WO2021027953A1 - 一种二苯甲烷二异氰酸酯的制备方法 - Google Patents

一种二苯甲烷二异氰酸酯的制备方法 Download PDF

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WO2021027953A1
WO2021027953A1 PCT/CN2020/109493 CN2020109493W WO2021027953A1 WO 2021027953 A1 WO2021027953 A1 WO 2021027953A1 CN 2020109493 W CN2020109493 W CN 2020109493W WO 2021027953 A1 WO2021027953 A1 WO 2021027953A1
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diphenylmethane diisocyanate
diphenylmethane
copper
dicarbamate
preparing
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PCT/CN2020/109493
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English (en)
French (fr)
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李会泉
何奇奇
王利国
贺鹏
曹妍
陈家强
徐爽
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中国科学院过程工程研究所
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Priority to US17/635,075 priority Critical patent/US20220281808A1/en
Publication of WO2021027953A1 publication Critical patent/WO2021027953A1/zh

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    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C263/00—Preparation of derivatives of isocyanic acid
    • C07C263/04—Preparation of derivatives of isocyanic acid from or via carbamates or carbamoyl halides
    • 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
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
    • B01J23/72—Copper
    • 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
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
    • B01J23/74—Iron group metals
    • B01J23/745—Iron
    • 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
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
    • B01J23/74—Iron group metals
    • B01J23/755—Nickel
    • 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
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/20—Catalysts, in general, characterised by their form or physical properties characterised by their non-solid state
    • B01J35/23—Catalysts, in general, characterised by their form or physical properties characterised by their non-solid state in a colloidal state
    • 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
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/50—Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
    • B01J35/58—Fabrics or filaments
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C265/00—Derivatives of isocyanic acid
    • C07C265/12—Derivatives of isocyanic acid having isocyanate groups bound to carbon atoms of six-membered aromatic rings
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C265/00—Derivatives of isocyanic acid
    • C07C265/14—Derivatives of isocyanic acid containing at least two isocyanate groups bound to the same carbon skeleton

Definitions

  • This application relates to the field of organic chemical technology, for example, to a method for preparing diphenylmethane diisocyanate.
  • MDI diphenylmethane diisocyanate
  • MDI 50 50% 2,4'-MDI and 50% 4,4 '-MDI mixture
  • PMDI polymeric MDI
  • 4,4'-MDI is mainly used to synthesize spandex and elastomers, while PMDI is mainly used to synthesize polyurethane.
  • PMDI has a larger market share (80%) and is the main raw material for the preparation of polyurethane due to its liquid state, easy transportation, good stability and performance.
  • the main method for producing MDI at home and abroad is the liquid phase phosgene method.
  • the liquid phase direct phosgenation process the amine compound is dissolved in the solvent, and then phosgene is passed into the solvent to react to obtain the MDI product.
  • This process is particularly suitable for amine compounds with high boiling point and low reactivity, and is widely used in large-scale industrial production of isocyanate products such as MDI and TDI.
  • the liquid-phase phosgene process includes: the liquid-phase direct phosgenation tank continuous process (ICI) process represented by Huntsman; the tower continuous process represented by Bayer and Basf; and the loop represented by the Swedish International Chemical Company (Loop) Continuous process.
  • ICI liquid-phase direct phosgenation tank continuous process
  • Bayer and Basf the tower continuous process represented by Bayer and Basf
  • the loop represented by the Swedish International Chemical Company (Loop) Continuous process.
  • the phosgene production process is relatively mature, but phosgene is volatile and a highly toxic gas. There are huge safety hazards in the production process. At the same time, the by-product HCl of the phosgene production of isocyanate causes serious corrosion to production equipment. Production costs increase and affect product quality.
  • the existing processes mainly include aniline, carbon monoxide, ethanol and oxygen developed by Japan’s Asahi Kasei company to produce MDI in liquid phase by oxidative carbonylation; the United States Monsanto company in the early 1990s developed MDI with aniline and CO 2 as raw materials The route; the process of producing MDI with nitrobenzene and carbon monoxide as raw materials developed by ARCO; Catalytica Associates/Halodor Topsoe and Kokan of Japan jointly developed a mixture of nitrobenzene, aniline and methanol in carbonyl rhodium or ruthenium complex
  • DMC dimethyl carbonate
  • the gas phase pyrolysis method is a method in which the raw material phenylcarbamate powder is brought into a fixed bed, a liquidized bed and other gas reactors with inert gas, and the pyrolysis reaction is carried out under high temperature conditions to prepare isocyanate;
  • the liquid phase pyrolysis method is a method of phenylcarbamate
  • the similar raw materials and the solvent (high boiling point) are added to the reactor in a certain proportion, and under reduced pressure, normal pressure or pressure operation with or without catalyst, the isocyanate product is obtained by pyrolysis.
  • CN1721060A adopts the carbamate pyrolysis method, in an inert solvent, the reaction temperature is 150-300 DEG C, the ultrafine metal oxide is used to catalyze the pyrolysis of methyl diphenylmethane dicarbamate (MDC) to prepare MDI.
  • MDC methyl diphenylmethane dicarbamate
  • the yield of MDI obtained by this reaction is only 52.1%-63.1%.
  • CN1850792A pyrolyzes MDC in an inert solvent such as di-n-octyl sebacate at 0.09-0.093MPa and 210-290°C to obtain MDI.
  • the concentration of MDC used in this reaction is high and side reactions are prone to occur.
  • the purpose of this application is to provide a method for preparing diphenylmethane diisocyanate.
  • This preparation method has high reaction conversion rate and yield, simple equipment and technology, relatively mild reaction conditions, can meet the needs of industrial production, and has high industrial application value.
  • this application provides a method for preparing diphenylmethane diisocyanate, the preparation method comprising: under catalyst conditions, diphenylmethane dicarbamate has a boiling point lower than the inertness of diphenylmethane diisocyanate.
  • the pyrolysis reaction is carried out in a solvent to obtain the diphenylmethane diisocyanate.
  • the inert solvent described in this application refers to a solvent that neither reacts with the reactants nor with the product.
  • a solvent with a boiling point lower than the product is selected.
  • the thermal decomposition reaction occurs, the methanol produced by the solvent is evaporated from the system, and the pyrolysis product MDI remains in the solvent as a heavy component. After the reaction is completed, the product is separated from the MDI and the solvent. .
  • the evaporation of the solvent promotes the elimination of methanol, promotes the reaction to proceed in the positive direction, and improves the reaction efficiency; on the other hand, the thermal degradation product MDI remains in the solvent, and the solvent is constantly replenished during the reaction, which can avoid High-concentration polymerization of MDI improves the yield of MDI.
  • the reaction temperature is reduced, the reaction time is shortened, the pyrolysis reaction is carried out at a relatively low temperature, and the energy consumption is greatly reduced.
  • the catalyst is selected from the elementary metals and/or metal alloys of the IB, IIB, IIIA, IVA, IVB, VB, VIII groups in the periodic table, and may be iron, copper, nickel, copper-aluminum alloy Or any one or a combination of at least two of the copper-nickel alloys, and optionally copper and/or copper-nickel alloys.
  • the copper includes any one or a combination of at least two of powdered copper, foamed copper or nano-copper.
  • Foamed copper, copper fiber or copper powder has a large specific surface area, can fully contact with the reaction raw materials, and thus can play a better catalytic effect.
  • the mass ratio of the catalyst and the diphenylmethane dicarbamate is 1:(5-25), for example, 1:6, 1:9, 1:10, 1:13, 1:15 , 1:18, 1:20, 1:21, 1:22, 1:24, etc., can be 1:(15-20).
  • the substrate concentration will be too low, which will greatly increase the process cost; if the solvent content is too low, the substrate concentration will be too high, which is likely to cause isocyanate polymerization.
  • the inert solvent is selected from alkane inert solvents and/or halogenated hydrocarbon inert solvents, and can be any one or at least two of chlorobenzene, o-dichlorobenzene, o-xylene or p-xylene. combination.
  • the time of the pyrolysis reaction is 0.1-10h, such as 1h, 2h, 3h, 4h, 5h, 6h, 7h, 8h, 9h, etc., and may be 1-5h, such as 2h, 3h, 4h Wait.
  • the temperature of the pyrolysis reaction is 140-280°C, such as 150°C, 160°C, 170°C, 180°C, 190°C, 200°C, 215°C, 220°C, 230°C, 240°C, 250°C. °C, 260°C, 270°C, etc.
  • the pressure is 0.2-1MPa, such as 0.3MPa, 0.4MPa, 0.5MPa, 0.6MPa, 0.7MPa, 0.8MPa, 0.9MPa, etc., 0.2-0.8MPa can be selected.
  • the pyrolysis reaction of the present application has the advantage of lower reaction temperature and can prepare diphenylmethane diisocyanate with higher yield in a shorter time.
  • the diphenylmethane dicarbamate includes methyl diphenylmethane dicarbamate, ethyl diphenylmethane dicarbamate, propyl diphenylmethane dicarbamate, or butyl diphenylmethane dicarbamate Any one or a combination of at least two of them.
  • the diphenylmethane diisocyanate includes any one or at least two of 4,4'-diphenylmethane diisocyanate, 2,4'-diphenylmethane diisocyanate or polymeric diphenylmethane diisocyanate combination.
  • the diphenylmethane diisocyanate prepared by the preparation method of the present application includes both 4,4'-MDI and PMDI.
  • the preparation method includes the following steps:
  • diphenylmethane dicarbamate is pyrolyzed in an inert solvent with a boiling point lower than diphenylmethane diisocyanate for 0.1-10h, the reaction pressure is 0.2-1MPa, and the reaction temperature is 140-280°C. The diphenylmethane diisocyanate is obtained.
  • This application selects a solvent with a lower boiling point than the product.
  • the thermal decomposition reaction occurs, the methanol produced by the solvent is evaporated from the system, and the pyrolysis product MDI remains in the solvent as a heavy component. After the reaction, the MDI and the solvent The product is separated.
  • the evaporation of the solvent promotes the elimination of methanol, promotes the reaction to proceed in the positive direction, and improves the reaction efficiency;
  • the thermal degradation product MDI remains in the solvent, and the solvent is constantly replenished during the reaction, which can avoid High-concentration polymerization of MDI increases the yield of MDI; at the same time, under the catalysis of the catalyst, the reaction temperature is reduced, the reaction time is shortened, and the pyrolysis reaction is carried out at a relatively low temperature, which greatly reduces the energy. Consumption
  • the preparation method provided by this application has a high conversion rate and yield. Among them, the reaction conversion rate can reach 99.9%, and the yield can reach up to 98.9%.
  • the equipment and process are simple and the reaction conditions are relatively mild, which can meet the requirements of industrial production. Demand.
  • a preparation method of 4,4'-diphenylmethane diisocyanate is as follows:
  • the mass ratio of nano-copper to methyl 4,4'-diphenylmethane dicarbamate is 1:20
  • the mass ratio of methyl 4,4'-diphenylmethane dicarbamate to p-xylene solvent is 1: 19.
  • Example 2 The only difference from Example 1 is that the amount of nano-copper added is changed to control the mass ratio of nano-copper to 4,4'-diphenylmethane dicarbamate to 1:5 (Example 2), 1:15 ( Example 3), 1:25 (Example 4), 1:4 (Example 5), 1:30 (Example 6).
  • Example 1 The only difference from Example 1 is that the amount of p-xylene solvent added is changed to control the mass ratio of 4,4'-diphenylmethane dicarbamate to p-xylene solvent to 1:7 (Example 7), 1:50 (Example 8), 1:4 (Example 9), 1:55 (Example 10).
  • Example 1 The only difference from Example 1 is that the nano-copper is replaced with a copper-nickel alloy (Example 11) and iron (Example 12).
  • a preparation method of 4,4'-diphenylmethane diisocyanate is as follows:
  • the mass ratio of copper fiber to methyl 4,4'-diphenylmethane dicarbamate is 1:19
  • the mass ratio of methyl 4,4'-diphenylmethane dicarbamate to p-xylene solvent is 1: 19.
  • a preparation method of 4,4'-diphenylmethane diisocyanate is as follows:
  • the mass ratio of foamed copper to methyl 4,4'-diphenylmethane dicarbamate is 1:9
  • the mass ratio of methyl 4,4'-diphenylmethane dicarbamate to p-xylene solvent is 1: 9.
  • a preparation method of 4,4'-diphenylmethane diisocyanate is as follows:
  • the mass ratio of foamed copper to methyl 4,4'-diphenylmethane dicarbamate is 1:19
  • the mass ratio of methyl 4,4'-diphenylmethane dicarbamate to p-xylene solvent is 1: 19.
  • a preparation method of 4,4'-diphenylmethane diisocyanate is as follows:
  • the mass ratio of foamed copper to methyl 4,4'-diphenylmethane dicarbamate is 1:19
  • the mass ratio of methyl 4,4'-diphenylmethane dicarbamate to o-xylene solvent is 1: 10.
  • a preparation method of polymerized diphenylmethane diisocyanate is as follows:
  • the mass ratio of the foamed copper to the polymerized methyl diphenylmethane dicarbamate is 1:20
  • the mass ratio of the polymerized diphenylmethane dicarbamate to the chlorobenzene solvent is 1:20.
  • a preparation method of 4,4'-diphenylmethane diisocyanate is as follows:
  • the mass ratio of nano-copper to methyl 4,4'-diphenylmethane dicarbamate is 1:20
  • the mass ratio of methyl 4,4'-diphenylmethane dicarbamate to p-xylene solvent is 1: 19.
  • a preparation method of 4,4'-diphenylmethane diisocyanate is as follows:
  • the mass ratio of nano-copper to methyl 4,4'-diphenylmethane dicarbamate is 1:20
  • the mass ratio of methyl 4,4'-diphenylmethane dicarbamate to p-xylene solvent is 1: 19.
  • Example 1 The difference from Example 1 is that the catalyst nano copper is replaced with the catalyst nano copper oxide.
  • Example 1 The difference from Example 1 is that the catalyst nano copper is not added.
  • Example 2 The difference from Example 1 is that the solvent p-xylene is replaced with dioctyl sebacate.
  • Reactant conversion rate chromatographic analysis after constant volume of methanol/aqueous solution, and quantitative analysis using Agilent-1200 high performance liquid chromatograph from Agilent;
  • Example 1 98.9 98.7
  • Example 2 99.2 96.5
  • Example 3 99.1 97.3
  • Example 4 99.5 97.1
  • Example 5 99.6 92.3
  • Example 6 98.2 92.5
  • Example 7 98.5 72.5
  • Example 8 99.2 98.4
  • Example 9 98.9 50.3
  • Example 10 99.4 98.7
  • Example 11 97.4 78.2
  • Example 12 96.2 72.5
  • Example 13 99.2 90.8
  • Example 14 99.9 96.6
  • Example 15 98.6 92.6
  • Example 16 99.9 96.6
  • Example 17 98.5 96.2
  • Example 18 40.3 15.2
  • Example 19 100 54.2
  • Comparative example 1 92.5 67.8 Comparative example 2 91.6 48.7 Comparative example 3 90.6 75.5
  • the method for preparing diphenylmethane diisocyanate provided in the present application has the advantages of mild reaction conditions and high yield. Among them, the conversion rate of the reactants can reach more than 97%, and the yield of the product The highest can reach more than 90%.
  • Example 1 and Comparative Example 2 it can be seen from the comparison between Example 1 and Comparative Example 2 that when no catalyst is added, the conversion rate of diphenylmethane dicarbamate is lower due to the lower reaction temperature and reaction pressure, and the final yield of MDI is also lower. . From the comparison of Example 1 and Comparative Example 3, when a high boiling point solvent is selected, since MDI and methanol are distilled out at the same time during the reaction, on the one hand, reversible side reactions are prone to occur, and on the other hand, the MDI concentration is too high and easy to polymerize. , Thus resulting in a lower yield of MDI.

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  • Engineering & Computer Science (AREA)
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Abstract

本文公开了一种二苯甲烷二异氰酸酯的制备方法，所述制备方法包括：在催化剂条件下，将二苯甲烷二氨基甲酸酯在沸点低于二苯甲烷二异氰酸酯的惰性溶剂中进行热解反应，得到所述二苯甲烷二异氰酸酯。

Description

一种二苯甲烷二异氰酸酯的制备方法 技术领域
本申请涉及有机化工技术领域，例如涉及一种二苯甲烷二异氰酸酯的制备方法。
背景技术
异氰酸酯是分子结构中含有-N＝C＝O官能团异氰酸的各种酯的总称，是一种重要的有机合成中间体。目前，工业上应用最多的异氰酸酯是二苯基甲烷二异氰酸酯(MDI)，主要分为MDI 100(4,4'-MDI)，MDI 50(50％2,4'-MDI和50％4,4'-MDI的混合物)和聚合MDI(PMDI)，其中PMDI为4,4'-MDI与多苯基多亚甲基多异氰酸酯的混合物。4,4'-MDI主要用于合成氨纶和弹性体，而PMDI主要用于合成聚氨酯。相对于4,4'-MDI，PMDI由于其呈现液态，容易运输，稳定性好以及性能更适合发泡制备聚氨酯的特性，市场份额更大(80％)，是制备聚氨酯的主要原料。
目前，国内外生产MDI的主要方法是液相光气法。液相直接光气化工艺采用胺类化合物溶于溶剂后，将光气通入溶剂中，反应制得MDI产品。此工艺特别适用于沸点高、反应活性低的胺类化合物，被广泛运用于MDI、TDI等异氰酸酯产品大规模工业化生产。液相光气法工艺包括：以Huntsman为代表的液相直接光气化釜式连续工艺(ICI)工艺；Bayer、Basf为代表的塔式连续工艺和瑞典国际化工公司为代表的循环(Loop)连续工艺。光气法生产工艺已经相对成熟，但光气易挥发，是一种剧毒的气体，在生产过程中存在巨大的安全隐患；同时，光气法生产异氰酸酯的副产物HCl对生产设备腐蚀严重，生产成本增加，并且影响产品质量。
因此，随着人们环保意识的加强，无毒无污染的绿色合成方法制备异氰酸酯的技术路线越来越受到人们的关注。现有工艺主要有日本旭化成公司开发的以苯胺、一氧化碳、乙醇和氧气为原料经氧化羰基化法液相生产MDI；美国Monsanto公司于20世纪90年代初期开发的以苯胺和CO 2为原料制造MDI的路线；美国ARCO公司开发的以硝基苯和一氧化碳为原料生产MDI的工艺；Catalytica Associates/Halodor Topsoe公司与日本Kokan公司联合开发出以硝基苯、苯胺及甲醇混合物在羰基铑或钌络合物催化剂存在下进行氧化羰基化法生产MDI的非光气法新工艺、碳酸二甲酯(DMC)替代光气法等工艺。但由于设备工艺复杂、反应条件苛刻、收率不高、生产成本过高等原因都没能实现工业化生产。
随着人们对节能、环保的要求越来越高，非光气制备异氰酸酯工艺研究应运而生，并得到了快速地发展。在大环境的影响下，科研工作者提出多种非光气法制备异氰酸酯，其中有代表性的有三种：三光气法(BTC)，酯交换法和氨基甲酸酯热解法。它们都避开剧毒的光气，采用无毒的原料以及绿色的合成路线，满足人们对节能环保的要求，其中最有工业化前景的是氨基甲酸酯热解法。氨基甲酸酯热解法根据反应相分为气相热解法和液相热解法。气相热解法即将原料苯氨基甲酸酯类粉末随惰性气体带入固定床、液化床等气体反应器，在高温条件下进行热解反应制备异氰酸酯的方法；液相热解法即将苯氨基甲酸酯类原料与溶剂(高沸点)按一定的比例加入反应器中，在有或无催化剂条件下，采用减压、常压或加压操作，热解得到异氰酸酯产品。
采用高沸点溶剂热解MDC制备MDI，具有反应速度快，容易分离的优势。但是该过程同时也具有出口MDI浓度高易聚合，且MDI和甲醇同时蒸出，容 易发生可逆副反应，反应结束后高沸点溶剂与絮状副产物难以分离，使得溶剂的重复利用性低等缺陷。
CN1721060A采用氨基甲酸酯热解法，在惰性溶剂中，反应温度为150-300℃下，利用金属的超细氧化物催化热解二苯甲烷二氨基甲酸甲酯(MDC)制备得到MDI。但此反应得到MDI的收率仅为52.1％-63.1％。CN1850792A在0.09-0.093MPa，210-290℃条件下，在癸二酸二正辛酯等惰性溶剂中热解MDC，得到MDI。该反应所用MDC浓度高，易于发生副反应。
因此，开发出一种设备工艺简单、反应条件温和且具有较高收率的MDI的制备方法以满足工业化生产需求，是当下研究的重要课题。
发明内容
本申请的目的在于提供一种二苯甲烷二异氰酸酯的制备方法。这种制备方法具有较高的反应转化率和收率，且设备工艺简单，反应条件较为温和，能够满足工业化生产需求，具有较高的工业化应用价值。
为达此目的，本申请采用以下技术方案：
第一方面，本申请提供了一种二苯甲烷二异氰酸酯的制备方法，所述制备方法包括：在催化剂条件下，将二苯甲烷二氨基甲酸酯在沸点低于二苯甲烷二异氰酸酯的惰性溶剂中进行热解反应，得到所述二苯甲烷二异氰酸酯。
本申请所述的惰性溶剂指的是既不与反应物发生反应又不与产物发生反应的溶剂。
本申请选用沸点低于产物的溶剂，当热分解反应发生时，溶剂携带生成的甲醇从体系蒸出，而热解产物MDI做为重组分留在溶剂中，反应结束后MDI和溶剂分离得到产品。一方面，由于溶剂的蒸发促进了甲醇的排除，促进了反 应向正方向进行，提高了反应效率；另一方面，热降解产物MDI留在溶剂中，在反应过程中不断的补充溶剂，可以避免MDI高浓度聚合，进而提高了MDI的收率。
同时，在催化剂的催化下，降低了反应温度，缩短了反应时间，使热解反应在温度相对较低的条件下进行，大大的降低了能耗。
在本申请中，所述催化剂选自元素周期表中的IB、IIB、IIIA、IVA、IVB、VB、VIII族的金属单质和/或金属合金，可选铁、铜、镍、铜-铝合金或铜-镍合金中的任意一种或至少两种的组合，可选铜和/或铜镍合金。
可选地，所述铜包括粉末铜、泡沫铜或纳米铜中的任意一种或至少两种的组合。
区别于现有技术中常用金属氧化物作为二苯甲烷二氨基甲酸酯的催化剂，本申请选用金属和/或金属合金作为制备芳香族二异氰酸酯的催化剂，具有不易流失，催化活性高的有益效果。
泡沫铜、铜纤维或铜粉末具有较大的比表面积，能够充分的与反应原料接触，因而能够起到更好的催化作用。
可选地，所述催化剂和所述二苯甲烷二氨基甲酸酯的质量比为1:(5-25)，例如1:6、1:9、1:10、1:13、1:15、1:18、1:20、1:21、1:22、1:24等，可选为1:(15-20)。
若催化剂添加量过低，则起不到催化作用，若催化剂添加量过高，则会引起聚合反应。
可选地，所述二苯甲烷二氨基甲酸酯与所述惰性溶剂的质量比为1:(7-50)。
若溶剂含量过高，会导致底物浓度过低，大大增加了工艺成本；若溶剂含量过低，底物浓度偏高，容易引起异氰酸酯聚合。
在本申请中，所述惰性溶剂选自烷烃惰性溶剂和/或卤代烃惰性溶剂，可选氯苯、邻二氯苯、邻二甲苯或对二甲苯中的任意一种或至少两种的组合。
在本申请中，所述热解反应的时间为0.1-10h，例如1h、2h、3h、4h、5h、6h、7h、8h、9h等，可选为1-5h，例如2h、3h、4h等。
在本申请中，所述热解反应的温度为140-280℃，例如150℃、160℃、170℃、180℃、190℃、200℃、215℃、220℃、230℃、240℃、250℃、260℃、270℃等，压力为0.2-1MPa，例如0.3MPa、0.4MPa、0.5MPa、0.6MPa、0.7MPa、0.8MPa、0.9MPa等，可选0.2-0.8MPa。
本申请的热解反应具有反应温度较低的优点，可以在较短时间内制备得到较高产率的二苯甲烷二异氰酸酯。
可选地，所述二苯甲烷二氨基甲酸酯包括二苯甲烷二氨基甲酸甲酯、二苯甲烷二氨基甲酸乙酯、二苯甲烷二氨基甲酸丙酯或二苯甲烷二氨基甲酸丁酯中的任意一种或至少两种的组合。
可选地，所述二苯甲烷二异氰酸酯包括4,4'-二苯甲烷二异氰酸酯、2,4'-二苯甲烷二异氰酸酯或聚合二苯甲烷二异氰酸酯中的任意一种或至少两种的组合。
本申请的制备方法制备得到的二苯甲烷二异氰酸酯既包括4,4'-MDI，也包括PMDI。
作为可选技术方案，所述制备方法包括如下步骤：
在催化剂条件下，将二苯甲烷二氨基甲酸酯在沸点低于二苯甲烷二异氰酸酯的惰性溶剂中进行热解反应0.1-10h，反应压力为0.2-1MPa，反应温度为140-280℃，得到所述二苯甲烷二异氰酸酯。
相对于现有技术，本申请具有以下有益效果：
(1)本申请选用沸点低于产物的溶剂，当热分解反应发生时，溶剂携带生成的甲醇从体系蒸出，而热解产物MDI做为重组分留在溶剂中，反应结束后MDI和溶剂分离得到产品。一方面，由于溶剂的蒸发促进了甲醇的排除，促进了反应向正方向进行，提高了反应效率；另一方面，热降解产物MDI留在溶剂中，在反应过程中不断的补充溶剂，可以避免MDI高浓度聚合，进而提高了MDI的收率；同时，在催化剂的催化下，降低了反应温度，缩短了反应时间，使热解反应在温度相对较低的条件下进行，大大的降低了能耗；
(2)本申请提供的制备方法具有较高转化率和收率，其中，反应转化率可达99.9％，收率最高可达98.9％，且设备工艺简单，反应条件较为温和，能够满足工业生产的需求。
具体实施方式
下面通过具体实施方式来进一步说明本申请的技术方案。本领域技术人员应该明了，所述实施例仅仅是帮助理解本申请，不应视为对本申请的具体限制。
实施例1
一种4,4'-二苯甲烷二异氰酸酯的制备方法如下：
在1000mL反应釜中，加入4,4'-二苯甲烷二氨基甲酸甲酯、纳米铜和对二甲苯溶剂，然后在220℃、0.35MPa条件下反应2h。
其中，纳米铜与4,4'-二苯甲烷二氨基甲酸甲酯的质量比为1:20，4,4'-二苯甲烷二氨基甲酸甲酯与对二甲苯溶剂的质量比为1:19。
实施例2-6
与实施例1的区别仅在于，改变纳米铜的加入量，控制纳米铜与4,4'-二苯甲烷二氨基甲酸甲酯的质量比为1:5(实施例2)、1:15(实施例3)、1:25(实施例4)、1:4(实施例5)、1:30(实施例6)。
实施例7-10
与实施例1的区别仅在于，改变对二甲苯溶剂的加入量，控制4,4'-二苯甲烷二氨基甲酸甲酯与对二甲苯溶剂的质量比为1:7(实施例7)、1:50(实施例8)、1:4(实施例9)、1:55(实施例10)。
实施例11-12
与实施例1的区别仅在于，将纳米铜替换为铜镍合金(实施例11)、铁(实施例12)。
实施例13
一种4,4'-二苯甲烷二异氰酸酯的制备方法如下：
在1000mL反应釜中，加入4,4'-二苯甲烷二氨基甲酸甲酯、铜纤维和对二甲苯溶剂，然后在220℃、0.55MPa条件下反应2h。
其中，铜纤维与4,4'-二苯甲烷二氨基甲酸甲酯的质量比为1:19，4,4'-二苯甲烷二氨基甲酸甲酯与对二甲苯溶剂的质量比为1:19。
实施例14
一种4,4'-二苯甲烷二异氰酸酯的制备方法如下：
在1000mL反应釜中，加入4,4'-二苯甲烷二氨基甲酸丙酯、泡沫铜和对二甲苯溶剂，然后在250℃、0.55MPa条件下反应2h。
其中，泡沫铜与4,4'-二苯甲烷二氨基甲酸甲酯的质量比为1:9，4,4'-二苯甲烷二氨基甲酸甲酯与对二甲苯溶剂的质量比为1:9。
实施例15
一种4,4'-二苯甲烷二异氰酸酯的制备方法如下：
在1000mL反应釜中，加入4,4'-二苯甲烷二氨基甲酸丁酯、铜粉末和对二甲苯溶剂，然后在250℃、0.55MPa条件下反应2h。
其中，泡沫铜与4,4'-二苯甲烷二氨基甲酸甲酯的质量比为1:19，4,4'-二苯甲烷二氨基甲酸甲酯与对二甲苯溶剂的质量比为1:19。
实施例16
一种4,4'-二苯甲烷二异氰酸酯的制备方法如下：
在1000mL反应釜中，加入4,4'-二苯甲烷二氨基甲酸甲酯、泡沫铜和邻二甲苯溶剂，然后在270℃、0.55MPa条件下反应2h。
其中，泡沫铜与4,4'-二苯甲烷二氨基甲酸甲酯的质量比为1:19，4,4'-二苯甲烷二氨基甲酸甲酯与邻二甲苯溶剂的质量比为1:10。
实施例17
一种聚合二苯甲烷二异氰酸酯的制备方法如下：
在1000mL反应釜中，加入聚合二苯甲烷二氨基甲酸甲酯、铜粉末和氯苯溶剂，然后在250℃、0.55MPa条件下反应2h。
其中，泡沫铜与聚合二苯甲烷二氨基甲酸甲酯的质量比为1:20，聚合二苯甲烷二氨基甲酸甲酯与氯苯溶剂的质量比为1:20。
实施例18
一种4,4'-二苯甲烷二异氰酸酯的制备方法如下：
在1000mL反应釜中，加入4,4'-二苯甲烷二氨基甲酸甲酯、纳米铜和对二甲苯溶剂，然后在280℃、0.2MPa条件下反应0.1h。
其中，纳米铜与4,4'-二苯甲烷二氨基甲酸甲酯的质量比为1:20，4,4'-二苯甲烷二氨基甲酸甲酯与对二甲苯溶剂的质量比为1:19。
实施例19
一种4,4'-二苯甲烷二异氰酸酯的制备方法如下：
在1000mL反应釜中，加入4,4'-二苯甲烷二氨基甲酸甲酯、纳米铜和对二甲苯溶剂，然后在140℃、1MPa条件下反应10h。
其中，纳米铜与4,4'-二苯甲烷二氨基甲酸甲酯的质量比为1:20，4,4'-二苯甲烷二氨基甲酸甲酯与对二甲苯溶剂的质量比为1:19。
对比例1
与实施例1的区别在于，将催化剂纳米铜替换为催化剂纳米氧化铜。
对比例2
与实施例1的区别在于，不添加催化剂纳米铜。
对比例3
与实施例1的区别在于，将溶剂对二甲苯替换为癸二酸二辛脂。
性能测试
对实施例1-19和对比例1-3提供的二苯甲烷二异氰酸酯进行性能测试，方法如下：
(1)反应物转化率：甲醇/水溶液定容后进行色谱分析，利用美国安捷伦公司Agilent-1200高效液相色谱仪进行定量分析；
(2)产物收率：甲醇/水溶液定容后进行色谱分析，利用美国安捷伦公司Agilent-1200高效液相色谱仪进行定量分析；
测试结果见表1；
表1
样品 反应物转化率/％ 产物收率/％
实施例1 98.9 98.7
实施例2 99.2 96.5
实施例3 99.1 97.3
实施例4 99.5 97.1
实施例5 99.6 92.3
实施例6 98.2 92.5
实施例7 98.5 72.5
实施例8 99.2 98.4
实施例9 98.9 50.3
实施例10 99.4 98.7
实施例11 97.4 78.2
实施例12 96.2 72.5
实施例13 99.2 90.8
实施例14 99.9 96.6
实施例15 98.6 92.6
实施例16 99.9 96.6
实施例17 98.5 96.2
实施例18 40.3 15.2
实施例19 100 54.2
对比例1 92.5 67.8
对比例2 91.6 48.7
对比例3 90.6 75.5
由实施例和性能测试可知，本申请提供的二苯甲烷二异氰酸酯的制备方法具有反应条件温和，产率较高的优点，其中，反应物的转化率最高可达97％以上，产物的收率最高可达90％以上。
由实施例1-6的对比可知，在本申请中，催化剂和反应物的质量比在1:(5-25)范围内时，MDI的产率较高。由实施例1和实施例7-10的对比可知，惰性溶剂的添加量与反应物的质量比在(7-50):1范围内时，MDI的产率较高，当惰性溶剂的添加量与反应物的质量比在(19-50):1范围内时，MDI的产率更高。由实施例1和对比例1的对比可知，当选择金属氧化物作为催化剂时，效果不如选用金属或者金属合金的效果好。由实施例1和对比例2的对比可知，当不添加催化剂时，由于反应温度和反应压力较低而导致二苯甲烷二氨基甲酸酯的转化率较低，最后MDI的产率也较低。由实施例1和对比例3的对比可知，当选用高沸点溶剂时，由于在反应过程中是MDI与甲醇同时蒸出，一方面是容易发生可逆副反应，另一方面MDI浓度过高容易聚合，因此导致MDI产率较低。
申请人声明，本申请通过上述实施例来说明本申请的二苯甲烷二异氰酸酯的制备方法，但本申请并不局限于上述实施例，即不意味着本申请必须依赖上述实施例才能实施。

Claims (12)

  1. 一种二苯甲烷二异氰酸酯的制备方法，其包括：
    在催化剂条件下，将二苯甲烷二氨基甲酸酯在沸点低于二苯甲烷二异氰酸酯的惰性溶剂中进行热解反应，得到所述二苯甲烷二异氰酸酯。
  2. 根据权利要求1所述的二苯甲烷二异氰酸酯的制备方法，其中，所述催化剂选自元素周期表中的IB、IIB、IIIA、IVA、IVB、VB、VIII族的金属单质和/或金属合金。
  3. 根据权利要求1或2所述的二苯甲烷二异氰酸酯的制备方法，其中，所述催化剂和所述二苯甲烷二氨基甲酸酯的质量比为1:(5-25)。
  4. 根据权利要求3所述的二苯甲烷二异氰酸酯的制备方法，其中，所述催化剂和所述二苯甲烷二氨基甲酸酯的质量比为为1:(15-20)。
  5. 根据权利要求1-3中的任一项所述的二苯甲烷二异氰酸酯的制备方法，其中，所述催化剂为铁、铜、镍、铜-铝合金或铜-镍合金中的任意一种或至少两种的组合，可选铜和/或铜镍合金；
    可选地，所述铜包括粉末铜、泡沫铜或纳米铜中的任意一种或至少两种的组合。
  6. 根据权利要求1-5中的任一项所述的二苯甲烷二异氰酸酯的制备方法，其中，所述二苯甲烷二氨基甲酸酯与所述惰性溶剂的质量比为1:(7-50)。
  7. 根据权利要求1-6中的任一项所述的二苯甲烷二异氰酸酯的制备方法，其中，所述惰性溶剂选自烷烃惰性溶剂和/或卤代烃惰性溶剂，可选氯苯、邻二氯苯、邻二甲苯或对二甲苯中的任意一种或至少两种的组合。
  8. 根据权利要求1-7中的任一项所述的二苯甲烷二异氰酸酯的制备方法，其中，所述热解反应的时间为0.1-10h，可选为1-5h。
  9. 根据权利要求1-8中的任一项所述的二苯甲烷二异氰酸酯的制备方法，其中，所述热解反应的温度为140-280℃，压力为0.2-1MPa，可选0.2-0.8MPa。
  10. 根据权利要求1-9中的任一项所述的二苯甲烷二异氰酸酯的制备方法，其中，所述二苯甲烷二氨基甲酸酯包括二苯甲烷二氨基甲酸甲酯、二苯甲烷二氨基甲酸乙酯、二苯甲烷二氨基甲酸丙酯或二苯甲烷二氨基甲酸丁酯中的任意一种或至少两种的组合。
  11. 根据权利要求1-10中的任一项所述的二苯甲烷二异氰酸酯的制备方法，其中，所述二苯甲烷二异氰酸酯包括4,4'-二苯甲烷二异氰酸酯、2,4'-二苯甲烷二异氰酸酯或聚合二苯甲烷二异氰酸酯中的任意一种或至少两种的组合。
  12. 根据权利要求1-11中的任一项所述的二苯甲烷二异氰酸酯的制备方法，其中，所述制备方法包括如下步骤：
    在催化剂条件下，将二苯甲烷二氨基甲酸酯在沸点低于二苯甲烷二异氰酸酯的惰性溶剂中进行热解反应0.1-10h，反应压力为0.2-1MPa，反应温度为140-280℃，得到所述二苯甲烷二异氰酸酯。
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