammonium.
• HDT hexamethylene diisocyanate trimer
• the present invention also relates to a process as defined above for the preparation of hexamethylene diisocyanate trimer (HDT) comprising a step of converting 1,6-hexamethylene diisocyanate (HDI) in the presence of tetrabutylammonium hydroxide.
• the process of the invention is a process as defined above in which the isocyanate monomer contains more than 30 ppm of hydrolyzable chlorine.
• hydrolyzable chlorine constitutes an additional advantage of the continuous process compared to the batch process. Indeed, in the context of a batch process, part of the catalyst is consumed by species of the type "hydrolyzable chlorine".
• hydrolyzable chlorine is meant molecules for which chlorine is covalently bound and that may be released as CI.
• the analysis of the hydrolyzable chlorine content is carried out by action of a water / methanol mixture ( 2h reflux) to the monomer in question and determining the concentration of CI "by appropriate means.
• the partial consumption of the catalyst by the species of the "hydrolyzable chlorine” type results in a delayed reaction start and a lower yield for an isocyanate containing a concentration of about 120 ppm Cl (see Example 3 hereinafter).
• Figure 1 shows the stationary temperature profiles in the presence of the catalyst (choline) (curve in solid line with the lozenges) and steady state without catalyst (dashed curve with circles). These curves represent the temperature (in O) as a function of the variable z / L, L corresponding to the total length of the splines of the reactor plates and z / L corresponding to the position of the temperature probes along this length.
• Figure 2 shows the temperature profile in the batch mode in the presence of the choline catalyst.
• the dashed line represents the evolution of the temperature (O) as a function of time (min) and the solid line curve with the black circles represents the conversion rate of I 1 HDI (%) as a function of time (min ).
• Figure 3 shows the temperature profile in batch mode in the presence of TBAOH catalyst.
• the dashed line represents the evolution of the temperature (O) as a function of time (min) and the solid line curve with the black circles represents the rate of transformation of the HDI (%) as a function of time (min ).
• Figure 4 shows the superposition of test temperature profiles with HDI with high hydrolysable chlorine content (curve with white circles) and HDI with low hydrolysable chlorine content (line curve). full).
• This figure represents the temperature variation ⁇ T (O) as a function of time (min).
• “B” indicates the end of catalyst introduction.
• Example 1 Continuous Tests in a Plate Reactor
• the plate reactor used is a laboratory scale stainless steel reactor that can process flow rates from 200 milliliters per hour to 10 liters per hour. It consists of 3 plates whose structure (grooves of about 2 mm in diameter dug in the plate) was designed to promote the turbulence of the fluid that passes through it and thus provide optimal heat transfer performance.
• the performances were characterized by a heat exchange coefficient (U) of 5000 Watt per square meter and per degree Celsius.
• the coefficient U was measured as indicated above using water as fluid.
• the three plates arranged in series have an overall volume of 37.01 cm 3 and an exchange area of 0.074 m 2 .
• the specific heat exchange coefficient (USA /) is therefore 8 020 Kilowatt per cubic meter and per degree Celsius.
• Each of these plates is disposed between two other plates in which circulates the coolant for the evacuation of calories.
• Several temperature probes are arranged along the "process" plates (plates receiving the reaction mixture) in order to measure the temperature profile in the reactor during the test.
• the tests consisted in feeding the plate reactor by co-addition of hexamethylene diisocyanate (HDI, Rhodia) and of the catalyst (45% choline in methanol or 40% tetrabutylammonium hydroxide in methanol, Aldrich) in solution in ethylhexanol (Aldrich ).
• HDI hexamethylene diisocyanate
• Rhodia hexamethylene diisocyanate
• the catalyst 45% choline in methanol or 40% tetrabutylammonium hydroxide in methanol, Aldrich
• Aldrich ethylhexanol
• the plate reactor is brought to the desired working temperature by circulation of the coolant in the corresponding plates.
• the reagents are then fed with co-current or against the current of the coolant (In particular silicone oil previously heated to 90O) through the adjacent process plates.
• the reactants are fed cocurrently.
• the conversion of HDI to HDT occurs in the microstructure of the plates and leads to a heat release corresponding to 18 kcal / mole of converted HDI. It is this release of heat that must be evacuated efficiently and quickly to control chemistry and optimize productivity.
• This same plate reactor is tested for the trimerization of HDI using tetrabutylammonium hydroxide (TBAOH) as a catalyst.
• TBAOH tetrabutylammonium hydroxide
• the catalyst solution used in this test contains 1.3% by weight of TBAOH catalyst in ethylhexanol.
• This catalyst has the same catalytic properties as Choline for the synthesis of HDT from HDI. On the other hand, it is thermally much more stable than Choline. As a result, the catalytic activity of TBAOH is much greater and the kinetics of trimerization increased.
• the conversion rate can also be controlled by the catalytic charge.
• the table below shows the sensitivity of the chemistry carried out continuously with respect to the catalytic charge:
• the volume of reagents added to this reactor is about 0.3 I (300 ml) which represents a wall contact area of about 0.03 m 2 .
• the heat transfer coefficient of the glass in contact with an organic solution is conventionally given to about 180 W.nn ⁇ 2 .'C ⁇ 1 .
• the specific heat exchange coefficient (USA /) of the reactor is therefore about 18 kilowatts per cubic meter and per degree Celsius.
• the graphs in Figure 2 and Figure 3 give the temperature profiles of the reaction medium and that of the conversion of the HDI.
• Test with choline The reaction is initiated around 7OO and the reaction accelerates. The heat generated is not efficiently removed and accumulates in the reaction mixture. This has the effect of raising the temperature of the medium which itself accelerates the reaction again. We are in the presence of a thermal runaway which leads the temperature quickly to about 135O. At this temperature, the catalyst is completely thermally destroyed (the conversion stops abruptly), then the reaction medium slowly cools progressively evacuating its calories through the jacket.
• Test with TBAOH The reaction is also initiated around 700 with the same phenomenon as with choline. Thermal runaway leads the temperature rapidly to around 230O. At this temperature, the catalyst is still active but the conversion of the HDI is complete. This total conversion took one to two minutes, then the reaction medium slowly cooled by gradually removing its calories through the jacket. Here, the reaction medium is too viscous.
• choline hydroxide catalyst system was tested in a double glass stirred reactor with two HDI monomers of different hydrolysable chlorine contents (-25 and 120 ppm expressed in chloride).
• the reaction is carried out under batch conditions, the monomer is placed in the reactor, then the heat transfer fluid which passes through the double jacket is brought to
• the temperature of the jacket is then maintained at 85 ° C. until the experiment is stopped.
• the catalytic solution (1.3% by weight of choline hydroxide in 2-ethylhexanol) is gradually introduced via a syringe pump into the reaction medium.
• the reactor used is identical to that used in Example 2.
• the volume of reagents added to this reactor is about 0.8 to 1 I (1000 ml), which represents a wall contact area of 0.04. at 0.05 m 2 .
• the heat transfer coefficient of the glass in contact with an organic solution is conventionally given to about 180 W.nn ⁇ 2 .'C ⁇ 1 .
• the specific heat exchange coefficient (USA /) of the reactor is therefore about 8 to 9 kilowatts per cubic meter and per degree Celsius.
• Test with an HDI of low hydrolyzable chlorine content The reaction begins approximately 10 minutes after the beginning of the addition of the catalyst. The heat generated in the first part is not evacuated completely which raises the temperature of the medium. The cryothermostat compensates and the temperature of the reaction medium falls before the increase in temperature becomes linear, sign of the accumulation of the catalyst in the reaction medium and the progress of the reaction. After stopping the catalyst flow, the reaction stops slowly
• Test with high hydrolyzable chlorine HDI The reaction begins with a shift of about 6 minutes compared to the low chlorine HDI. The amount of heat generated during this phase is less important and the temperature increases gradually without jerks.
• the joint injection of the HDI monomer and the catalyst makes it possible to operate with an optimum ratio for the oligomerization which, combined with a short residence time, makes it possible to eliminate the impact of the hydrolyzable chlorine.
• the use of a continuous reactor, and more particularly of the reactor described above, therefore allows greater flexibility with regard to the quality of the raw materials.

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