WO2021247314A1 - Composés ramifiés - Google Patents

Composés ramifiés Download PDF

Info

Publication number
WO2021247314A1
WO2021247314A1 PCT/US2021/034189 US2021034189W WO2021247314A1 WO 2021247314 A1 WO2021247314 A1 WO 2021247314A1 US 2021034189 W US2021034189 W US 2021034189W WO 2021247314 A1 WO2021247314 A1 WO 2021247314A1
Authority
WO
WIPO (PCT)
Prior art keywords
branched
catalyst
aldehyde
stream
olefin
Prior art date
Application number
PCT/US2021/034189
Other languages
English (en)
Inventor
Kyle KILLEBREW
Samuel Livingston Lane
Original Assignee
SCION Holdings LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from PCT/US2021/030341 external-priority patent/WO2021247177A1/fr
Application filed by SCION Holdings LLC filed Critical SCION Holdings LLC
Priority to US18/007,900 priority Critical patent/US20230271906A1/en
Priority to PCT/US2021/035169 priority patent/WO2021247516A1/fr
Priority to EP21817011.6A priority patent/EP4161696A1/fr
Priority to US17/928,368 priority patent/US20230219873A1/en
Priority to US17/336,099 priority patent/US20220024837A1/en
Priority to MX2022014196A priority patent/MX2022014196A/es
Priority to CN202180036251.3A priority patent/CN115916947A/zh
Priority to US17/338,641 priority patent/US20210387933A1/en
Priority to PCT/US2021/035772 priority patent/WO2021247917A1/fr
Priority to JP2022570559A priority patent/JP2023528766A/ja
Priority to CA3178431A priority patent/CA3178431A1/fr
Priority to EP21816908.4A priority patent/EP4162021A1/fr
Priority to US17/923,381 priority patent/US20230219871A1/en
Publication of WO2021247314A1 publication Critical patent/WO2021247314A1/fr
Priority to US17/553,752 priority patent/US20220176361A1/en
Priority to US18/202,775 priority patent/US20230303488A1/en

Links

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
    • B01J31/00—Catalysts comprising hydrides, coordination complexes or organic compounds
    • B01J31/16—Catalysts comprising hydrides, coordination complexes or organic compounds containing coordination complexes
    • B01J31/18—Catalysts comprising hydrides, coordination complexes or organic compounds containing coordination complexes containing nitrogen, phosphorus, arsenic or antimony as complexing atoms, e.g. in pyridine ligands, or in resonance therewith, e.g. in isocyanide ligands C=N-R or as complexed central atoms
    • B01J31/1845—Catalysts comprising hydrides, coordination complexes or organic compounds containing coordination complexes containing nitrogen, phosphorus, arsenic or antimony as complexing atoms, e.g. in pyridine ligands, or in resonance therewith, e.g. in isocyanide ligands C=N-R or as complexed central atoms the ligands containing phosphorus
    • B01J31/185—Phosphites ((RO)3P), their isomeric phosphonates (R(RO)2P=O) and RO-substitution derivatives thereof
    • 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
    • B01J31/00—Catalysts comprising hydrides, coordination complexes or organic compounds
    • B01J31/16—Catalysts comprising hydrides, coordination complexes or organic compounds containing coordination complexes
    • B01J31/24—Phosphines, i.e. phosphorus bonded to only carbon atoms, or to both carbon and hydrogen atoms, including e.g. sp2-hybridised phosphorus compounds such as phosphabenzene, phosphole or anionic phospholide ligands
    • B01J31/2404—Cyclic ligands, including e.g. non-condensed polycyclic ligands, the phosphine-P atom being a ring member or a substituent on the ring
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C45/00—Preparation of compounds having >C = O groups bound only to carbon or hydrogen atoms; Preparation of chelates of such compounds
    • C07C45/49—Preparation of compounds having >C = O groups bound only to carbon or hydrogen atoms; Preparation of chelates of such compounds by reaction with carbon monoxide
    • C07C45/50—Preparation of compounds having >C = O groups bound only to carbon or hydrogen atoms; Preparation of chelates of such compounds by reaction with carbon monoxide by oxo-reactions
    • 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
    • B01J2231/00—Catalytic reactions performed with catalysts classified in B01J31/00
    • B01J2231/30—Addition reactions at carbon centres, i.e. to either C-C or C-X multiple bonds
    • B01J2231/32—Addition reactions to C=C or C-C triple bonds
    • B01J2231/321—Hydroformylation, metalformylation, carbonylation or hydroaminomethylation
    • 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
    • B01J2231/00—Catalytic reactions performed with catalysts classified in B01J31/00
    • B01J2231/50—Redistribution or isomerisation reactions of C-C, C=C or C-C triple bonds
    • B01J2231/52—Isomerisation reactions
    • 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
    • B01J2531/00—Additional information regarding catalytic systems classified in B01J31/00
    • B01J2531/80—Complexes comprising metals of Group VIII as the central metal
    • B01J2531/82—Metals of the platinum group
    • B01J2531/822—Rhodium
    • 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
    • B01J31/00—Catalysts comprising hydrides, coordination complexes or organic compounds
    • B01J31/16—Catalysts comprising hydrides, coordination complexes or organic compounds containing coordination complexes
    • B01J31/20—Carbonyls
    • 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
    • B01J31/00—Catalysts comprising hydrides, coordination complexes or organic compounds
    • B01J31/16—Catalysts comprising hydrides, coordination complexes or organic compounds containing coordination complexes
    • B01J31/22—Organic complexes
    • B01J31/2204—Organic complexes the ligands containing oxygen or sulfur as complexing atoms
    • B01J31/2208—Oxygen, e.g. acetylacetonates
    • B01J31/2226—Anionic ligands, i.e. the overall ligand carries at least one formal negative charge
    • B01J31/223—At least two oxygen atoms present in one at least bidentate or bridging ligand
    • B01J31/2234—Beta-dicarbonyl ligands, e.g. acetylacetonates

Definitions

  • the present invention relates to branched compounds and methods for producing and manufacturing branched compounds.
  • a two-step process is disclosed herein that produces greater than 20% branched aldehyde products, with 25% to 98+% branching, that are produced from an alpha olefin feedstock. Additionally, the two-step process disclosed herein employs a rhodium organophosphorous catalyst for both the first step which is an isomerization reaction step and the second step which is a hydroformylation reaction step.
  • the method disclosed herein can be a process having a first process step and a second process step.
  • the first process step can be a reaction isomerizing an alpha olefin under a CO/H2 atmosphere at a first pressure.
  • the isomerizing step can be catalyzed by a first catalyst comprising an organometallic complex of rhodium and one type of an organophosphorus ligand or an organometallic complex of rhodium and more than one type of an organophosphorus ligand, said isomerizing producing an isomerized olefin.
  • the second step of this embodiment can be a reaction hydroformylating the isomerized olefin under a CO/H2 atmosphere at a second pressure higher than said first pressure.
  • the hydroformylating step can be catalyzed by the first catalyst and said hydroformylating step can produce a branched aldehyde.
  • the catalyst used in the isomerizing step can be the same catalyst as in the hydroformylating step.
  • the second pressure can be lower than the first pressure.
  • the first pressure and second pressure are different.
  • the second pressure can be either higher or lower than the first pressure.
  • the organophosphorous ligand can be a phosphine.
  • the phosphine ligand can be triphenylphosphine.
  • the organophosphorous ligand can be a phosphite.
  • the phosphite ligand can be tris (2, 4-di-t-butylphenyl) phosphite.
  • a mixture of organophosphorous ligands of different types can be used, such as a mixture of a phosphine and a phosphite.
  • the organophosphorous ligands can be a mixture of triphenylphosphine and tris (2, 4-di-t-butylphenyl) phosphite.
  • the alpha olefin can be a C4-C36 alpha olefm.
  • the first catalyst can be formed when the molar ratio of phosphorous to rhodium is in a range of 1 : 1 to 1000 : 1.
  • the alpha olefin can comprise at least one of a short chain alpha olefin, a medium chain alpha olefin and a long chain alpha olefin.
  • the alpha olefm can comprise at least one of a C4 or greater alpha olefin.
  • the alpha olefin can comprise at least one of a C4 or greater alpha olefin, a C6 or greater alpha olefin, a CIO or greater alpha olefin, a C 16 or greater alpha olefin, a C20 or greater alpha olefin, and a C30 or greater alpha olefin and a C36 or greater alpha olefin.
  • the isomerizing produces a reaction product comprising an isomerized olefin which comprises a 20 wt.% or greater isomerized olefin.
  • said isomerizing step produces a reaction product comprising a 20 wt.% or greater isomerized olefin, or a 30 wt.% or greater isomerized olefin, or a 40 wt.% or greater isomerized olefin, or a 50 wt.% or greater isomerized olefin, or a 60 wt.% or greater isomerized olefin, or a 70 wt.% or greater isomerized olefin, or a 80 wt.% or greater isomerized olefin, or a 90 wt.% or greater isomerized olefin, or a 95 wt.% or greater isomerized olefin, or a 99 wt.% pr greater isomerized olefin.
  • said hydroformylating step produces a reaction product comprising a 25 wt.% or greater branched aldehyde, or a 30 wt.% or greater branched aldehyde, or a 40 wt.% or greater branched aldehyde, or a 50 wt.% or greater branched aldehyde, or a 60 wt.% or greater branched aldehyde, or a 70 wt.% or greater branched aldehyde, or a 80 wt.% or greater branched aldehyde, or a 90 wt.% or greater branched aldehyde, or a 95 wt.% or greater branched aldehyde, or a 99 wt.% or greater branched aldehyde.
  • a process can have the steps of: providing a first catalyst which is an organometallic complex of rhodium and one type of an organophosphorus ligand or an organometallic complex of rhodium and more than one type of an organophosphorus ligand; activating said first catalyst with CO to achieve an activated first catalyst; isomerizing an alpha olefin by said activated first catalyst at a first pressure to produce an isomerized olefin; providing hydrogen; hydroformylating said isomerized olefin by reaction with CO and H2 at a second pressure to produce a branched aldehyde.
  • the alpha olefin is a linear alpha olefin having a number of carbons in the range of C4-C36. In an embodiment, the alpha olefin can be a C4-C36 alpha olefin.
  • the organophosphorous ligand can be a phosphine. In a nonlimiting example of a phosphine ligand, the phosphine ligand can be triphenylphosphine. In another embodiment, the organophosphorous ligand can be a phosphite.
  • the phosphite ligand can be tris (2, 4-di-t-butylphenyl) phosphite.
  • a mixture of organophosphorous ligands of different types can be used, such as a mixture of a phosphine and a phosphite.
  • the organophosphorous ligands can be a mixture of triphenylphosphine and tris (2, 4-di-t-butylphenyl) phosphite.
  • the first catalyst can be formed when the molar ratio of phosphorous to rhodium is in a range of 1 : 1 to 1000: 1.
  • a process can have the steps of: providing CO and H2; providing a first catalyst which is an organometallic complex of rhodium and one type of an organophosphorus ligand or an organometallic complex of rhodium and more than one type of an organophosphorus ligand; providing a linear alpha olefin; isomerizing said linear alpha olefin (also herein described as a normal alpha olefin) by said first catalyst in the presence of CO and H2 at a first pressure to produce an isomerized olefin; and hydroformylating said isomerized olefin by said first catalyst in the presence of CO and H2 at a second pressure different from said first pressure to produce a branched aldehyde.
  • a first catalyst which is an organometallic complex of rhodium and one type of an organophosphorus ligand or an organometallic complex of rhodium and more than one type of an organophosphorus
  • the branched aldehyde is a 2-alkyl branched aldehyde.
  • the linear alpha olefin is a C4-C36 linear alpha olefin.
  • the branched aldehyde produced from the C4-C36 linear alpha olefin is a C5-C37 branched aldehyde.
  • the linear alpha olefin can be 1 -Butene and said branched aldehyde can be branched Pentanals.
  • the linear alpha olefin can be 1 -Hexene and said branched aldehyde can be branched Heptanals.
  • the linear alpha olefin can be 1-Octene and said branched aldehyde can be branched Nonanals. In an embodiment, the linear alpha olefin can be 1-Decene and said branched aldehyde can be branched Undecanals. In an embodiment, the linear alpha olefin can be 1-Dodecene and said branched aldehyde can be branched Tridecanals. In an embodiment, the linear alpha olefin can be 1-Tetradecene and said branched aldehyde can be branched Pentadecanals.
  • the linear alpha olefin can be 1-Hexadecene and said branched aldehyde can be branched Heptadecanals. In an embodiment, the linear alpha olefin can be 1-
  • the organophosphorous ligand can be a phosphine.
  • the phosphine ligand can be triphenylphosphine.
  • the organophosphorous ligand can be a phosphite.
  • the phosphite ligand can be tris (2, 4-di-t-butylphenyl) phosphite.
  • a mixture of organophosphorous ligands of different types can be used, such as a mixture of a phosphine and a phosphite.
  • the organophosphorous ligands can be a mixture of triphenylphosphine and tris (2, 4- di-t-butylphenyl) phosphite.
  • the first catalyst is formed when the molar ratio of phosphorous to rhodium is in a range of 1 : 1 to 1000: 1. In an embodiment, the first catalyst is formed when the molar ratio of phosphorous to rhodium is in a range of 1:1 to 1000:1 in the isomerization step and/or reactor. In an embodiment, the first catalyst is formed when the molar ratio of phosphorous to rhodium is in a range of 1:1 to 1000:1 in the hydroformylation step and/or reactor.
  • a process can have the steps of: providing CO and H2; providing a first catalyst which is an organometallic complex of rhodium and one type of an organophosphorus ligand or an organometallic complex of rhodium and more than one type of an organophosphorus ligand; providing an alpha olefin; isomerizing said alpha olefin by said first catalyst in the presence of CO and H2 at a first pressure to produce an isomerized olefin; and hydroformylating said isomerized olefin by said first catalyst in the presence of CO and H2 at a second pressure different from said first pressure to produce a branched aldehyde.
  • the alpha olefin can be a C4-C36 alpha olefin.
  • the organophosphorous ligand can be a phosphine.
  • the phosphine ligand can be triphenylphosphine.
  • the organophosphorous ligand can be a phosphite.
  • the phosphite ligand can be tris (2, 4-di-t-butylphenyl) phosphite.
  • a mixture of organophosphorous ligands of different types can be used, such as a mixture of a phosphine and a phosphite.
  • the organophosphorous ligands can be a mixture of triphenylphosphine and tris (2, 4- di-t-butylphenyl) phosphite.
  • the first catalyst can be formed when the molar ratio of phosphorous to rhodium is in a range of 1 : 1 to 1000: 1.
  • a process can have the steps of: providing CO and H2; providing a first catalyst which is an organometallic complex of rhodium and one type of an organophosphorus ligand or an organometallic complex of rhodium and more than one type of an organophosphorus ligand; providing an alpha olefin; isomerizing said alpha olefin by said first catalyst in the presence of CO and H2 at a first pressure to produce an isomerized olefin; and hydroformylating said isomerized olefin by said first catalyst in the presence of CO and H2 at a second pressure different from said first pressure to produce a branched aldehyde; and hydrogenating said branched aldehyde to produce a branched alcohol.
  • the isomerizing step produces a reaction product comprising 20 wt.% or greater isomerized olefins, or 40 wt.% or greater isomerized olefins.
  • the hydroformylating step produces a reaction product comprising 25 wt.% or greater branched aldehydes, or 50 wt.% or greater branched aldehydes.
  • the hydrogenating step produces a reaction product comprising 40 wt.% or greater branched alcohols, or 50 wt.% or greater branched alcohols.
  • a process for producing a branched aldehyde can have the steps of: providing an alpha olefin; providing a first catalyst; isomerizing said alkene catalyzed by said first catalyst under an atmosphere comprising a CO and an 3 ⁇ 4 at a first pressure; producing an intermediate isomerized olefin product composition having internal olefins; hydroformylating said intermediate isomerized olefin product catalyzed by said first catalyst under an atmosphere comprising a CO and an 3 ⁇ 4 at a second pressure higher than said first pressure; and producing a branched aldehyde product.
  • this process can also have the step of separating said branched aldehyde product from the first catalyst stream via a distillation process. In an embodiment, this process can also have the steps of: hydrogenating said branched aldehyde in the presence of a hydrogenation catalyst; and producing a branched alcohols product composition.
  • the alpha olefin is a C4 to C36, or greater, alpha olefin.
  • the catalyst is a rhodium catalyst. In an embodiment, the catalyst is a homogeneous rhodium catalyst. In an embodiment, the catalyst is a homogeneous rhodium catalyst having an organophosphorous ligand.
  • the first pressure is in a range of from 0.1 bar(g) and 10 bar(g).
  • the intermediate isomerized olefin product comprises at least 20 wt.% of internal olefins.
  • the second pressure is in a range of from 5 bar(g) to 400 bar(g).
  • the branched aldehyde product comprises at least 25 wt.% of branched aldehydes.
  • a process can have the steps of: providing CO and H2; providing a first catalyst which is an organometallic complex of rhodium and one type of an organophosphorus ligand or an organometallic complex of rhodium and more than one type of an organophosphorus ligand; providing an alpha olefin; isomerizing said alpha olefin by said first catalyst in the presence of CO and H2 at a first pressure to produce an isomerized olefin; hydroformylating said isomerized olefin by said first catalyst in the presence of CO and H2 at a second pressure different from said first pressure to produce a branched aldehyde; hydrogenating said branched aldehyde to produce a branched alcohol; and producing a branched surfactant from said branched alcohol.
  • the producing step comprises sulfating the branched alcohol to produce a branched alcohol sulfate. In an embodiment, the producing step comprises alkoxylating the branched alcohol to produce a branched alkoxylated alcohol.
  • the alkoxylating agent can be ethylene oxide, propylene oxide or mixtures of ethylene oxide and propylene oxide. In an embodiment, the alkoxylating agent can be ethylene oxide and propylene oxide, added simultaneously or stepwise (i.e. block oxide). In an embodiment, the alkoxylating agent can be ethylene oxide, propylene oxide, butylene oxide and mixtures of ethylene oxide, propylene oxide and butylene oxide.
  • the alkoxylated alcohol can be sulfated to produce a branched sulfated alkoxylated alcohol.
  • the isomerizing step can produce a reaction product comprising 20 wt.% or greater internal olefins. In an embodiment, the isomerizing can produce a reaction product comprising 50 wt.% or greater internal olefins.
  • the hydroformylating can produce a reaction product comprising 25 wt.% or greater branched aldehydes. In an embodiment, the hydroformylating can produce a reaction product comprising 50 wt.% or greater branched aldehydes.
  • the hydrogenating can produce a reaction product comprising 40 wt.% or greater branched alcohols. In an embodiment, the hydrogenating step can produce a reaction product comprising 50 wt.% or greater branched alcohols. In an embodiment, the said surfactant can have 40 wt.% or greater branched surfactants. In an embodiment, the surfactant can have 50 wt.% or greater branched surfactants.
  • a method can have the steps of: providing a feed having an alpha olefin; providing a catalyst; catalyzing an isomerization of said alpha olefin by said catalyst; producing an isomerized olefin by said isomerization of said alpha olefin; catalyzing a hydroformylation of said isomerized olefin by said catalyst; and producing an branched aldehyde by said hydroformylation of said isomerized olefin.
  • this method can also have the steps of: reacting said branched aldehyde with hydrogen; and producing a branched alcohol by said reacting said branched aldehyde.
  • this method can also have the step of: providing said feed having one or more internal olefins. In an embodiment, this method can also have the step of: providing said feed having one or more internal olefins which are C4 to C36 internal olefins.
  • a method can have the steps of: providing a feed having one or more internal olefins; providing a catalyst; catalyzing an isomerization of said internal olefin(s) by said catalyst; producing an isomerized olefin mixture by said isomerization of said internal olefm(s); catalyzing a hydroformylation of said isomerized olefin mixture by said catalyst; and producing an branched aldehyde mixture by said hydroformylation of said isomerized olefin mixture.
  • this method can also have the steps of: reacting said branched aldehyde mixture with hydrogen; and producing a branched alcohol mixture by said reacting said branched aldehyde mixture.
  • this method can also have the step of: providing a mixed olefins feed which is a mixture of an internal olefin and an alpha olefin. In an embodiment, this method can also have the step of: providing said mixed olefins feed which is a mixture of one or more C4 to C36 internal olefins, and one or more C4 to C36 alpha olefins.
  • a method can have the steps of: providing said mixed olefins feed; providing a catalyst; catalyzing an isomerization of said mixed olefins by said catalyst; producing an isomerized olefin mixture by said isomerization of said mixed olefins; catalyzing a hydroformylation of said mixed olefins by said catalyst; and producing a branched aldehyde mixture by said hydroformylation of said mixed olefins.
  • this method can also have the steps of: reacting said branched aldehyde mixture with hydrogen; and producing a branched alcohol mixture by said reacting said branched aldehyde mixture.
  • a method can have the steps of: providing a C4-C36 alkene; providing a first catalyst; isomerizing said C4-C36 alkene catalyzed by said first catalyst; and producing an intermediate product composition having a plurality of isomerized alkenes, wherein said intermediate product composition has at least 60 wt. % of said plurality of isomerized alkenes; and hydroformylating said plurality of isomerized alkenes.
  • this process can further have the step of: producing a branched aldehyde.
  • this process can further have the step of: producing a branched aldehyde product composition by said hydroformylating that has a branched aldehyde product of at least 60 wt. % of said plurality of branched aldehydes.
  • a method can have the steps of: providing a first catalyst; isomerizing an alpha olefin by catalysis by said first catalyst to produce an isomerized olefin; conducting a hydroformylation of said isomerized olefin by said first catalyst to produce a branched aldehyde; producing a branched alcohol from said branched aldehyde; and producing a surfactant from said branched alcohol.
  • a method can have the steps of: providing a feed composition comprising a first linear olefin; providing a first quantity of a first catalyst composition comprising a first catalyst; catalyzing an isomerization of said alpha olefin by said first catalyst of said first quantity; producing an isomerized olefin by said isomerization of said first linear olefin; providing a second quantity of said catalyst composition comprising said first catalyst; catalyzing a hydroformylation of said isomerized olefin by said first catalyst of said second quantity; and producing an aldehyde by said hydroformylation of said isomerized alpha olefin.
  • a branched surfactant can be produced by a process, comprising the steps of: isomerizing a C4-C36 alpha olefin by a first catalyst which is an organometallic complex of rhodium and one type of an organophosphorus ligand or an organometallic complex of rhodium and more than one type of an organophosphorus ligand; in the presence of a gas phase having CO at a first pressure producing an isomerized olefin; hydroformylating said isomerized olefin by said first catalyst in the presence of a gas having CO and H2 at second pressure different from said first pressure producing a C5-C37 branched aldehyde; hydrogenating said C5-C37 branched aldehyde to produce a C5-C37 branched alcohol; and producing a branched surfactant from said C5-C37 branched alcohol.
  • the branched surfactant can be produced from the method in which the isomerized olefin mixture is 20 wt.% to 100 wt.% isomerized. In an embodiment, the branched surfactant can be produced from the method in which the branched aldehyde mixture is 25 wt.% to 100 wt.% branched. In an embodiment, the branched surfactant can be produced from the method in which the branched alcohol mixture is 25 wt.% to 100 wt.% branched. In an embodiment, the branched surfactant can be produced from the method in which the branched surfactant is 25 wt.% to 100 wt.% branched.
  • FIG. 1 shows an embodiment of a chemical manufacturing process having an isomerization reactor and an hydroformylation reactor
  • FIG. 2 shows an embodiment of a chemical manufacturing process having an isomerization reactor with an isomerization reactor bypass and a hydroformylation reactor;
  • FIG. 3 shows an embodiment of a chemical manufacturing process having an isomerization reactor, a hydroformylation reactor and catalyst recovery;
  • FIG. 4 shows an embodiment of a chemical manufacturing process having an isomerization reactor, a hydroformylation reactor, catalyst recovery and aldehyde distillation;
  • FIG. 5 shows an embodiment of a chemical manufacturing process having an isomerization reactor, a hydroformylation reactor, catalyst recovery and an aldehyde hydrogenation reactor;
  • FIG. 6 shows an embodiment of a chemical manufacturing process having an isomerization reactor, a hydroformylation reactor, catalyst recovery, aldehyde distillation and an aldehyde hydrogenation reactor;
  • FIG. 7 shows Sales Specification 1 ;
  • FIG. 8 shows Sales Specification 2
  • FIG. 9 A shows Sales Specification 3, page 1;
  • FIG. 9B shows Sales Specification 3, page 2;
  • FIG. 10 shows Sales Specification 4.
  • FIG. 11A shows Sales Specification 5, page 1;
  • FIG. 1 IB shows Sales Specification 5, page 2;
  • FIG. 12 shows Sales Specification 6.
  • a two-step process is disclosed herein that produces branched aldehyde products, with 25% to 98+% branching, that are produced from an alpha olefin feedstock. Additionally, the two-step process disclosed herein employs an organometallic complex of rhodium and at least one organophosphorous ligand for both the first step which is an isomerization reaction step and the second step which is a hydroformylation reaction step.
  • Numeric values and ranges herein, unless otherwise stated, also are intended to have associated with them a tolerance and to account for variances of design and manufacturing. Thus, a number can include values “about” that number. For example, a value X is also intended to be understood as “about X”.
  • a range of Y-Z is also intended to be understood as within a range of from “about Y-about Z”.
  • significant digits disclosed for a number are not intended to make the number an exact limiting value. Variance and tolerance are inherent in mechanical design and the numbers disclosed herein are intended to be construed to allow for such factors (in non-limiting e.g., ⁇ 10 percent of a given value). Likewise, the claims are to be broadly construed in their recitations of numbers and ranges.
  • Every numerical range given throughout this specification will include every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein.
  • every maximum numerical limitation given throughout this specification includes every lower numerical limitation, as if such lower numerical limitations were expressly written herein.
  • Every minimum numerical limitation given throughout this specification will include every higher numerical limitation, as if such higher numerical limitations were expressly written herein.
  • reactor means one or more physical reactors that individually or in combination are used to achieve a reactive step in chemical processing.
  • reaction step and “reactive step” are used synonymously.
  • a “reactor” can be a single vessel or optionally multiple vessels.
  • a “reactor” can optionally be configured such that a reactive step occurs in one or more reactor vessels. If there are a number of reactor vessels, such reactor vessels can be operated in series, in parallel, or any combination thereof.
  • reactor is the unit operation of conducting a chemical reaction processing step, also referred to as a reaction step, or reactive step.
  • reactor should be construed to mean a reactive step which in fact could be carried out in one or more reactors operating in series, parallel, or any combination thereof. Therefore, “isomerization reactor” should be construed to mean an isomerization step (meaning an isomerization reaction step) occurring in one or more reactors operating in series, parallel, or any combination thereof.
  • hydroformylation reactor should be construed to mean a hydroformylation step (meaning an hydroformylation reaction step) occurring in one or more reactors operating in series, parallel, or any combination thereof.
  • hydroformylation reactor should be construed to mean a hydrogenation step (meaning a hydrogenation reaction step) occurring in one or more reactors operating in series, parallel, or any combination thereof.
  • concentration can be expressed in units of parts per million, or ppm.
  • a “Cl 2” molecule is a molecule having 12 carbons (i.e. 1-dodecene for example).
  • olefin is used synonymously with the term “alkene”, meaning a molecule containing a carbon-carbon double bond.
  • branched is defined as a molecule, compound or chemical structure, having one or more alkyl groups attached along a carbon backbone. “Branched” molecules are isomers of linear (i.e. straight-chain) molecules having the same number of carbon atoms.
  • percent branched in additional to its ordinary and customary meaning, is defined herein to mean the wt.% branched molecules in a composition.
  • percent branching is use synonymously with “percent branched” and has the same meaning as “percent branched”.
  • percent branching for an aldehyde composition, the “percent branching” of the aldehyde means the wt.% of the aldehyde being branched, i.e.
  • [70] 100 * (wt. % branched aldehyde) ⁇ (wt. % branched aldehyde + wt. % linear aldehyde).
  • branched C6 aldehyde composition comprising:
  • percent isomerized in additional to its ordinary and customary meaning, is defined herein to mean the wt.% of olefin molecules where the olefin has been isomerized from the alpha position to an internal olefin position.
  • percent isomerized means the wt.% of the olefin composition being internal olefins, i.e. :
  • internal olefin means an olefin in which a d uble bond is present in a position other than the alpha position.
  • branched alcohols can be manufactured by the following process method steps:
  • FIG. 1 shows an embodiment of a chemical manufacturing process having an isomerization reactor and an hydroformylation reactor.
  • FIG. 1 describes a two-step process in which Stream 1 having alpha olefins that is fed to isomerization reactor 100 which produces Stream 2 having isomerized olefins that is fed to hydroformylation reactor 200 which produces Stream 3 having branched aldehydes.
  • the same catalyst is used in each of the first step and second step of the two-step process.
  • the same catalyst is used in the isomerization reactor 100 and the hydroformylation reactor 200.
  • the isomerization and hydroformylation reactions can be catalyzed by a rhodium organophosphorus ligand catalyst.
  • the organophosphorus ligand catalyst can be activated by the presence of CO.
  • the catalyst can be a rhodium (-PPI13) catalyst system.
  • a rhodium triphenylphosphine (-PPI13) catalyst system can exist in different states and/or configurations which allow for use in different reactions such as for the isomerization reactions and hydroformylation reactions disclosed herein.
  • the catalyst is in an inactive state because the three attached -PPh3 groups “block” the sites for catalyst activity.
  • the -RR13 ⁇ 4 groups on the rhodium are increasingly replaced with CO groups which “opens” up the catalyst and makes it active and able to catalyze the isomerization and hydroformylation reactions of the embodiments disclosed herein.
  • Sequence 1 Activation Sequence For Rhodium Triphenylphosphine
  • the molar ratio (P:Rh) of phosphorous (“P”) to rhodium (“Rh”) in the isomerization reaction or the hydroformylation reaction can be in a range of 1:1 to 1000:1, or 3:1 to 200:1, or 5:1 to 50:1, such as for non-limiting example 1:1, 3:1, 5:1, 10:1, 20:1, 30:1, 40:1, 50:1, 100:1, 200:1, 500:1 or 1000:1.
  • the concentration of Rh in the isomerization reaction or the hydroformylation reaction can be in a range of 1 to 10000 ppm, 10 to 1,000 ppm, or 20-200 ppm, such as in non-limiting example 1 ppm, 20 ppm, 50 ppm, 100 ppm, 200 ppm, 300 ppm, 400 ppm, 500 ppm, 1000 ppm, 2000 ppm, 5000 ppm, 7500 ppm, or 10000 ppm
  • the catalyst used in the isomerization and hydroformylation reactions is an organometallic rhodium ligand complex formed from Rh(CO)2ACAC ((Acetylacetonato)dicarbonylrhodium(I)) and tris (2,4,-di-t-butylphenyl) phosphite ligand.
  • the first step occurs in isomerization reactor 100 where the Stream 1 feed to isomerization reactor 100 can have a composition comprising:
  • Stream 1 can have a high-boiling inert solvent, for example Polyalphaolefin.
  • Rhodium catalyst A is an organometallic complex of Rhodium and at least one organophosphorus ligand.
  • the isomerization reaction can proceed at a temperature of 30- 300°C, e.g. 90°C in the presence of CO and H2 at a pressure of 0.1-10 bar(g).
  • the isomerization reaction conditions can also be described as proceeding at a temperature of 30- 300°C, e.g. 90°C under a CO and H2 atmosphere at a pressure of 0.1-10 bar(g).
  • the isomerization process can be processed batchwise, or on a continuous basis. All reactions and unit operations disclosed herein can be processed batchwise, or on a continuous basis.
  • the catalyst used in this isomerization and hydroformylation reaction is a rhodium ligand complex as Rh(CO)2 AC AC ((Acetylacetonato)dicarbonylrhodium(I)) with tris (2,4,-di-t-butylphenyl) phosphite in a PAO-4 (polyalphaolefm) highboiling inert solvent.
  • Rh(CO)2 AC AC (Acetylacetonato)dicarbonylrhodium(I)
  • PAO-4 polyalphaolefm
  • Stream 1 can have one or more of the feedstocks specific in the sales specification of figures 7- 12.
  • the feed having an alpha olefin, or having a mixture of linear olefins can be isomerized at a temperature in a range of 30°C to 500°C, or 40°C to 200°C, or 50°C to 120°C, such as in non-limiting example 30°C, 50°C, 80°C, 90°C, 100°C, 120°C, I50°C, 180°C, 200°C, 250°C, 300°C, 400°C, or 500°C.
  • the feed having an alpha olefin, or having a mixture of linear olefins can be isomerized at a pressure in a range of 0.0 bar(g) to 20 bar(g), 0.1 bar(g) to 10 bar(g), 0.5 bar(g) to 5 bar(g), such as in non-limiting example 0.01 bar(g), 1 bar(g), 5 bar(g), 7.5 bar(g), 9 bar(g), 10 bar(g), 12 bar(g), 15 bar(g), 18 bar(g), or 20 bar(g).
  • an isomerization of a linear alpha olefin, or mixture of linear alpha olefins can be isomerized at a pressure in a range of 0 bar(g) to 20 bar(g), such as 0 bar(g), 0.1 bar(g), 0.5 bar(g), 1 bar(g), 2 bar(g), 5 bar(g), 10 bar(g), or 20 bar(g).
  • an isomerization of a linear alpha olefin, or mixture of linear alpha olefins can be isomerized at a pressure of 20 bar(g) or less and 100°C or less, e.g. 1 bar(g) and 90°C.
  • Stream 1 can be a C4-C36 linear alpha olefin.
  • the Stream 1 feed can be a 1-dodecene feedstock which substantially is a C12 linear alpha olefin, such as the AlphaPlus® 1-Dodecene (Chevron Phillips Chemical Company LP, P.O. Box 4910, The Woodlands, TX 77387-4910, phone (800) 231-3260) as shown in FIG. 7, Sales Specification 1.
  • the Stream 1 feed can be a 1 -dodecene feedstock which substantially is a C 12 linear alpha olefin, such as the NEODENE® 12 (Shell Global Solutions, One Shell Plaza, 910 Louisiana, Houston, TX 77002-4916, US, phone (832) 337-2000) as shown in Sales specification 3, as shown in FIG. 9A-9B.
  • NEODENE® 12 Shell Global Solutions, One Shell Plaza, 910 Louisiana, Houston, TX 77002-4916, US, phone (832) 337-2000
  • Stream 1 feed can be a 1-dodecene feedstock which substantially is a C12 linear alpha olefin, such as INEOS Oligomers, Alpha Olefin C12 (dodecane-l) (2600 South Shore Boulevard, Suite 400, League City, Texas 77573, phone (281) 535-4266) as shown in Sales specification 4, as shown in FIG. 10.
  • C12 linear alpha olefin such as INEOS Oligomers, Alpha Olefin C12 (dodecane-l) (2600 South Shore Boulevard, Suite 400, League City, Texas 77573, phone (281) 535-4266) as shown in Sales specification 4, as shown in FIG. 10.
  • the Stream 1 feed can be a 1-tetradecene feedstock which substantially is a C14 linear alpha olefin, such as the AlphaPlus® 1-tetradecene (Chevron Phillips Chemical Company LP, P.O. Box 4910, The Woodlands, TX 77387-4910, US, phone (800) 231-3260) as shown in FIG. 8, Sales Specification 2.
  • AlphaPlus® 1-tetradecene Chevron Phillips Chemical Company LP, P.O. Box 4910, The Woodlands, TX 77387-4910, US, phone (800) 231-3260
  • the Stream 1 feed can be a 1-tetradecene feedstock which substantially is a C 14 linear alpha olefin, such as the NEODENE® 14 (Shell Global Solutions, One Shell Plaza, 910 Louisiana, Houston, TX 77002-4916, US, phone (832) 337-2000) as shown in FIG. 11 A-l IB, Sales specification 5.
  • NEODENE® 14 Shell Global Solutions, One Shell Plaza, 910 Louisiana, Houston, TX 77002-4916, US, phone (832) 337-2000
  • Stream 1 feed can be a 1-tetradecene feedstock which substantially is a C14 linear alpha olefin, such as INEOS Oligomers, Alpha Olefin C14 (tetradecane-1) (2600 South Shore Boulevard, Suite 400, League City, Texas 77573, phone (281) 535-4266) as shown in FIG. 12, Sales specification 6.
  • INEOS Oligomers Alpha Olefin C14 (tetradecane-1) (2600 South Shore Boulevard, Suite 400, League City, Texas 77573, phone (281) 535-4266) as shown in FIG. 12, Sales specification 6.
  • the Stream 1 feedstock can be a composition having one or more alpha olefins.
  • the alpha olefins of the Stream 1 feed can be the same, or different, and have the same or different carbon chain lengths.
  • the Stream 1 alpha olefins fed as reactants for isomerization can be one or more alpha olefins from the group of C4-C36 alpha olefins, or greater.
  • a C12 linear alpha olefin fed as a reactant for isomerization can be 90.0 wt.% or greater, such as greater than 94.0 wt.% C12 linear alpha olefin, or 94.6 wt.% C12 linear alpha olefin, or 99 wt.% C12 linear alpha olefin, or greater.
  • a C14 alpha olefin fed as a reactant for isomerization can be 90.0 wt.% or greater, such as greater than 93.0 wt.% C14 linear alpha olefin, or 93.4 wt.% C14 linear alpha olefin, or 99 wt.% C14 linear alpha olefin, or greater.
  • the alpha olefin feedstock to the isomerization reactor has a concentration of vinylidene of 10 wt.% or less, e.g. 4 wt.% or less.
  • the isomerization reaction of isomerization reactor 100 produces an isomerization reaction product stream which can be fed into hydroformylation reaction 200.
  • Stream 2 can have a composition comprising internal olefin products of the isomerization reaction in which a portion of the starting alpha olefins have been isomerized to an olefin mixture comprising in non-limiting example:
  • Stream 2 is an isomerization reactor product stream having isomerized olefins which can have a percent isomerization in a range of 10 wt.% to 99%, or greater, e.g. 10 wt.%, 15 wt.%, 20 wt.%, 25 wt.%, 30 wt.%, 35 wt.%, 40 wt.%, 45 wt.%, 50 wt.%, 60 wt.%, 70 wt.%, 80 wt.%, 90 wt.%, or 99 wt.%.
  • stream 2 which is an isomerization reactor product stream can have internal olefins in a composition of 20 wt.%, or greater.
  • stream 3 which is a hydroformylation product stream can have a composition which is greater than 25 wt.% branched aldehydes.
  • the second step of the two-step process depicted in Figure A occurs in Hydroformylation Reactor 200.
  • the feed (Stream 2) has a composition comprising:
  • stream 2 can comprise a high-boiling inert solvent.
  • the reaction in Hydroformylation Reactor 200 proceeds using the same Rhodium Catalyst A and at a temperature of 30-300C.
  • the reaction in Hydroformylation Reactor 200 occurs under a CO/H2 atmosphere and at a pressure greater than the pressure in Isomerization Reactor (100) as the higher pressure favors the production of the desired branched aldehydes.
  • This step produces a reaction product (Stream 3) where the olefin mixture (or a portion of the olefin mixture) has been hydroformylated to produce an aldehyde mixture comprising:
  • the feed to hydroformylation having an internal olefin, or having a mixture alpha olefins and internal olefins can be hydroformylated at a temperature in a range of 30°C to 500°C, or 40°C to 200°C, or 50°C to 120°C, such as in non-limiting example 30°C, 50°C, 80°C, 90°C, 100°C, 120°C, 150°C, 180°C, 200°C, 250°C, 300°C, 400°C, or 500°C.
  • the feed to hydroformylation having an internal olefin, or having a mixture of alpha olefins and internal olefins can be hydroformylated at a pressure in a range of 0 bar(g) to 500 bar(g), 5 bar(g) to 100 bar(g), 7 bar(g) to 30 bar(g), such as in non-limiting example 0 bar(g), 1 bar(g), 5 bar(g), 7 bar(g), 10 bar(g), 15 bar(g), 30 bar(g), 50 bar(g), 100 bar(g), 150 bar(g), 200 bar(g), 250 bar(g), 300 bar(g), 350 bar(g), 400 bar(g), 500 bar(g).
  • the feed having an alpha olefin, or having a mixture of linear olefins can be hydroformylated at a pressure of 15 bar(g) and 90°C.
  • Stream 2 may also contain a small portion of mixed aldehydes of carbon number C5- C37 produced from hydroformylation of the C4-C36 alpha olefins and C4-C36 internal olefins.
  • the production of aldehydes in Isomerization Reactor (100) is not an intended purpose but is to be expected to occur at low rates. Production of aldehydes in this step should be controlled at a low level as aldehydes formed in this step tend to be disproportionately linear aldehydes rather than the desired branched aldehydes.
  • FIG. 2 shows an embodiment of a chemical manufacturing process having an isomerization reactor 100 and which uses a Stream 4, which is optional, and which is an isomerization reactor bypass that can be used to control the feed composition to the hydroformylation reactor 200.
  • isomerization reactor products Stream 2 is blended with the isomerization reactor bypass stream of Stream 4 to produce Stream 6 which is a hydroformylation reactor feed stream of the embodiment of FIG. 2.
  • FIG. 2 describes the two-step process of Figure 1 in an embodiment that has Stream 4, which is an optional olefin bypass stream around Isomerization Reactor (100).
  • Stream 4 is an optional olefin bypass stream around Isomerization Reactor (100).
  • Stream 1 can be bypassed around the Isomerization Reactor (100) as Stream 4 and a portion of Stream 1 is fed to Isomerization Reactor (100) as Stream 5.
  • Stream 2 is the isomerized output of Isomerization Reactor (100) and is combined with Stream 4 to provide Stream 6, which is the reactor feed to Hydroformylation Reactor 200.
  • the bypass functionality of Stream 4 provides a convenient and effective means to control the degree of olefin isomerization in the process.
  • the degree of olefin isomerization can be controlled to a specified, desired value.
  • the degree of olefin isomerization is a key variable in determining the degree of aldehyde branching achieved.
  • the degree of olefin isomerization one can control the degree of aldehyde branching achieved in Stream 3 to a specified, desired value.
  • compositions of Stream 1, the isomerization reactor bypass stream of Stream 4 and Stream 5 can be the same. As shown in FIG. 2, Stream 4 and Stream 5 are streams split from Stream 1.
  • FIG. 3 shows an embodiment of a chemical manufacturing process having an isomerization reactor, a hydroformylation reactor and catalyst recovery.
  • the process of FIG. 2 is modified by the addition of a catalyst recovery step, i.e. Catalyst Recovery 300, which recovers the rhodium catalyst and produces Stream 7 which is a recovered rhodium catalyst stream that is recycled back to the isomerization reactor 100 and produces Stream 8 having a composition of branched aldehydes and unreacted olefins.
  • Stream 8 is a branched aldehydes and unreacted olefins product stream.
  • FIG. 3 the process of FIG. 2 with the addition of catalyst recovery 300.
  • Stream 3 is the reactor product of Hydroformylation Reactor 200 and has a stream 3 composition having:
  • a C5-C37 aldehyde mixture comprising:
  • the stream 3 composition can optionally comprise a high-boiling inert solvent.
  • the non-volatile liquid residue from Catalyst Recovery 300 is shown as Stream 7 which has the recovered rhodium Catalyst A and optionally the high- boiling inert solvent, if such solvent is used.
  • Stream 7 the recovered rhodium catalyst stream, is then recycled back to isomerization reactor 100 for re-use in the process. While it is not required for the invention to include a high-boiling inert solvent in the system, it is often convenient to do so in order to provide a convenient liquid carrier for the recovered rhodium catalyst.
  • Polyalphaolefins (PAO’s) are an example of such a high boiling inert solvent.
  • FIG. 4 shows the process of FIG. 3 to which an aldehyde distillation unit 400 has been added.
  • FIG. 4 shows an embodiment of a chemical manufacturing process having an isomerization reactor, a hydroformylation reactor, catalyst recovery and aldehyde distillation.
  • FIG. 4 shows the process of FIG. 3 with the addition of an aldehyde distillation step shown an aldehyde distillation 400.
  • Stream 8 is the feed stream to Aldehyde Distillation (400) and can in an embodiment have a composition of, e.g. :
  • the C5-C37 aldehyde mixture of Stream 8 produced by catalyst recovery 300 is further refined and purified by distillation in aldehyde distillation 400 to produce a distilled, high purity C5-C37 branched aldehyde product stream shown as Stream 11 which in an embodiment is free of, or nearly free of, unreacted C4-C36 olefins.
  • FIG. 5 shows an embodiment of a chemical manufacturing process having an isomerization reactor, a hydroformylation reactor, catalyst recovery and an aldehyde hydrogenation reactor.
  • FIG. 5 shows a different embodiment modifying the process of FIG. 3 in which Stream
  • FIG. 5 shows the process of Figure 3 with the addition of an aldehyde hydrogenation step shown as aldehyde hydrogenation reactor 500.
  • Stream 11 is the feed stream to the Aldehyde Hydrogenation Reactor (500) and can have a composition, e.g. :
  • a C5-C37 aldehyde mixture containing, a. > 25 wt.% branched aldehydes, b. ⁇ 75 wt.% linear aldehydes, and
  • suitable hydrogenation catalysts are supported base metal catalysts on high surface area supports such as ceramics, carbons, aluminas, silicas, titanias and zirconias, where the metal is affixed to and dispersed on the surface of the support such as hydrogenation catalysts having primary base metal components of nickel, cobalt, copper, manganese, molybdenum, zinc and/or iron or varied combinations thereof.
  • hydrogenation catalysts having primary base metal components of nickel, cobalt, copper, manganese, molybdenum, zinc and/or iron or varied combinations thereof.
  • nickel on alumina catalysts nickel on silica catalysts, nickel on titania catalysts, nickel on zirconia catalysts or nickel on carbon catalysts.
  • Analogous supported metal catalysts can be found for the other base metals.
  • Supported precious metal catalysts on high surface area supports such as ceramics, carbons, aluminas, silicas, titanias and zirconias, where the metal is affixed to and dispersed on the surface of the support, are also suitable, including those of whose metals consist of platinum, palladium, gold, silver, iridium and ruthenium or varied combinations thereof.
  • the precious metal platinum platinum on carbon, platinum on silica, platinum on titania, platinum on zirconia or platinum on alumina catalysts.
  • Analogous supported precious metal catalysts can be found for the other precious metals.
  • Stream 12 is a branched alcohols product and in an embodiment can have a composition comprising:
  • a C5-C37 alcohol mixture containing, a. > 30 wt.% branched alcohols, b. ⁇ 70 wt.% linear alcohols, and
  • the C5-C37 alcohols are produced from the hydrogenation of the corresponding aldehydes in aldehyde hydrogenation reactor 500 and the C4-C36 paraffins also produced in aldehyde hydrogenation reactor 500 resulting from the hydrogenation of the unreacted C4-C36 olefins contained in Stream 8.
  • the C5-C37 alcohols content can be increased in Stream 12, with a related decrease in the C4-C36 paraffin content by using an optional distillation step after aldehyde hydrogenation reactor 500 to remove the low-boiling C4-C36 paraffins and produce a distilled, high purity C5-C37 Branched Alcohols Product which is free of, or nearly free of, C4-C36 paraffins.
  • Stream 12 can be a branched alcohols product composition having greater than 40 % branching.
  • Downstream Products Of Branched Alcohols are branched alcohols product composition having greater than 40 % branching.
  • the branched alcohol products of the processes disclosed herein can be used to produce fuel and lubricant additives, food additives, solvents, emulsifiers, emollients, thickeners, coatings, elastomers, adhesives, antioxidants, polymer stabilizers, cosmetics.
  • the branched alcohol products of the processes disclosed herein can be carboxylated by reaction with carboxylic acids, dicarboxylic acids or polyacids to produce esters.
  • Applications for such esters produced by the processes disclosed herein can be lubricants, plasticizers, solvents, coatings, inks, cleaners, binders, paint strippers, oilfield chemicals.
  • FIG. 6 shows an embodiment of a chemical manufacturing process having an isomerization reactor, a hydroformylation reactor, catalyst recovery, aldehyde distillation and an aldehyde hydrogenation reactor.
  • FIG. 6 shows the process of FIG. 4 with the addition of an aldehyde hydrogenation reactor 500.
  • Stream 11 the branched aldehyde product stream, is the feed stream to the Aldehyde Hydrogenation Reactor (500) and can have a C5-C37 aldehyde mixture containing, e.g. :
  • the C5- C37 aldehydes are hydrogenated in the presence of hydrogen and a hydrogenation catalyst to produce Stream 12.
  • Stream 12 is a branched alcohols product stream and can have a C5-C37 alcohol composition of, e.g. :
  • the C5-C37 alcohols are produced from the hydrogenation of the corresponding aldehydes which are the reaction products of the hydroformylation reactor 200.
  • the C5-C37 alcohols content (purity) in Stream 12 can be increased and the level of any undesired impurities decreased, for example low levels of C4-C36 paraffins, by adding a distillation step after aldehyde hydrogenation reactor 500 to remove such impurities and produce a purified, distilled C5-C37 Branched Alcohols Product.
  • numerous downstream products can be manufactured as products of the processes disclosed herein.
  • the branched aldehydes produced by the embodiments herein can be reacted to produce a number of branched aldehyde products.
  • the branched aldehydes can be further reacted to produce branched amine products.
  • the branched aldehydes can be reacted to produce branched carboxylic acid products.
  • branched aldehyde products of the processes disclosed herein can be for example, but not limited to, fragrance molecules, flavoring agents, solvents, intermediates in the manufacture of plastics, dyes, and pharmaceuticals.
  • the branched aldehydes produced by the processes disclosed herein can be reacted with ammonia and hydrogen to produce primary branched amines.
  • the branched aldehydes produced by the processes disclosed herein can be reacted with amines and hydrogen to produce secondary branched amines.
  • the branched aldehydes produced by the processes disclosed herein can be reacted with secondary amines to produce tertiary branched amines.
  • the branched amine products of the processes disclosed herein can be for example, but not limited to, chemical catalysts, corrosion inhibitors, emulsifiers, flotation aids, ion exchange resins, rubber chemicals, antioxidants, stabilizers, antistatic agents, plasticizers, dyes, gasoline and lubricant additives, hardeners for epoxy resins, solvents, metal extraction, photographic developers and anticaking agents.
  • the branched amine products of the processes disclosed herein can be intermediates for the synthesis of pharmaceuticals, herbicides, fungicides and insecticides.
  • the branched amine products of the processes disclosed herein can be alkoxylated to produce alkoxylated amine surfactants.
  • the branched amine products of the processes disclosed herein can be oxidized to produce amine oxide surfactants.
  • the branched aldehyde products of the processes disclosed herein can be oxidized with oxygen or other oxidizing agents to produce branched carboxylic acids.
  • the branched carboxylic acid products of the processes disclosed herein can be corrosion inhibitors, emulsifiers, ion exchange resins, food additives, fragrance molecules, plastic additives, lubricants, solvents, coatings, dyes, rubber chemicals, plasticizers.
  • Branched aldehydes, alcohols and surfactants can respectively range from 10 wt.% branched to 100 wt.% branched, as well all numbers in between.
  • branched aldehydes, alcohols and surfactants can respectively have branching of 10 wt.% or greater, 20 wt.% or greater, 25 wt.% or greater, 30 wt.% or greater, 40 wt.% or greater, 50 wt.% or greater, 60 wt.% or greater, 70 wt.% or greater, 80 wt.% or greater, 90 wt.% or greater, or 99 wt.% or greater.
  • isomerized olefins can be at least 10 wt.% internal olefins resulting in aldehydes, alcohols and surfactants that each respectively have at least 10 wt.% branching. In an embodiment, isomerized olefins can be at least 20 wt.% internal olefins resulting in aldehydes, alcohols and surfactants that each respectively have at least 20 wt.% branching. In an embodiment, isomerized olefins can be at least 25 wt.% internal olefins resulting in aldehydes, alcohols and surfactants that each respectively have at least 25 wt.% branching.
  • isomerized olefins can be at least 30 wt.% internal olefins resulting in aldehydes, alcohols and surfactants that each respectively have at least 30 wt.% branching. In an embodiment, isomerized olefins can be at least 40 wt.% internal olefins resulting in aldehydes, alcohols and surfactants that each respectively have at least 40 wt.% branching. In an embodiment, isomerized olefins can be at least 50 wt.% internal olefins resulting in aldehydes, alcohols and surfactants that each respectively have at least 50 wt.% branching.
  • isomerized olefins can be at least 75 wt.% internal olefins resulting in aldehydes, alcohols and surfactants that each respectively have at least 75 wt.% branching. In an embodiment, isomerized olefins can be at least 90 wt.% internal olefins resulting in aldehydes, alcohols and surfactants that each respectively have at least 90 wt.% branching.
  • isomerization hydroformylation and hydrogenation reactions produce two branched alcohol products based on two starting alpha olefins.
  • a mixture of a number of alpha olefins can be used.
  • a first alpha olefin, 1-Dodecene can be converted through the process chemistry described herewith to a mixture of branched tridecanols, while the second alpha olefin, 1-Tetradecene, is converted through analogous process chemistry to a mixture of branched pentadecanols.
  • the process can be run batchwise, or as a continuous process.
  • the first step in the process can be the batch-wise isomerization of the individual alpha olefins at moderate temperatures and pressures utilizing a homogeneous rhodium organophosphorus ligand catalyst system.
  • the second step can be a hydroformylation with the same rhodium organophosphorus ligand catalyst system that proceeds with high yield and selectivity to the corresponding branched tridecanals and branched pentadecanals.
  • the branched tridecanals product from such an isomerization and hydroformylation process would yield a composition comprising a mixture of linear 1 -tridecanal and 2-alkyl branched tridecanals. isomers, i. e. :
  • the catalyst used in the isomerization and hydroformylation reactions is an organometallic rhodium ligand complex formed from Rh(CO)2ACAC ((Acetylacetonato)dicarbonylrhodium(I)) and tris (2,4,-di-t-butylphenyl) phosphite ligand.
  • the crude aldehydes can be flashed distilled to remove the high value catalyst ligand complex for recycle.
  • the flashed aldehydes vapor can be fed directly to distillation to provide a high purity branched aldehyde intermediate.
  • the branched tridecanals and pentadecanals can be separately batch hydrogenated at high pressures and moderate temperature in the presence of a hydrogenation catalyst such as a base metal catalyst, a supported nickel catalyst, a Raney® ( . R. Grace & Co., 7500 Grace Drive, Columbia, MD 21044, US, phone 1-410-531-4000) nickel catalyst or a precious metal catalyst.
  • a hydrogenation catalyst such as a base metal catalyst, a supported nickel catalyst, a Raney® ( . R. Grace & Co., 7500 Grace Drive, Columbia, MD 21044, US, phone 1-410-531-4000) nickel catalyst or a precious metal catalyst.
  • the aldehyde functionality will be converted into the equivalent alcohol, producing the desired branched tridecanols and the desired branched pentadecanols.
  • the isomerization and hydroformylation reactions can be performed in the same or different reactors.
  • the isomerization can be executed under one set of reaction conditions and the hydroformylation can be executed under a different set of reaction conditions.
  • the reaction temperatures of the isomerization and hydroformylation reactions can be the same or different.
  • the reaction pressures of the isomerization and hydroformylation reactions can be the same or different. In one embodiment, the hydroformylation reaction is conducted at a higher pressure than the isomerization reaction.
  • the batchwise hydroformylation reaction will be performed at moderate temperatures of 80°C to 100°C and at a moderate pressure of 15-20 bar(g).
  • the flash removal of the branched aldehydes can be performed in a flash unit operation, e.g. flash drum, optionally in conjunction with a distillation column.
  • the flash removal of the branched aldehydes can be performed in an evaporator ;on unit operation, e.g. a wiped-film evaporator or a falling film evaporator, optionally in conjunction with a distillation column.
  • the optional distillation can be performed at pressures including variable vacuums down from 1 millibar absolute to 999 millibar absolute, such as in nonlimiting example 5 millibar absolute, 10 millibar absolute, or 20 millibar absolute, or 50 millibar absolute, or 100 millibar absolute, or 500 millibar absolute, or higher.
  • the hydrogenation of the branched aldehyde intermediate(s) will be performed in a batch reactor at hydrogen pressures of between 10 bar(g) and 100 bar(g) e.g. 20 bar(g), 30 bar(g), 40 bar(g), 50 bar(g), 60 bar(g), 70 bar(g), 80 bar(g), 90 bar(g), or higher.
  • This hydrogenation can be performed at temperatures between 50°C and 300°C, e.g. 50°C, 100°C, 150°C, 200°C, 250°C, 300°C, 350°C, 400°C, 450°C.
  • the reaction of the reactants will be considered complete once there is less than 1% of the Branched Aldehyde intermediate remaining. In an embodiment, the reaction of the reactants will be considered complete once there is less than 0.1% of the Branched Aldehyde intermediate remaining. In this embodiment, the filtered crude Branched Alcohol would be a low color, high purity ( > 97% purity), highly branched ( > 80% branched) product.
  • branched alcohols products can be manufactured from the alpha olefin feeds through a batch isomerization process, a batch hydroformylation process, followed by flash distillation to produce the Branched Aldehydes intermediates.
  • the Branched Aldehydes intermediates will then be batch hydrogenated and the product will be filtered to remove the hydrogenation catalyst to produce the finished Branched Alcohols.
  • a Cl 2 linear alpha olefin feedstock (1-Dodecene) was obtained from the Chevron Phillips Chemical Company LP, as identified by product name AlphaPlus® 1-Dodecene (Chevron Phillips Chemical Company LP, P.O. Box 4910, The Woodlands, TX 77387-4910, US, phone (800) 231-3260).
  • the homogeneous rhodium organophosphorus catalyst used in this example is prepared in a high pressure, stainless steel stirred autoclave.
  • Rh(CO)2ACAC (Acetylacetonato)dicarbonylrhodium(I)
  • 1.36wt.% tris (2,4,-di-t-butylphenyl) phosphite ligand and 98.62 wt.% Synfluid® PAO 4 cSt (Chevron Phillips Chemical Company LP, P.O. Box 4910, The Woodlands, TX 77387-4910, phone (800) 231-3260) inert solvent.
  • the 1-Dodecene linear alpha olefin was added to the rhodium catalyst solution in the autoclave producing a starting reaction mixture with a rhodium concentration of 35 ppm.
  • the alpha olefin feed was then isomerized at 80°C in the presence of a CO/H2 atmosphere and 1 bar(g) pressure for 10 hours.
  • the isomerized olefin was then hydroformylated at 70°C in the presence of a CO/H2 atmosphere and 20 bar(g) pressure for 8 hours.
  • the molar ratio of CO to H2 in both the isomerization step and the hydroformylation step was equal to 1:1.15.
  • the resulting hydroformylation reaction product was flash distilled at 140-150°C and 25 millibar to recover the rhodium catalyst solution as a bottoms product and recover a branched C13 Aldehyde overheads product with a composition comprising:
  • the branched Cl 3 aldehyde product was hydrogenated in a high pressure, Inconel 625 stirred autoclave at 150C and 20 bar(g) hydrogen pressure.
  • the hydrogenation catalyst used was a Raney® Nickel 3111 (W. R. Grace & Co., 7500 Grace Drive, Columbia, MD 21044, US, phone 1-410-531-4000) catalyst used at a 0.25wt.% loading.
  • the aldehyde was hydrogenated for 10 hours and the resultant reaction mixture was filtered to produce a branched Cl 3 alcohol product comprising: Weight %
  • the isomerized olefin was then hydroformylated at 70°C in the presence of a CO/H2 atmosphere and 20 bar(g) pressure for 8 hours.
  • the resulting reaction product was flash distilled at 150-160°C and 25 millibar to recover the rhodium catalyst solution as a bottoms product and recover a branched Cl 5 Aldehyde overheads product.
  • the recovered rhodium catalyst solution was then used again to complete a second 1 -tetradecene batch isomerization (4 hours) and hydroformylation (6 hours).
  • the resulting Cl 5 aldehyde products from the two batches were combined to give a branched Cl 5 Aldehyde product comprising: Weight %
  • the branched Cl 5 aldehyde product was hydrogenated in a high pressure, Inconel 625 stirred autoclave at 150C and 20 bar(g) hydrogen pressure.
  • the hydrogenation catalyst used was a Raney® Nickel 3111 (W. R. Grace & Co., 7500 Grace Drive, Columbia, MD 21044, US, phone 1-410-531-4000) catalyst used at a 0.25wt.% loading.
  • the aldehyde was hydrogenated for 10 hours and the resultant reaction mixture was filtered to produce a branched Cl 5 alcohol product comprising:
  • a Cl 4 linear alpha olefin feedstock (1-Tetradecene) was obtained from the Chevron Phillips Chemical Company LP, as identified by product name AlphaPlus® 1-Tetradecene (Chevron Phillips Chemical Company LP, P.O. Box 4910, The Woodlands, TX 77387-4910, US, phone (800) 231-3260).
  • the homogeneous rhodium organophosphorus catalyst used in this example is an organometallic complex of Rh(CO)2ACAC ((Acetylacetonato)dicarbonylrhodium(I)) and triphenylphosphine ligand.
  • the alpha olefin feed was then isomerized at 80°C in the presence of a CO/H2 atmosphere and 1.5 bar(g) pressure for 3.5 hours.
  • the isomerized olefin was then hydroformylated at 95 °C in the presence of a CO/H2 atmosphere and 14 bar(g) pressure for 9 hours.
  • the molar ratio of CO to H2 in both the isomerization step and the hydroformylation step was equal to 1:1.15.
  • the resulting hydroformylation reaction product was flash distilled at 140-150°C and 5 millibar to recover a branched Cl 5 Aldehyde overheads product with aldehyde composition comprising:
  • This disclosure regards branched compounds and methods for producing and manufacturing branched compounds in their many aspects, features and elements. Such compounds and manufacturing processes can be dynamic in its use and operation.
  • This disclosure is intended to encompass the equivalents, means, systems and methods of the use of the branched compounds and methods for producing and manufacturing branched compounds and their many aspects consistent with the description and spirit of the apparatus, means, methods, functions and operations disclosed herein.
  • Other embodiments and modifications will be recognized by one of ordinary skill in the art as being enabled by and within the scope of this disclosure.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Organic Low-Molecular-Weight Compounds And Preparation Thereof (AREA)

Abstract

L'invention concerne un processus de production d'oléfines isomérisées, d'aldéhydes ramifiés, d'alcools ramifiés et de tensioactifs ramifiés par isomérisation, hydroformylation, hydrogénation et formation de tensioactifs.
PCT/US2021/034189 2020-06-05 2021-05-26 Composés ramifiés WO2021247314A1 (fr)

Priority Applications (15)

Application Number Priority Date Filing Date Title
US18/007,900 US20230271906A1 (en) 2020-06-05 2021-05-26 Branched Compounds
PCT/US2021/035169 WO2021247516A1 (fr) 2020-06-05 2021-06-01 Alcools ramifiés
EP21817011.6A EP4161696A1 (fr) 2020-06-05 2021-06-01 Alcools ramifiés
US17/928,368 US20230219873A1 (en) 2020-06-05 2021-06-01 Branched Alcohols
US17/336,099 US20220024837A1 (en) 2020-06-05 2021-06-01 Branched Alcohols
US17/923,381 US20230219871A1 (en) 2020-06-05 2021-06-03 Branched Products
CN202180036251.3A CN115916947A (zh) 2020-06-05 2021-06-03 支化产品
MX2022014196A MX2022014196A (es) 2020-06-05 2021-06-03 Productos ramificados.
US17/338,641 US20210387933A1 (en) 2020-06-05 2021-06-03 Branched Products
PCT/US2021/035772 WO2021247917A1 (fr) 2020-06-05 2021-06-03 Produits ramifiés
JP2022570559A JP2023528766A (ja) 2020-06-05 2021-06-03 分岐生成物
CA3178431A CA3178431A1 (fr) 2020-06-05 2021-06-03 Produits ramifies
EP21816908.4A EP4162021A1 (fr) 2020-06-05 2021-06-03 Produits ramifiés
US17/553,752 US20220176361A1 (en) 2020-06-05 2021-12-16 Branched Products
US18/202,775 US20230303488A1 (en) 2020-06-05 2023-05-26 Branched Technologies

Applications Claiming Priority (12)

Application Number Priority Date Filing Date Title
US202063035073P 2020-06-05 2020-06-05
US202063035479P 2020-06-05 2020-06-05
US202063035280P 2020-06-05 2020-06-05
US63/035,073 2020-06-05
US63/035,479 2020-06-05
US63/035,280 2020-06-05
US202063126780P 2020-12-17 2020-12-17
US63/126,780 2020-12-17
PCT/US2021/030341 WO2021247177A1 (fr) 2020-06-05 2021-04-30 Production d'alcools
US17/246,580 2021-04-30
US17/246,580 US11680032B2 (en) 2020-06-05 2021-04-30 Alcohols production
USPCT/US2021/030341 2021-04-30

Related Parent Applications (3)

Application Number Title Priority Date Filing Date
PCT/US2021/030341 Continuation-In-Part WO2021247177A1 (fr) 2020-06-05 2021-04-30 Production d'alcools
US17/246,580 Continuation-In-Part US11680032B2 (en) 2020-06-05 2021-04-30 Alcohols production
PCT/US2021/063934 Continuation-In-Part WO2022133157A1 (fr) 2020-06-05 2021-12-16 Technologie de ramification

Related Child Applications (5)

Application Number Title Priority Date Filing Date
PCT/US2021/030341 Continuation-In-Part WO2021247177A1 (fr) 2020-06-05 2021-04-30 Production d'alcools
US17/336,099 Continuation-In-Part US20220024837A1 (en) 2020-06-05 2021-06-01 Branched Alcohols
PCT/US2021/035169 Continuation-In-Part WO2021247516A1 (fr) 2020-06-05 2021-06-01 Alcools ramifiés
PCT/US2021/035772 Continuation-In-Part WO2021247917A1 (fr) 2020-06-05 2021-06-03 Produits ramifiés
US17/338,641 Continuation-In-Part US20210387933A1 (en) 2020-06-05 2021-06-03 Branched Products

Publications (1)

Publication Number Publication Date
WO2021247314A1 true WO2021247314A1 (fr) 2021-12-09

Family

ID=78830636

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2021/034189 WO2021247314A1 (fr) 2020-06-05 2021-05-26 Composés ramifiés

Country Status (1)

Country Link
WO (1) WO2021247314A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP4161893A4 (fr) * 2020-06-05 2024-03-13 SCION Holdings LLC Production d'alcools
US11993565B2 (en) 2021-12-16 2024-05-28 SCION Holdings LLC Branched products

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1997039091A1 (fr) * 1996-04-16 1997-10-23 The Procter & Gamble Company Tensioactifs ramifies en milieu de chaine
US6225507B1 (en) * 1996-02-14 2001-05-01 Basf Aktiengesellschaft Method of preparing aldehydes by hydroformylation with a rhodium catalyst and recovery of the rhodium catalyst by extraction
US20020183567A1 (en) * 2001-02-15 2002-12-05 Fenouil Laurent Alain Michel Process for preparing a branched olefin, a method of using the branched olefin for making a surfactant, and a surfactant

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6225507B1 (en) * 1996-02-14 2001-05-01 Basf Aktiengesellschaft Method of preparing aldehydes by hydroformylation with a rhodium catalyst and recovery of the rhodium catalyst by extraction
WO1997039091A1 (fr) * 1996-04-16 1997-10-23 The Procter & Gamble Company Tensioactifs ramifies en milieu de chaine
US20020183567A1 (en) * 2001-02-15 2002-12-05 Fenouil Laurent Alain Michel Process for preparing a branched olefin, a method of using the branched olefin for making a surfactant, and a surfactant

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP4161893A4 (fr) * 2020-06-05 2024-03-13 SCION Holdings LLC Production d'alcools
US11993565B2 (en) 2021-12-16 2024-05-28 SCION Holdings LLC Branched products

Similar Documents

Publication Publication Date Title
US20210387933A1 (en) Branched Products
EP4162021A1 (fr) Produits ramifiés
TWI464134B (zh) 從２－乙基己醇出發製造異壬胺之製法及其製品和使用
US4401834A (en) Process for producing alcohols
WO2021247314A1 (fr) Composés ramifiés
US20220194886A1 (en) Branched Products
US20220024837A1 (en) Branched Alcohols
KR102073751B1 (ko) 신규 지환식 디올 화합물, 및 그 제조방법
US20210380510A1 (en) Branched Compounds
US20230271906A1 (en) Branched Compounds
US20220176361A1 (en) Branched Products
US11993565B2 (en) Branched products
US20230219873A1 (en) Branched Alcohols
US20230219871A1 (en) Branched Products
US20220289650A1 (en) Branched Technologies
EP4347770A1 (fr) Technologies ramifiées
US20230303488A1 (en) Branched Technologies
JP2946790B2 (ja) アルデヒド類の製造法
US11680032B2 (en) Alcohols production
US20230159422A1 (en) Alcohols Production
WO2023235268A1 (fr) Technologies ramifiées
TW515790B (en) Process for preparing alkanals using a rhodium tri(polyethylene glycolate) and this compound itself
US9809518B2 (en) Feed sources for butanediol production processes
JP2021187800A (ja) アルデヒドの製造方法
TW202342653A (zh) 方法

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 21817831

Country of ref document: EP

Kind code of ref document: A1

DPE1 Request for preliminary examination filed after expiration of 19th month from priority date (pct application filed from 20040101)
NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 21817831

Country of ref document: EP

Kind code of ref document: A1