WO2013030035A1 - Process for preparing sulfates and/or sulfonates in a micro-reaction system - Google Patents

Process for preparing sulfates and/or sulfonates in a micro-reaction system Download PDF

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Publication number
WO2013030035A1
WO2013030035A1 PCT/EP2012/066231 EP2012066231W WO2013030035A1 WO 2013030035 A1 WO2013030035 A1 WO 2013030035A1 EP 2012066231 W EP2012066231 W EP 2012066231W WO 2013030035 A1 WO2013030035 A1 WO 2013030035A1
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Prior art keywords
micro
reaction
reaction system
reactor
stands
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PCT/EP2012/066231
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English (en)
French (fr)
Inventor
Miriam Becherer
Bernhard Gutsche
Saskia Müller-Meskamp
Thomas Kruppa
Kjeld Kraft
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Cognis Ip Management Gmbh
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Priority to US14/241,705 priority Critical patent/US8921588B2/en
Priority to KR1020147007806A priority patent/KR20140060546A/ko
Priority to BR112014004752A priority patent/BR112014004752A2/pt
Priority to CN201280042037.XA priority patent/CN103764627B/zh
Priority to AU2012301130A priority patent/AU2012301130A1/en
Priority to IN2423CHN2014 priority patent/IN2014CN02423A/en
Priority to JP2014527584A priority patent/JP2014527536A/ja
Priority to CA2843817A priority patent/CA2843817A1/en
Priority to RU2014111846/04A priority patent/RU2014111846A/ru
Publication of WO2013030035A1 publication Critical patent/WO2013030035A1/en

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    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C303/00—Preparation of esters or amides of sulfuric acids; Preparation of sulfonic acids or of their esters, halides, anhydrides or amides
    • C07C303/24—Preparation of esters or amides of sulfuric acids; Preparation of sulfonic acids or of their esters, halides, anhydrides or amides of esters of sulfuric acids
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C303/00—Preparation of esters or amides of sulfuric acids; Preparation of sulfonic acids or of their esters, halides, anhydrides or amides
    • C07C303/02—Preparation of esters or amides of sulfuric acids; Preparation of sulfonic acids or of their esters, halides, anhydrides or amides of sulfonic acids or halides thereof
    • C07C303/04—Preparation of esters or amides of sulfuric acids; Preparation of sulfonic acids or of their esters, halides, anhydrides or amides of sulfonic acids or halides thereof by substitution of hydrogen atoms by sulfo or halosulfonyl groups
    • C07C303/06—Preparation of esters or amides of sulfuric acids; Preparation of sulfonic acids or of their esters, halides, anhydrides or amides of sulfonic acids or halides thereof by substitution of hydrogen atoms by sulfo or halosulfonyl groups by reaction with sulfuric acid or sulfur trioxide

Definitions

  • the present invention belongs to the area of anionic surfactants and refers to a specific sul- fation/sulfonation process using liquid sulfur trioxide in a micro-reaction system.
  • the current technology for sulfation or sulfonation processes in order to produce anionic surfactants stars from gaseous sulfur dioxide which is oxidized to sulfur trioxide. Subsequently, the gaseous S0 3 is mixed with dry air and then reacted with organic compounds as for exam ple primary alcohols, olefins, alkyl phenols, alkyl benzenes or their alkoxylation products. While the reaction with a hydroxyl group leads to a sulfate, addition of S0 3 to a double bond results in the formation of a sulfonate.
  • the standard procedure is carried out in falling film reactors and described in detail for example by B. Gutsche et al.
  • micro-reaction technology provides various advantages, in particular with regard to higher conversion, lower contents of waste materials and by-products, and significantly better product color, a major disadvantage is the need for diluting the liquid sulf(on)ation agent in high amounts of typical about 90 Vol.-%, since inert gases are extremely expensive and using air requires a high electric energy demand for compression and drying.
  • the object of the present invention has been to provide a process for sulfation or sulfonation in a micro-reaction system using liquid sulfur trioxide as sulf(on)ation agent that is free from the disadvantages cited above and is particular useful for the manufacture of anionic surfactants with low level of unwanted by-products.
  • Object of the present invention is a process for preparing sulfates and/or sulfonates by add- ing sulfur trioxide to a compound comprising at least one hydroxyl function and/or at least one double bond, which is characterized in that
  • the sulfation/sulfonation agent used is a liquid sulfur trioxide
  • reaction is conducted in the presence of 0 to 20 Vol.-% of air, inert gas or organic solvents.
  • a central element of the present invention consists in the finding that structured reactors enable the oxidation of ethylene and propylene to be performed irrespective of the explosion limits, since the reaction can be conducted isothermally, the reactants have only a minimal residence time in the reactor and the reaction channels have diameters which do not exceed the maximum experimental safe gap.
  • maximum experimental safe gap is understood to mean the maximum diameter of a reactor at which a flame resulting from explosion is still automatically extinguished.
  • structured reactor is understood to mean an array of reaction channels which can be operated individually, in modules or else altogether and are disposed in a matrix which serves for stabilization, securing, heating or cooling.
  • a preferred embodiment of a structured reactor is that of micro-reaction systems, which are also referred to in general as micro- or ⁇ -reactors. They have the feature that at least one of the three dimensions of the reaction chamber has a measurement in the range from 1 to 2000 ⁇ , and they thus fea- ture a high transfer-specific inner surface area, short residence times of the reactants and high specific heat and mass transfer performances.
  • a detailed article on this subject can be found, for example, in Jahnisch et al. in Angewandte Chemie Vol.
  • Ref- erence is made by way of example to European patent application EP 0903174 Al (Bayer), in which the liquid phase oxidation of organic compounds in a micro-reactor consisting of an array of parallel reaction channels is described.
  • Micro-reactors may additionally comprise microelectronic components as integral constituents.
  • useful micro-reactors are also those in which a particular number of micro-channels are bundled, such that micro- and macro-channels or parallel operation of a multitude of micro-channels may be present alongside one another.
  • the channels are preferably arranged parallel to one another in order to enable a high throughput and to keep the pressure drop as low as possible.
  • micro-reaction systems can be made in one piece for example from ceramic or steel (Hastelloy) or are mounted on a support.
  • the supports in which the structure and dimensions of the micro-reaction systems are defined may be material combinations, for example silicon-silicon, glass-glass, metal-metal, metal-plastic, plastic-plastic or ceramic-ceramic, or combinations of these materials, although the preferred embodiment is a silicon-glass composite.
  • Useful supports also include polyacrylates which are produced by layer-by-layer hardening and are particularly inexpensive to produce.
  • a further alternative is that of HAT ceramics, specifically those which are surrounded by a pressure-resistant jacket, and also all-metal reactors in which the reaction channels are coated appropriately to prevent decomposition of the oxidizing agent.
  • a wafer of thickness for example, from 100 to 2000 ⁇ , preferably about 400 ⁇ , is structured preferably by means of suitable micro-structuring or etching techniques, for example reactive ion etching, through which it is possible, for example, to manufacture three- dimensional structures irrespective of the crystal orientation in silicon [cf. James et al. in Sci. Am. 4, 248 (1993)]. It is also possible, for example, to treat micro-reactors of glass in the same way.
  • Wafers treated in this way may have from 10 to 1000, preferably from 100 to 500 and especially from 200 to 300 micro-reaction systems running parallel to one another, which may be actuated and operated either in parallel or sequentially.
  • the geometry i.e. the two- dimensional profile of the channels, may be very different: possible profiles include straight lines, curves, angles and the like, and combinations of these shape elements. Not all micro- reaction systems need have the same geometry.
  • the structures feature measurements of from about 1 to 2000 ⁇ , preferably from about 50 to 1500 ⁇ , more preferably from about 10 to 1000 ⁇ , and vertical walls, the depth of the channels being from about 20 to 1800 ⁇ and preferably from about 200 to 500 ⁇ .
  • each micro- reaction chamber which may but need not be square, are generally in the order of magni- tude of from about 20 ⁇ 20 to 1500 ⁇ 1500 ⁇ 2 and especially from about 100 ⁇ 100 to 300 x 300 ⁇ 2 , as is specified as typical, for example, by Burns et al. in Trans IChemE 77(5). 206 (1999).
  • the micro-reaction systems are channels which have a length of from about 1 to 5000 and preferably about 25 to 1000 mm.
  • the wafer is etched through at the points intended for this purpose.
  • the structured wafer is bonded by a suitable process, for example anodic bonding, to a further wafer, for example of glass, preferably Pyrex glass, and the individual flow channels are sealed tightly to one another.
  • a suitable process for example anodic bonding
  • a further wafer for example of glass, preferably Pyrex glass
  • impervious flow sys- terns which will be apparent to the person skilled in the art, without any need for an inventive step for this purpose.
  • the micro-reaction systems may be divided into one or more mixing zones, one or more reaction zones, one or more mixing and reaction zones, one or more heating and cooling zones, or any combinations thereof. They preferably have three zones, specifically two reaction zones and one cooling zone, as a result of which especially two- or multistage reactions can be carried out efficiently in the liquid phase or else in the gaseous phase.
  • In the first zone two reaction participants are mixed and reacted; in the second zone, the reaction be- tween the product of the first zone and a further reactant takes place, while the termination of the reaction is brought about in the third zone by lowering the temperature. It is not absolutely necessary to thermally strictly separate the first reaction zone and the second reaction zone from one another.
  • reaction zone 2 when the addition of a further reactant is required or several mixing points are desired instead of one, this can also take place in reaction zone 2 over and above zone 1.
  • the micro-reaction systems may be operated sequentially or else simultaneously, i.e. in parallel with defined amounts of reactant in each case and having identical or different geometries. For example it is possible to start with small channels having a width of about 200 ⁇ and enlarging them over the length of the reactor to a width of about 800 ⁇ .
  • a further possible way in which the geometry of the micro-reaction systems may differ consists in the mixing angle at which the reactants meet one another and which may be between 15 and 270° and preferably from 45 to 180°. Furthermore, it is possible to cool or to heat each of the three zones independently, or to vary the temperature within one zone as desired, the reaction chambers in this example being channels whose length per zone may be from 10 to 500 mm.
  • the structured micro reactors which were found suitable for conducting the reaction comprise at least one, preferably up to three mixing zones and at least one zone of re- action.
  • the mixer shows a channel width of about 10 to 2000 ⁇ and the reactor of about 100 to 5000 ⁇ .
  • the micro-reaction system is either a micro-multi-channel reactor with about 100 to about 1.000.000 and preferably about 500 to about 250.000 micro channels or a micro-tube bundle reactor with about 1 to 100, preferably about 40 to 80 and more preferably about 50 to 70 micro-tubes. It is also possible to conduct the process in a micro-falling film reactor. At least in one dimension of the reactor the channel width is between about 20 and 2000 ⁇ .
  • the molar ratio S0 3 to organic compound can vary between about 0.5 to 3.0, preferably about 0.8 to 2.6:1, more preferably about 0.9 to 1.5:1 and most preferably about 1:1.
  • the reaction with liquid sulfur trioxide for example in a micro multichannel reactor allows using higher S0 3 concentrations compared to working in a macro reactor (e.g. a falling film reactor), without losing color performance of the reaction products. Since no or very little dilution is necessary the sulf(on)ation agent can be used directly without evaporation coming from the supplying facility (e.g. pipeline, bottle etc.). It is possible to perform the sulfation/sulfonation at temperatures in the range from about -20 to 180°C, however with respect to product color and yield it has been found rather advanta- geously to adjust the temperature to about 30 to 60 °C and avoid any increase caused by the exothermic reaction by external cooling. I n the alternative also high temperatures of about 60 to 120 °C are possible on condition that the residence time is very short. The cooling of the reactor can take place by heat exchange in parallel, counter-current or crosscurrent flow.
  • micro-reaction systems allow a precise adjustment of residence time, a defined degree of reaction and significantly lower levels of unwanted sulfuric acid and - in case of pol- yglycol ethers as starting materials - dioxane can be achieved.
  • Suitable neutralization agents encompass alkaline hydroxide solutions as for example aqueous sodium or potassium hydroxide solutions, ammonia, alkyl amines or alkanol amines.
  • a first group of preferred educts encompass compounds comprising at least one hydroxyl moiety following general formula (I)
  • R 1 stands for an saturated or unsaturated, optionally hydroxy substituted hydrocarbyl group having about 1 to 22, preferably about 12 to 18 carbon atoms and 0 or 1 to 3 double bonds, or an alkyl phenol group having about 1 to 12, preferably about6 to 9 carbon atoms in the alkyl chain;
  • n stands either for 0 or 1;
  • n stands either for 0 or an integer of about 2 to 200, preferably about 1 to 50 and more preferably about 1 to 25;
  • AO stands for an ethylene oxide, propylene oxide or butylene oxide unit or their mixtures.
  • This group encompasses in particular primary alcohols and the respective polyglycol ethers, as for example ethanol, propanol, isopropyl alcohol, butanol and its isomers, pentanol, hex- anol, octanol, 2-ethylhexanol, decanol, lauryl alcohol, myrystyl alcohol, cetyl alcohol, stearyl alcohol, cetearyl alcohol, isostearyl alcohol, 12-hydroxy stearyl alcohol, oleyl alcohol, elaidyl alcohol, linolyl alcohol, linolenyl alcohol, conjugated linolyl alcohol, ricinoleyl alcohol, gado- leyl alcohol, arachidonyl alcohol, behenyl alcohol, erucyl alcohol, and their technical mix- tures as for example coco fatty alcohol or tallow fatty alcohol.
  • primary alcohols and the respective polyglycol ethers as for example ethanol,
  • Suitable polyglycol ethers are adducts of on average about 1 to 100, preferably about 2 to 50 and more preferably about 5 to 25 moles ethylene oxide, propylene oxide and/or butylene oxide to said primary alcohols.
  • the resulting polyglycol ethers may show a block or random distribution of the different units. As far as ethoxylates are concerned these products may also show a so-called narrow range distribution.
  • the process according to the present invention is particular useful for the manufacture of Ci 2 -Ci 8 fatty alcohol ether sulfates with an average degree of ethoxylation of about 1 to 10, preferably about 2, since these products, representing major anionic surfactants for both detergent and cosmetics industry, show a significantly lower level of unwanted by-products, in particu- lar dioxane, than similar products produced in standard multi-tube sulfation reactors.
  • a second group of suitable starting materials comprises alkoxylation products of carboxylic acids, such as capronic acid, caprylic acid, 2-ethylhexanoic acid, caprinic acid, lauric acid, myristic acid, palmitic acid, palmoleic acid, stearic acid, isostearic acid, oleic acid, elaidinic acid, linoic acid, linolenic acid, 12-hydroxy stearic acid, ricinoleic acid, gadoleic acid, arachi- donic acid, behenic acid, erucic acid and their technical mixtures, like for example coco fatty acid, palm fatty acid, tallow fatty acid, sunflower fatty acid, soy fatty acid and the like.
  • carboxylic acids such as capronic acid, caprylic acid, 2-ethylhexanoic acid, caprinic acid, lauric acid, myristic acid, palmitic acid, palmoleic acid, stearic acid, is
  • Suitable polyglycol ethers are adducts of on average about 1 to 100, preferably about 2 to 50 and more preferably 5 to 25 moles ethylene oxide, propylene oxide and/or butylene oxide to said carboxylic acids. In case mixtures of ethylene and propylene oxide are applied the resulting polyglycol ethers may show a block or random distribution of the different units.
  • alkoxylation products of alkyl phenols comprising about 1 to 12 and preferably about 6 to 9 carbon atoms in the alkyl chain, such as hexyl phenol, heptyl phenol, octyl phenol, nonyl phenol or their mixtures.
  • suitable polyglycol ethers are adducts of on average about 1 to 200, preferably about 1 to 50 and more preferably about 1 to 25 moles ethylene oxide, propylene oxide and/or butylene oxide to said alkyl phenols. I n case mixtures of ethylene and propylene oxide are applied the resulting polyglycol ethers may show a block or random distribution of the different units.
  • a second group of suitable starting materials encompasses compounds comprising at least one double bond follow general formula (I I) R 2 -Ph (II)
  • R 2 stands for an alkyl group having about 1 to 22 carbon atoms and Ph represents a phenyl group.
  • This group mainly concerns alkyl benzenes, where a sulfonate group is introduced into the aromatic ring structure.
  • alkyl phenols can react in the same way, that means that sulfonation of the aromatic ring structure takes place beside sulfation of the hydroxyl moiety. Since sulfation represents the by far faster reaction, adding sulfur trioxide for example to a nonyl phenol+lOEO molecule mainly leads to the formation of the respective sulfate, while the sulfonate is formed in minor amounts.
  • olefins and functionalized olefins like for example unsaturated primary alcohols, unsaturated mono- or dicarboxylic acids and their esters, unsaturated synthetic glycerides or natural occurring fats and oils, unsaturated amides and their mixtures. Typically these compounds show a chain length of C 6 to C 22 .
  • a micro-reaction system consisting of a 400 ⁇ -thick silicon wafer was used, which was joined to a Pyrex glass wafer. 20 parallel, linear channels, with a depth of 300 ⁇ and a cross section of the micro-reaction chambers of 300 ⁇ 300 ⁇ 2 had been etched into the silicon wafer. The channels were operated in parallel and were each etched through for reactant introduction and for product removal. 481 g (0.38 mol) Nonylphe- nol+25EO were reacted with 30.2 g (0.38 mol) liquid sulfur trioxide at 35 to 40 °C. Neutralization was performed with 30.2 g of 50 % b.w. aqueous sodium hydroxide solution at 80°C. The neutralization product was aged for another 20 min.
  • Example 2 Example 2
  • a micro-multi-channel reactor consisting of about 500 channels with a channel width and a channel depth of about 300 ⁇ and a channel length of about 50 mm were used for conducting the sulfation of a lauryl alcohol+2EO (Dehydol ® LS2, BASF Personal Care & Nutrition GmbH, Dusseldorf).
  • the channels were operated in parallel and were etched through for educt input and product removal.
  • the cooling channels corresponded in their diameter to the reaction channels.
  • the reaction was conducted at an equimola r ratio of S0 3 and polyglycol ether and a temperature of 35 °C.
  • Neutralization was performed with 50 % b.w. aqueous sodium hydroxide solution at 80°C in a micro-mixing unit attached to the micro-multi-channel reactor.
  • the neutralization product was aged for another 20 min.
  • the resulting lauryl alcohol+2EO sulfate sodium salt was obtained as a clear, colorless liquid that was substantially free of dioxane.

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  • Organic Chemistry (AREA)
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PCT/EP2012/066231 2011-08-31 2012-08-21 Process for preparing sulfates and/or sulfonates in a micro-reaction system WO2013030035A1 (en)

Priority Applications (9)

Application Number Priority Date Filing Date Title
US14/241,705 US8921588B2 (en) 2011-08-31 2012-08-21 Process for preparing sulfates and/or sulfonates in a micro-reaction system
KR1020147007806A KR20140060546A (ko) 2011-08-31 2012-08-21 마이크로-반응 시스템에서의 술페이트 및/또는 술포네이트 제조 방법
BR112014004752A BR112014004752A2 (pt) 2011-08-31 2012-08-21 processo para a preparação de sulfatos e/ou sulfonatos em um sistema de microrreação
CN201280042037.XA CN103764627B (zh) 2011-08-31 2012-08-21 在微反应体系中制备硫酸盐和/或磺酸盐的方法
AU2012301130A AU2012301130A1 (en) 2011-08-31 2012-08-21 Process for preparing sulfates and/or sulfonates in a micro-reaction system
IN2423CHN2014 IN2014CN02423A (GUID-C5D7CC26-194C-43D0-91A1-9AE8C70A9BFF.html) 2011-08-31 2012-08-21
JP2014527584A JP2014527536A (ja) 2011-08-31 2012-08-21 ミクロ反応系における硫酸塩および／またはスルホン酸塩の製造方法
CA2843817A CA2843817A1 (en) 2011-08-31 2012-08-21 Process for preparing sulfates and/or sulfonates in a micro-reaction system
RU2014111846/04A RU2014111846A (ru) 2011-08-31 2012-08-21 Способ получения сульфатов и/или сульфонатов в микрореакторной системе

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EP11179488.9 2011-08-31
EP11179488.9A EP2565181B1 (en) 2011-08-31 2011-08-31 Process for preparing sulfates and/or sulfonates in a micro-reaction system

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CN105541669A (zh) * 2015-12-17 2016-05-04 广州市浪奇实业股份有限公司 一种生产2-乙基己基醇硫酸酯盐的方法
CN107827783B (zh) * 2017-11-16 2020-08-07 南京工业大学 一种利用微反应装置连续制备苯系物的磺化产物的方法
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US20140303393A1 (en) 2014-10-09
US8921588B2 (en) 2014-12-30
PL2565181T3 (pl) 2015-02-27
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JP2014527536A (ja) 2014-10-16
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