Title of Invention

PROCESS FOR PRODUCING ALKYLENE DERIVATIVE "

Abstract A process for producing an alkylene derivative such as ethylene glycol or ethylene carbonate wherein ethylene oxide is reacted with water or carbon dioxide in the presence of carbon dioxide by means of a quaternary phosphonium iodide or bromide catalyst, characterized in that the quaternary phosphonium iodide or bromide catalyst is recovered efficiently from the reaction system and is recycled for use, and in that quaternary phosphonium chloride formed in the reaction system is converted efficiently to a quaternary phoephonium iodide or bromide, and the resultant iodide or bromide is recovered and recycled to the reaction system for use.
Full Text DESCRIPTION
PROCESS FOR PRODUCING ALKYLENE DERIVATIVE AMD METHOD FOR
REGENERATING CATALYST FOR PRODCUCING ALKYLENE DERIVATIVE
TECHNICAL FIELD
The present invention relates to a process for
producing an alkylene derivative such as an alkylene
glycol or an alkylene carbonate. Particularly, it
relates to a process for producing an alkylene glycol
such as ethylene glycol, which comprises reacting an
alkylene oxide such as ethylene oxide, with water in the
presence of carbon dioxide by means of a quaternary
phosphonium iodide and/or bromide catalyst, or a process
for producing ethylene carbonate or the like, which
comprises reacting an alkylene oxide with carbon dioxide.
Especially, it relates to a method for efficiently
recovering the quaternary phosphonium iodide and/or
bromide catalyst from this reaction system and recycling
it for use.
In the present invention, an alkylene glycol means
an alkylene glycol having from about 2 to 10 carbon atoms
such as ethylene glycol or propylene glycol, and an
alkylene carbonate means an alkylene carbonate having
from about 2 to 10 carbon atoms, such as ethylene
carbonate or propylene carbonate.
BACKGROUND ART
Ethylene glycol is produced in a large scale by-
reacting ethylene oxide directly with water for
hydrolysis. However, in this method, in order to
suppress formation of a byproduct such as diethylene
glycol or triethylene glycol during the hydrolysis, it is
required to use water in large excess over the
stoichiometrical amount to ethylene oxide. Accordingly,
it is necessary to remove the large excess amount of
water by distillation of the formed ethylene glycol
aqueous solution, and there is a problem that a large
amount of energy is required to obtain purified ethylene
glycol.
As a method to solve such a problem, a method has
been proposed wherein ethylene oxide is reacted with
water in the presence of carbon dioxide, to produce
ethylene glycol. This reaction is a two step reaction
wherein ethylene carbonate is formed by a reaction of
ethylene oxide with carbon dioxide, and the ethylene
carbonate is hydrolyzed. In this two step reaction,
water is present in the reaction system, whereby the
reaction may proceed even in the same reactor, but in
order to complete the reaction of the second step, a
further reactor may be provided for the later step. In
the hydrolysis of ethylene carbonate, diethylene glycol
or triethylene glycol will not substantially be formed as
a byproduct, and accordingly, the hydrolysis can be
carried out with water in an amount slightly in excess of
the stoichiometrical amount, whereby the cost required
for removing water from the formed ethylene glycol
aqueous solution can be substantially reduced. Further,
carbon dioxide will be formed by the hydrolysis of
ethylene carbonate formed by the reaction of ethylene
oxide with carbon dioxide, and such carbon dioxide may be
recycled for reuse.
Further, in this method, it is also possible to
produce ethylene carbonate by suppressing the formation
of ethylene glycol by reducing the amount of water in the
starting material by lowering the temperature as a
reaction condition.
Thus, various types of catalysts have been proposed
for the production of ethylene glycol and/or ethylene
carbonate from ethylene oxide. One of preferred
catalysts is an organic phosphonium salt, and
particularly preferred is a quaternary phosphonium iodide
or bromide (JP-B-55-47617). Further, as a co-catalyst,
an alkali metal carbonate may be used in combination with
such an organic phosphonium salt (JP-A-12-12 8814).
Whereas, ethylene oxide as raw material is produced
by oxidation of ethylene, and in such a case, in order to
improve the selectivity for the oxidation reaction, a
chlorohydrocarbon such as ethyl chloride is supplied as a
selectivity-adjusting agent to the redaction system (JP-A-
2-1045,79).
As mentioned above, the method for producing
ethylene glycol or ethylene carbonate by reacting
ethylene oxide with water or carbon dioxide in the
presence of carbon dioxide, is an industrially
advantageous method free from a problem of byproducts,
but has a problem that the reaction efficiency
deteriorates when the reaction is continued.
The present inventors have studied the cause for
such deterioration of the reaction efficiency and as a
result, have found that it is the cause that the
quaternary phosphonium iodide or bromide catalyst in the
reaction system is converted to a chloride having a low
catalytic activity. In fact, by the operation of the
apparatus for about one year, about 2 0 wt% of the
quaternary phosphonium iodide or bromide catalyst in the
reaction system was found to be converted to a quaternary
phosphonium chloride.
The reason for the conversion of the quaternary
phosphonium iodide or bromide to the quaternary
phosphonium chloride was considered to be such that a
chlorine compound contained as an impurity in ethylene
oxide as raw material would be introduced into the
reaction system. Namely, as mentioned above, in the
process for producing ethylene oxide, a chlorohydrocarbon
is supplied as a selectivity-adjusting agent to the
reaction system in order to improve the selectivity for
the reaction, and chlorine contained in this
chlorohydrocarbon remains as a chlorine compound in the
product ethylene oxide even via a purification system,
and such a chlorine compound is included in the process
for producing ethylene glycol or ethylene carbonate. It
is considered that by the chlorine compound introduced as
included in the product ethylene oxide, the quaternary
phosphonium iodide or bromide will be converted to the
quaternary phosphonium chloride, although the details of
such reaction mechanism are not clearly understood.
Accordingly, in the process for producing ethylene
glycol or ethylene carbonate, it is necessary to separate
and remove from the reaction system the quaternary
phosphonium chloride having a low reactivity derived from
the catalyst, so as to let only the highly active
quaternary phosphonium iodide or bromide remain. However,
heretofore, it has not been ascertained even that the
decrease of the reaction efficiency with time is caused
by the conversion with time to the chloride. Further,
there has been no study made with respect to a method for
separating the quaternary phosphonium chloride from the
quaternary phosphonium iodide or bromide as the catalyst
in the reaction system, or a method for converting the
quaternary phosphonium chloride to the quaternary
phosphonium iodide or bromide.
DISCLOSURE OF THE INVENTION
It is an object of the present invention to solve
the above-mentioned conventional problems and to provide
a process for producing an alkylene derivative, such as
an alkylene glycol such as ethylene glycol, or an
alkylene carbonate such as ethylene carbonate, which
comprises reacting an alkylene oxide such as ethylene
oxide with water or carbon dioxide in the presence of
carbon dioxide by means of a quaternary phosphonium
iodide and/or bromide catalyst, wherein a quaternary
phosphonium chloride formed in the reaction system is
efficiently removed, or such quaternary phosphonium
chloride is converted to quaternary phosphonium iodide
and/or bromide, which will be recycled to the reaction
system for reuse, whereby the catalytic activities in the
reaction system can be maintained at a high level, and
the reaction for forming the alkylene derivative can be
efficiently carried out constantly over a long period of
time.
The present invention provides the following:
(1) A process for producing an alkylene derivative,
which comprises a reaction step of reacting an alkylene
oxide with water in the presence of carbon dioxide by
means of a quaternary phosphonium iodide or bromide
catalyst to form an alkylene glycol, characterized in
that from at least a part of the reaction solution and/or
the catalyst solution, the alkylene glycol is removed so
that the molar ratio of the alkylene glycol to the
catalyst becomes at most 2 0 times, followed by mixing
with water to recover the catalyst.
(2) The process according to the above (1),
characterized in that the molar ratio of the alkylene
glycol to the catalyst is made to be at most twice.
(3) The process according to the (1) or (2),
characterized in that the operation temperature at the
time of mixing with water to recover the catalyst is at
most 3 0°C.
(4) The process according to any one of the above (1) to
(3), characterized in that the amount of water to be
mixed is at least 0.1 time by weight, based on the
catalyst to be recovered.
(5) The process according to any one of the above (1) to
(4), characterized in that after mixing with water,
solid-liquid separation is carried out to separate the
catalyst, which is recycled to the reaction step.
(6) The process according to the above (5), wherein the
liquid separated by the solid-liquid separation is
recycled and used as water for washing the catalyst.
(7) The process according to any one of the above (1) to
(6), characterized in that the alkylene oxide is ethylene
oxide.
(8) A method for regenerating a catalyst, characterized
in that a mixture comprising a quaternary phosphonium
chloride and a quaternary phosphonium iodide and/or
bromide, obtained from a reaction step of reacting an
alkylene oxide containing a chlorinated compound as an
impurity, with water in the presence of carbon dioxide by
means of a quaternary phosphonium iodide and/or bromide
as a catalyst, to form an alkylene glycol, is mixed with
an iodide and/or bromide to have the quaternary
phosphonium chloride converted to a quaternary
phosphonium iodide and/or bromide, which is precipitated
in water.
(9) A method for regenerating a catalyst, characterized
in that a mixture comprising a quaternary phosphonium
chloride and a quaternary phosphonium iodide and/or
bromide, obtained from the reaction step of reacting an
alkylene oxide with carbon dioxide by means of a
quaternary phosphonium iodide and/or bromide as a
catalyst, to form an alkylene carbonate, is mixed with an
iodide and/or bromide to have the quaternary phosphonium
chloride converted to a quaternary phosphonium iodide
and/or bromide, which is precipitated in water.
(10) The method according to the above (8) or (9),
characterized in that the mixture comprising a quaternary
phosphonium chloride and a quaternary phosphonium iodide
and/or bromide, is a reaction solution withdrawn from the
above reaction step, or a residue after distilling water
and/or at least a part of the alkylene derivative as the
desired product, from such a reaction solution.
(11) The method according to the above (8) or (9),
characterized in that the mixture comprising a quaternary
phosphonium chloride and a quaternary phosphonium iodide
and/or bromide, is an aqueous solution obtained by mixing
the reaction solution withdrawn from the above reaction
step or the residue after distilling off water and/or at
least a part of the alkylene derivative as the desired
product from such a reaction solution, with water to let
the catalyst precipitate as solid, and separating the
precipitated catalyst.
(12) The method according to any one of the above (8) to
(11), characterized in that the precipitated quaternary
phosphonium iodide and/or bromide is recovered and
recycled to the above reaction step.
(13) A method for regenerating a catalyst, characterized
in that an iodide and/or bromide is added to a mixture
comprising a quaternary phosphonium chloride and a
quaternary phosphonium iodide and/or bromide, obtained
from the reaction step of reacting an alkylene oxide
containing a chlorinated compound as an impurity, with
water in the presence of carbon dioxide by means of a
quaternary phosphonium iodide and/or bromide as a
catalyst, to let chlorine derived from the quaternary
phosphonium chloride precipitate as an inorganic chloride
in an organic solvent, thereby to recover the quaternary
phosphonium iodide and/or bromide.
(14) A method for regenerating a catalyst, characterized
in that an iodide and/or bromide is added to a mixture
comprising a quaternary phosphonium chloride and a
quaternary phosphonium iodide and/or bromide, obtained
from the reaction step of reacting an alkylene oxide with
carbon dioxide by means of a quaternary phosphonium
iodide and/or bromide as a catalyst to form an alkylene
carbonate, to let chlorine derived from the quaternary
phosphonium chloride precipitate as an inorganic chloride
in an organic solvent thereby to recover the quaternary
phosphonium iodide and/or bromide.
(15) The method according to the above (13) or (14),
characterized in that the mixture comprising a quaternary
phosphonium chloride and a quaternary phosphonium iodide
and/or bromide, is any one of the following (a) to (c):
(a) A liquid or solid obtained by adding water to
the reaction solution withdrawn from the above reaction
step to precipitate the catalyst and dehydrating an
aqueous solution after separating the precipitated
catalyst,
(b) A liquid or solid obtained by adding water to a
residue after distilling off water and/or at least a part
of the alkylene derivative as the desired product from
the reaction solution withdrawn from the reaction step,
to precipitate the catalyst as solid, and dehydrating an
aqueous solution after separating the precipitated
catalyst,
(c) A liquid obtained by dissolving the liquid or
solid obtained by the dehydration in (a) or (b), in an
organic solvent.
(16) The method according to the above (13) or (14),
characterized in that the mixture comprising a quaternary
phosphonium chloride and a quaternary phosphonium iodide
and/or bromide, is either one of the following (d) and
(e) :
(d) A liquid obtained by diluting the reaction
solution withdrawn from the reaction step, with an
organic solvent,
(e) A residue after distilling off water and/or at
least a. part of the alkylene derivative as the desired
product from the reaction solution withdrawn from the
above reaction step, or a liquid obtained by dissolving
such a residue in an organic solvent.
(17) The method according to any one of the above (13) to
(16), characterized in that the recovered quaternary
phosphonium iodide and/or bromide is recycled to the
above reaction step.
(18) A process for producing an alkylene derivative,
which comprises a reaction step of reacting an alkylene
oxide and carbon dioxide by means of a quaternary
phosphonium iodide and/or bromide as a catalyst to form
an alkylene carbonate, characterized in that an iodide
and/or bromide is added to a mixture comprising a
quaternary phosphonium chloride and a quaternary
phosphonium iodide and/or bromide, obtained from the
reaction step, to have the quaternary phosphonium
chloride converted to a quaternary phosphonium iodide
and/or bromide, which is precipitated in water, and
recovered and recycled to the reaction step.
(19) A process for producing an alkylene derivative,
which comprises a reaction step of reacting an alkylene
oxide and carbon dioxide by means of a quaternary
phosphonium iodide and/or bromide as a catalyst to form
an alkylene carbonate, characterized in that an iodide
and/or bromide is added to a mixture comprising a
quaternary phosphonium chloride and a quaternary
phosphonium iodide and/or bromide, obtained from the
reaction step, to let chlorine derived from the
quaternary phosphonium chloride precipitate as an
inorganic chloride in an organic solvent, whereby the
quaternary phosphonium iodide and/or bromide is recovered
and recycled to the reaction step.
In the present invention, when the reaction solution
containing the catalyst in a high concentration and/or
the catalyst solution, is mixed with water, the iodide or
bromide will precipitate, while the chloride derived from
the catalyst will remain as dissolved in the liquid.
Namely, each of the iodide, bromide and chloride is
highly soluble in an alkylene glycol or an alkylene
carbonate, but the iodide or bromide has a low solubility
in water, while the chloride has a high solubility in
water. By subjecting the precipitated quaternary
phosphonium iodide or bromide to solid-liquid separation,
it is easily possible to separate and. recover the
catalyst.
In the present invention, the catalyst may be
precipitated, for example, as follows.
(1) The reaction solution containing the catalyst and/or
the catalyst solution, is mixed with water and then
cooled.
(2) From the reaction solution containing the catalyst
and/or the catalyst solution, at least a part of the
alkylene glycol, is removed, followed by mixing with
water.
In such a case, cooling operation is not necessarily
required. However, in order to lower the solubility of
the catalyst, it is preferred to carry out the cooling.
The quaternary phosphonium iodide or bromide thus
recovered, can be recycled to the reaction step for reuse.
On the other hand, in the separated liquid after
recovery of the quaternary phosphonium iodide or bromide
by solid-liquid separation, a quaternary phosphonium
chloride as a chlorine salt, is contained. This
quaternary phosphonium chloride may be converted to a
quaternary phosphonium iodide or bromide by e.g. ion
exchange, and then recovered, or recycled in a solution
state to the reaction step for reuse.
Further, in the present invention, by adding an
iodide and/or bromide to a mixture comprising a
quaternary phosphonium chloride and a quaternary
phosphonium iodide and/or bromide, obtained from a
reaction step of reacting an alkylene oxide with water or
carbon dioxide in the presence of carbon dioxide by means
of a quaternary phosphonium iodide and/or bromide
catalyst, it is possible to convert the quaternary
phosphonium chloride in the mixture to an iodide and/or
bromide. Thus, the already present quaternary
phosphonium iodide and/or bromide, and the quaternary
phosphonium iodide and/or bromide formed by the reaction
of the quaternary phosphonium chloride with an iodide
and/or bromide, can be precipitated in water and
recovered as precipitates.
In the following, the mixture comprising the
quaternary phosphonium chloride and the quaternary
phosphonium iodide and/or bromide, to which the iodide
and/or bromide is added to convert the quaternary
phosphonium chloride to a quaternary phosphonium iodide
and/or bromide, may sometimes be referred to as "the
mixture to be treated". Further, in the following, the
liquid flowing out from the reactor, or the liquid
withdrawn from the reactor, may sometimes be referred to
simply as "the reaction solution", and the liquid in
which the catalyst is concentrated by separating water
and the alkylene glycol or the alkylene carbonate from
the reaction solution by distillation, may sometimes be
referred to simply as "the catalyst solution".
The present invention may be applicable directly to
the reaction solution containing the catalyst, withdrawn
from the reaction step for an alkylene glycol or an
alkylene carbonate, as the mixture to be treated.
However, as another method, it may be applied to a liquid
after precipitating and recovering e. part of the catalyst
by adding water to a liquid-form catalyst solution or a
solid-form residue after removing by distillation a part
or all of the alkylene glycol or the alkylene carbonate
as the solvent in the reaction solution (hereinafter, the
recovery operation by precipitating a part of the
catalyst by adding water to such a catalyst solution or a
solid-form residue, may sometimes be referred to as "the
pre-recovery"). By such pre-recovery treatment, the
concentration of the quaternary phosphonium chloride in
the mixture to be treated, can be increased, and it is
possible to increase the conversion to and the recovery
of the quaternary phosphonium iodide and/or bromide.
Namely, the quaternary phosphonium iodide and/or
bromide has a lower solubility in water than the
quaternary phosphonium chloride. Accordingly, by such
addition of water, most of the quaternary phosphonium
iodide and/or bromide will be precipitated, while most of
the quaternary phosphonium chloride will be dissolved in
water. By such pre-recovery treatment, the concentration
of the quaternary phosphonium chloride in the mixture to
be treated can be increased, and it is possible to
increase the conversion to and the recovery of the
quaternary phosphonium iodide and/or bromide.
Further, as another method, at the time of carrying
out the above-mentioned pre-recovery, instead of adding
water to the catalyst solution or the solid-form residue,
an aqueous solution having an iodide and/or bromide
dissolved, may be used, whereby the recovery rate of the
quaternary phosphonium iodide and/or bromide may be
increased.
In either method, when an iodide and/or bromide is
added to the quaternary phosphonium chloride dissolved in
water, the quaternary phosphonium chloride is
precipitated in the form of the iodide and/or bromide,
and in the solution, the chloride corresponding to the
added compound remains as dissolved. Accordingly, the
precipitated product is subjected to solid-liquid
separation, whereby the quaternary phosphonium chloride
can easily be separated and recovered in the form of the
quaternary phosphonium iodide and/or bromide.
The quaternary phosphonium iodide and/or bromide
thus recovered may be recycled for use to the reaction
step for the alkylene glycol or the alkylene carbonate.
Further, according to the present invention, by
adding an iodide and/or bromide to a mixture comprising a
quaternary phosphonium chloride and a quaternary
phosphonium iodide and/or bromide, obtained from such a
reaction step or from the above recovery step, to let
chlorine derived from the quaternary phosphonium chloride
precipitate as an inorganic chloride in the organic
solvent, it is possible to recover the quaternary
phosphonium iodide and/or bromide.
Namely, by adding an iodide and/or bromide to a
mixture comprising the quaternary phosphonium chloride
and the quaternary phosphonium iodide and/or bromide,
obtained from the reaction step of reacting an alkylene
oxide with water or carbon dioxide in the presence of
carbon dioxide by means of a quaternary phosphonium
iodide and/or bromide catalyst to form an alkylene glycol
or an alkylene carbonate, it is possible to have the
quaternary phosphonium chloride in such a mixture
converted to a quaternary phosphonium iodide and/or
bromide. On the other hand, by letting chlorine derived
from the quaternary phosphonium chloride precipitate as
an inorganic chloride having a low solubility in an
organic solvent, in the organic solvent and separating
the precipitated inorganic chloride, it is possible to
recover the quaternary phosphonium iodide and/or bromide
dissolved in the organic solvent.
In the following, such an operation to let chlorine
derived from the quaternary phosphonium chloride
precipitate as an inorganic chloride in an organic
solvent may sometimes be referred to as "the operation to
precipitate an inorganic chloride". Further, the mixture
comprising a quaternary phosphonium chloride and a
quaternary phosphonium iodide and/or bromide, to which an
iodide and/or bromide is to be added to let chlorine of
the quaternary phosphonium chloride precipitate as an
inorganic chloride, may also be referred to as "the
mixture to be treated".
The separated liquid after converting the quaternary
phosphonium chloride to the iodide or bromide and letting
chlorine derived from the chloride precipitate as an
inorganic chloride in the organic solvent and separating
the inorganic chloride, contains the quaternary
phosphonium iodide and/or bromide dissolved in the
organic solvent. Accordingly, by removing the organic
solvent in the separated liquid by evaporation, the
quaternary phosphonium iodide and/or bromide can be
recovered in the form of a solid. The recovered
quaternary phosphonium iodide and/or bromide may be
washed with water, if desired, and then, it may be, as it
is or after being dissolved in a proper solvent, recycled
for use in the reaction step for an alkylene glycol or an
alkylene carbonate.
BEST MODE FOR CARRYING OUT THE INVENTION
Now, the practical mode of the process for producing
an alkylene glycol of the present invention is described
in detail.
In the following, the present invention is described
mainly with respect to a case where it is applied to a
reaction to produce ethylene glycol from ethylene oxide
by means of a quaternary phosphonium iodide catalyst, but
the present invention is by no means restricted thereto.
For example, the present invention is suitably applicable
also to the production of various alkylene glycols, such
as the production of propylene glycol from propylene
oxide.
Further, the present invention is likewise
applicable to a case where a quaternary phosphonium
bromide is employed as the catalyst, or to a case where a
quaternary phosphonium iodide and a quaternary
phosphonium bromide are used in combination as catalysts.
Further, as mentioned above, the present invention
is also applicable to a reaction to produce an alkylene
carbonate such as ethylene carbonate, in a manner similar
to such, a process for producing alkylene glycol by
changing the reaction conditions to lower the reaction
temperature to suppress the production of an alkylene
glycol such as ethylene glycol. Further, it can also be
applied to a reaction wherein both the alkylene carbonate
an the alkylene glycol are the desired products.
Further, in the following, a method is also
exemplified wherein an iodide is added to the mixture to
be treated, to have a quaternary phosphonium chloride
converted to a quaternary phosphonium iodide for recovery.
Instead of the iodide, a bromide may be added to have the
quaternary phosphonium chloride converted to a quaternary
phosphonium bromide for recovery, or an iodide and a
bromide may be added in combination to have the
quaternary phosphonium chloride converted to a quaternary
phosphonium iodide and a quaternary phosphonium bromide,
for recovery.
Further, in the following, a method may be
exemplified wherein an inorganic iodide is added to the
mixture to be treated to have a quaternary phosphonium
chloride converted to a quaternary phosphonium iodide,
and at the same time, chlorine derived from a quaternary
phosphonium chloride is precipitated as an inorganic
chloride. Instead of the iodide, a bromide may be added
to have the quaternary phosphonium chloride converted to
a quaternary phosphonium bromide, and at the same time to
let chlorine derived from the quaternary phosphonium
chloride precipitate as an inorganic chloride, or an
iodide and a bromide may be added in combination to have
the quaternary phosphonium chloride converted to a
quaternary phosphonium iodide and a quaternary
phosphonium bromide and at the same time to let chlorine
derived from the quaternary phosphonium chloride
precipitate as an inorganic chloride.
As quaternary phosphonium catalysts which may be
used in the present invention, the compounds disclosed in
JP-B-58-22448 may be mentioned. Typical ones may, for
example, be triphenylmethylphosphonion iodide,
triphenylpropylphosphonium iodide,
triphenylbenzylphosphonium iodide and
tributylmethylphosphonium iodide. Such a quaternary
phosphonium iodide catalyst is preferably supplied to the
reaction system so that it will be from 0.001 to 0.05
time by mol to ethylene oxide. Further, when a
quaternary phosphonium bromide catalyst is to be employed,
a bromide catalyst corresponding to the above quaternary
phosphonium iodide catalyst may be employed, and its
suitable amount is equal to the quaternary phosphonium
iodide catalyst.
In the present invention, an alkali metal carbonate
may be coexistent as a co-catalyst in the reaction system,
whereby the efficiency for the formation of ethylene
glycol may be increased. To let the alkali metal
carbonate be coexistent in the reaction system, a
hydroxide, carbonate or bicarbonate of an alkali metal
such as sodium or potassium, preferably potassium, may be
added, and when any one of the alkali metal compounds is
added, it will be present in the form of a carbonate in
the reaction system. In this case, an alkali metal
carbonate, preferably potassium carbonate, is preferably
incorporated so that it will be from 0.01 to 1 in a molar
ratio to the quaternary phosphonium iodide.
The amount of water to ethylene oxide may be reduced
to the stoichiometrical amount or lower than that
depending upon the reaction system. However, it is
preferably used in an amount of from 1.0 to 10.0 times by
mol to ethylene oxide. Further, with carbon dioxide, a
sufficient effect can be obtained in an amount of at most
equimolar to ethylene oxide, and under a usual condition,
it is employed in an amount of from 0.1 to 5.0 mols per
mol of ethylene oxide. However, such a ratio is not
necessarily strictly limited.
The reaction temperature varies depending upon the
type of the alkylene oxide, the type of the catalyst, the
composition of the reaction solution at the initial stage
of the reaction, etc., but, the reaction is usually
carried out within a range of from 50 to 180°C. The
pressure varies depending upon the amount of carbon
dioxide, the reaction temperature, etc., and it may
further vary depending upon the progress of the reaction,
but it is carried out usually within a range of from 0.5
to 5.0 MPa.
The type of the reactor is not particularly limited,
so long as it is one whereby the gas-liquid reaction can
be smoothly carried out. Further, the number of reactors
and the retention time, are selected so that the desired
conversion can be attained. Further, in a case where
ethylene glycol is to be produced, a reactor may be added
as the case requires to hydrolyze ethylene carbonate in
the reaction solution.
From the reaction solution discharged from the
reactor, water and the majority of ethylene glycol are
separated by distillation. The remained liquid (the
catalyst solution) containing the catalyst will be
recycled to the reactor so that the catalyst will be used
again for the reaction.
MODE FOR EFFICIENTLY RECOVERING THE QUATERNARY
PHOSPHONIUM IODIDE OR BROMIDE CATALYST FROM THE REACTION
SYSTEM AND RECYCLING IT FOR REUSE
In a case where the catalyst is to be recovered from
the reaction solution discharged from the reactor, the
catalyst concentration is thin, and the catalyst can
hardly be precipitated, as it is, and accordingly, it is
preferred to remove water and ethylene glycol contained
in the reaction solution to increase the catalyst
concentration, followed by mixing (the catalyst after
removal of ethylene glycol) again with water.
In a case where the catalyst solution is used for
recovery of the catalyst, it is possible to recover the
catalyst by mixing the solution as it is with water, but
it is preferred to further remove the contained ethylene
glycol by distillation, followed by mixing with water to
recover the catalyst, in order to increase the recovery
rate of the catalyst.
Namely, in this reaction, at least part of the
reaction solution or the catalyst solution is withdrawn
from such a reaction step, and water and the alkylene
glycol, or the alkylene glycol, is removed so that the
molar ratio of the alkylene glycol to the catalyst
contained in the solution be at most 2 0 times when the
molar ratio is higher than that, preferably at most twice,
followed by mixing with water again.
In a case where the molar ratio of the alkylene
glycol to the catalyst contained in the solution is lower
than 2 0 times by mol, water may simply be mixed to have
the catalyst precipitated and recovered.
When the liquid withdrawn from the reaction step is
to be mixed with water, there may be a case where cooling
is required to let the quaternary phosphonium iodide
precipitate. Namely, the. solubility of the quaternary
phosphonium iodide in water or ethylene glycol will be
smaller as the temperature is lower.
The reaction solution withdrawn from the reaction
step is usually at a level of from 100 to 180°C. It is
preferred to cool the reaction solution so that the
temperature of the solution after being mixed with water
becomes at most 3 0°C, preferably at a level of from 0 to
2 0°C, whereby the quaternary phosphonium iodide can be
precipitated more efficiently. Whether or not such
cooling is required, is determined depending upon the
temperature of the reaction solution and the temperature
and amount of water to be mixed.
Further, to ensure the precipitation, it is
preferred not only to carry out the cooling but also to
add or preliminarily incorporate seed crystals, whereby
the effect for precipitation under a stabilized condition
will be large.
Further, if at least a part, preferably the majority,
of the product ethylene glycol is removed from the liquid
withdrawn from the reaction step, for example, if
ethylene glycol (which may contain water) is removed so
that the catalyst concentration will be at least 40 wt%,
followed by mixing such a liquid with water, the
quaternary phosphonium iodide can be precipitated without
necessity to carry out cooling, but it is still preferred
to cool it to a level of at most 4 0°C, whereby the
precipitation can efficiently be carried out.
The amount of water to be mixed, varies depending
upon the amount of the quaternary phosphonium iodide in
the reaction solution, the amount of ethylene glycol, the
amount of the chloride, cooling or not cooling, the
recovery efficiency of the desired quaternary phosphonium
iodide, etc., but if the amount is too small, filtration
tends to be difficult, and the efficiency to dissolve the
quaternary phosphonium chloride tends to deteriorate. On
the other hand, if the amount is too large, the amount of
the quaternary phosphonium iodide contained in the liquid
phase after separating the quaternary phosphonium iodide,
tends to increase. Usually, the amount of water to be
added in one treatment is suitably determined within a
range of at least 0.1 time by weight, preferably from 0.1
to 5 times by weight, to the liquid to be treated.
The liquid phase after separated from the solid can
be used again as water for washing the reaction solution,
the catalyst solution or the catalyst separated from
ethylene glycol. In such a case, if it is used
repeatedly as water for washing, the concentration of the
quaternary phosphonium chloride contained in the water
for washing will increase, whereby the concentration of
the quaternary phosphonium chloride contained in the
quaternary phosphonium iodide to be recovered, will
increase, and accordingly, after it is used for washing
from once to five times, it is replaced with fresh water
for washing.
A method wherein washing of the reaction solution is
carried out a plurality of times to gradually change to
water for washing having a low concentration of
quaternary phosphonium chloride, may also be carried out
without any problem.
In a specific embodiment of this operation, cooled
water or a slurry of quaternary phosphonium iodide is
preliminarily put in a vessel, and the reaction solution
or the catalyst solution and water are continuously or
batch-wise supplied thereto, and the mixture thereby
obtained is continuously or batch-wise withdrawn, whereby
it is possible to recover the precipitate contained
therein, by filtration.
Further, in order to separate ethylene glycol from
the reaction solution, an operation of separating
ethylene glycol by distillation under reduced pressure,
may be carried out. Water may also be separated together
with ethylene glycol.
The precipitate thus obtained by mixing the reaction
solution with water, is usually a highly active
quaternary phosphonium iodide catalyst having an iodide
content of at least 90 wt% and a chloride content of at
most 10 wt% and can effectively be recycled to the
reaction step for reuse.
Further, the separated liquid after separating the
precipitate of the quaternary phosphonium iodide,
contains the chloride i.e. the quaternary phosphonium
chloride. Such a quaternary phosphonium chloride can be
converted to a quaternary phosphonium iodide, for example,
by a method wherein the separated liquid is subjected to
dehalogenation treatment with an OH type anion exchange
resin, followed by neutralization with hydrogen iodide,
or chlorine ions are directly exchanged to iodine ions by
an anion exchange resin substituted by iodine. Thus, the
catalyst can be regenerated, and the regenerated catalyst
thus obtained may also be effectively recycled to the
reaction step for reuse.
In an application of the present invention, a part
of the reaction solution may be continuously or
intermittently withdrawn from the reactor which is
continuously operated, followed by recovery of the
quaternary phosphonium iodide catalyst, and the recovered
quaternary phosphonium iodide catalyst may be recycled to
the reactor. In such a case, the amount of the reaction
solution and/or the amount of the catalyst solution, to
be withdrawn for the recovery of the quaternary
phosphonium iodide catalyst, is not particularly limited.
However, in order to remove the chloride and to maintain
the reaction efficiency at a high level within a range
not to excessively increase the recovery cost of the
catalyst, it is preferred to withdraw the reaction
solution continuously or intermittently for treatment,
when the weight ratio of the chloride to the iodide in
the reactor becomes within a range of from 0.01 to 1.0.
The amount of withdrawal is not particularly limited, but
preferably about 0.1 to 100 wt%, based on the amount of
the reaction solution or the amount of the catalyst
solution.
EMBODIMENT IN WHICH THE QUATERNARY PHOSPHONIUM CHLORIDE
IN THE REACTION SYSTEM IS CONVERTED TO A QUATERNARY
PHOSPHONIUM IODIDE AND/OR BROMIDE, WHICH IS RECOVERED AND
RECYCLED TO THE REACTION SYSTEM FOR REUSE
The ratio or composition of the quaternary
phosphonium chloride and iodide contained in the mixture
to be treated comprising the quaternary phosphonium
chloride and iodide, according to the present invention,
varies depending upon the ratio of chlorine to iodine in
the process for producing ethylene glycol, the breeding
position, or the subsequent treatment as mentioned below
(e.g. the presence or absence of the pre-recovery
operation). The existing ratio and concentrations of the
quaternary phosphonium chloride and iodide in the mixture
to be treated, are not particularly limited. However,
the higher the ratio of the chloride to the iodide and
the concentration of the chloride, the better from the
viewpoint of the efficiency of the recovery operation.
Namely, the quaternary phosphonium chloride to the
quaternary phosphonium iodide in the mixture to be
treated is preferably at least 1/20, more preferably at
least 1/10, by molar ratio, and the concentration of the
quaternary phosphonium chloride in the mixture to be
treated is preferably at least 0.1 wt%, particularly
preferably at least 1 wt%.
As specific examples for application of the present
invention, the following respective methods may be
mentioned for each of the method for obtaining the
mixture to be treated and the method for adding the
iodide. They will be sequentially described, but it
should be understood that the present invention is by no
means restricted to the following methods.
APPLICATION EXAMPLE I
As a liquid containing the catalyst, a part of the
liquid in the process for producing ethylene glycol is
withdrawn. So long as it is a liquid containing the
catalyst present in the process, there is no particular
limitation as to the position at which it is withdrawn.
As mentioned above, the reaction for forming ethylene
glycol from ethylene oxide is a two step reaction
comprising a reaction of ethylene oxide with carbon
dioxide to form ethylene carbonate, and the hydrolysis of
the ethylene carbonate to form ethylene glycol.
Accordingly, in a case where this reaction is carried out
by reactors provided in two steps in series, the liquid
from this production process may be withdrawn from either
reactor or may be withdrawn from both reactors.
In a case where the liquid is withdrawn at the
outlet of the reactor, in order to increase the recovery
rate of the quaternary phosphonium iodide in the later
step, it is preferred that the concentrations of the
quaternary phosphonium chloride and iodide in the mixture
to be treated, are high. Accordingly, in such a case, it.
is preferred to distil off water, ethylene glycol or
ethylene carbonate as the solvent for concentration. The
distillation may be carried out by a distillation column,
but a simple evaporator may otherwise be used.
Preferably, the concentration is carried out until the
concentration of the quaternary phosphonium iodide in the
mixture to be treated becomes at least 1/2 0 time by mol
of the solvent. Taking the heat resistance of the
quaternary phosphonium salt into consideration, it is
preferred to carry out this concentration operation by
distillation under reduced pressure, preferably at most
400 Torr (53.2 Pa), preferably at a temperature of from
60 to 210°C.
The highly concentrated catalyst solution obtained
by concentration of the reaction solution by distillation
contains a quaternary phosphonium iodide and a quaternary
phosphonium chloride formed by chlorination of the
quaternary phosphonium iodide in the process for
producing ethylene glycol. Here, the catalyst solution
may be one having the reaction solution taken out of the
process and concentrated, or may be a catalyst solution
withdrawn from a distillation column for separating the
catalyst solution from water, ethylene glycol and
ethylene carbonate, in the process.
As the iodide to be used for recovering the
quaternary phosphonium iodide, any iodide may be used so
long as it is an ionic compound which may be dissociated
in water and which is ion exchangeable with the
quaternary phosphonium chloride, and it may be suitably
selected by a person skilled in the art. However, from
the viewpoint of the solubility, toxicity, price, etc.,
an alkali metal salt such as a sodium salt or a potassium
salt, or hydroacid may, for example, be preferred.
The inorganic iodide may be any iodide so long as it
is an ionic compound which can be dissociated in water
and which can be ion exchanged with the quaternary
phosphonium chloride. However, from the viewpoint of the
solubility, toxicity and price, an alkali metal salt such
as a sodium salt or a potassium salt, is preferred.
The amount of the iodide to be added, may be at
least equivalent to the quaternary phosphonium chloride
present in the mixture to be treated. A preferred range
is from 0.5 to 10 mols, more preferably from 1 to 5 mols,
per mol of the quaternary phosphonium chloride present in
the mixture to be treated. If the iodide is added more
than necessary, the recovery rate may be increased, but
the excess iodide will be loss.
The iodide may be added in the form of solid or an
organic solvent solution or an aqueous solution. However,
in an industrial operation, it is preferably a liquid
from the viewpoint of the handling, and accordingly, it
is preferably added in the form of an organic solvent
solution or an aqueous solution.
In the case of the aqueous solution, the amount of
water may be an amount sufficient to dissolve the iodide,
and such an amount depends on the iodide to be used. For
example, in a case where potassium iodide is to be used,
the saturated solubility in water is 60%, and water may
be added so that the potassium iodide concentration in
the mixture to be treated will be at most this level.
Usually, it is added in the from of an aqueous solution
having a concentration of from 1 to 60 wt%.
The apparatus for adding the iodide to the mixture
to be treated may be a container of any form, but it is
preferred to employ a vessel having a stirring device to
accelerate the ion exchange reaction..
By this operation, the quaternary phosphonium
chloride present in the mixture to be treated will be
converted to a quaternary phosphonium iodide, which will
be precipitated in water together with the quaternary
phosphonium iodide already present in the mixture to be
treated. The temperature for precipitation is preferably
a low temperature, whereby remaining of the quaternary
phosphonium iodide in water will be less. The
precipitation is preferably carried out at a temperature
of from 0 to 3 0°C.
The precipitated quaternary phosphonium iodide will
be subjected to filtration for recovery. The method for
the filtration is not particularly limited, and not only
usual filtration by means of a filter, but also
centrifugal separation may, for example, be used.
The quaternary phosphonium iodide recovered in the
form of a solid, may sometimes contains about 10 wt% of
the quaternary phosphonium chloride and the added iodide.
At such a concentration, it may be recycled to the
reaction step for ethylene glycol, as it is. However, if
necessary, it may be washed with water to increase the
purity of the quaternary phosphonium iodide, before
recycling for reuse. Water after used for washing
contains the quaternary phosphonium iodide, and may be
used for next washing or may be reused as water to
dissolve the above-mentioned iodide to be added to the
mixture to be treated.
The recovered quaternary phosphonium iodide may, for
example, be dissolved in ethylene glycol and as such, may
be recycled to the reaction system.
In the forgoing, an embodiment was described wherein
a quaternary phosphonium chloride is converted to a
quaternary phosphonium iodide, which is recovered. This
operation can be carried out also in an organic solvent.
In the following, an embodiment will be described wherein
an operation to precipitate an inorganic chloride is
carried out in an organic solvent, whereby a quaternary
phosphonium chloride is converted to a quaternary
phosphonium iodide, which is recovered.
In the highly concentrated catalyst solution
obtained, ethylene glycol and/or ethylene carbonate is
present as a solvent. Accordingly, to such a catalyst
solution, the inorganic chloride-precipitating operation
of the present invention may be applied, but it is also
effective to add another organic solvent in which the
solubility of the inorganic chloride formed by the
addition of the iodide, is low. Further, it is preferred
that ethylene glycol and/or ethylene carbonate in the
highly concentrated catalyst solution is further removed
to obtain a solid containing substantially no solvent,
which is re-dissolved in another organic solvent, whereby
the solubility of the inorganic chloride may be further
decreased so that the precipitation efficiency will be
improved.
As the organic solvent to be used here, it is
preferred to have a high ability to dissolve the
quaternary phosphonium salt while it has a low ability to
dissolve the inorganic chloride. As a preferred solvent,,
an aliphatic halogenated hydrocarbon, a ketone, an
alcohol, a nitrile, an amide, a urea, compound or a
carbonate may, for example, be mentioned.
Among them, the alcohol may, for example, be ethanol,
1-propanol, 2-propanol, 1-butanol, 2-butanol, 2-methyl-l-
propanol, 1,1-dimethylethanol, 1-pentanol, 2-pentanol, 3-
pentanol, 3-methyl-1-butanol, 2-methyl-l-butanol, 1,1-
dimethyl-1-propanol, 1-hexanol, 2-hexanol, 3-hexanol, 2-
methyl-1-pentanol, 4-methyl-2-pentanol, 1-heptanol, 2-
heptanol, 3-heptanol, 4-heptanol, 1-octanol, 2-octanol,
2-ethyl-l-hexanol, 1-nonanol, 2-nonanol, 1-decanol, 1-
undecanol, 1-dodecanol, 1,6-hexanediol, cyclopentanol,
cyclohexanol, benzyl alcohol or phenethyl alcohol.
The aliphatic halogenated hydrocarbon may, for
example, be methylene chloride, chloroform, 1,2-
dichloroethane, 1,1,1-trichloroethane, 1,1,2-
trichloroethane, 1,2-dichloropropane, 1,3-dichloropropane,
1,2,3-trichloropropane, 1,4-dichlorobutane or 1,6-
dichlorohexane.
The nitrile may, for example, be acetonitrile,
propionitrile, butyronitrile, adiponitrile or
benzonitrile. The amide may, for example, be
dimethylformamide or dimethylacetamide. The urea
compound may, for example, be tetramethylurea or 1,3-
dimethylimidazolidin-2-on. The ketone may, for example,
be acetone, methyl ethyl ketone or methyl isopropyl
ketone. The carbonate may, for example, be ethylene
carbonate, propylene carbonate or butylene carbonate.
As the organic solvent, one of them may be used
alone, or two or more of them may be used in combination
as a mixture. The amount of the organic solvent to be
added, is not particularly limited, but it is usually
from 1 to 10 times by weight to the sum of the quaternary
phosphonium chloride and iodide in the mixture to be
treated.
For example, sodium iodide is soluble in acetone
very well, and such is a good combination. Further,
potassium iodide is soluble in ethylene glycol very well,
and such a combination is also good. However, in this
case, it is not necessarily required that the iodide is
completely soluble in the organic solvent. Even if the
saturated soluble amount of the iodide is very small,
after added to the mixture to be treated, the iodide will
be consumed by the reaction with the quaternary
phosphonium chloride, and the dissolution will further
proceed to supplement the consumption. Consequently, the
amount, beyond the solubility will be reacted to form an
inorganic chloride. Required for the selection of the
iodide and the organic solvent is that there is a
difference in the mol solubility to the organic solvent
between the iodide and the inorganic chloride to be
formed by the reaction of this iodide with the quaternary
phosphonium chloride. As such a combination, butanol or
ethylene glycol to potassium iodide may be mentioned as
an example.
The apparatus for adding the iodide to the mixture
to be treated may be a container of any form, but it is
preferred to employ a vessel having a stirring device in
order to accelerate the ion exchange reaction.
By this operation, the quaternary phosphonium of the
quaternary phosphonium chloride present in the mixture to
be treated will be converted to a quaternary phosphonium
iodide, while chlorine will be precipitated as an
inorganic chloride. The precipitation temperature is not
particularly limited and may be determined in view of the
dependency of the inorganic chloride on the dissolution
temperature, the boiling point or viscosity of the
organic solvent to be used, and the solubility of the
quaternary phosphonium salt. Usually, the precipitation
is carried out at a normal temperature of from 0 to 50°C,
The reaction of the iodide with the quaternary
phosphonium chloride will swiftly proceed when the
viscosity of the solvent is low. However, in a case
where the solvent has a high viscosity, or the solubility
of the iodide is low, it is preferred to prolong the
mixing time. Preferably, the reaction will be completed
in from about 1 minute to 3 hours. By this operation,
the quaternary phosphonium of the quaternary phosphonium
chloride in the organic solvent will be converted to the
iodide at a conversion of at least 9 0%, and at the same
time, an inorganic chloride will be precipitated.
The precipitated inorganic chloride is removed by
filtration. The method for the filtration is not
particularly limited, and not only filtration by means of
a usual filter, but also centrifugal separation or the
like may be applied.
In the filtrate after separation of the inorganic
chloride by filtration, a quaternary phosphonium iodide
as the catalyst is dissolved. Accordingly, by removing
the organic solvent from this filtrate by evaporation,
the quaternary phosphonium iodide and, when added in an
excess amount, the iodide, will be recovered in the form
of a solid. Removal of the organic solvent may be
carried out by a usual evaporator. Such removal of the
organic solvent by evaporation is preferably carried out
at a temperature of at most 200°C, if necessary, under
reduced pressure, taking the heat resistance of the
recovered quaternary phosphonium iodide into
consideration, as mentioned above.
The purity of the quaternary phosphonium iodide thus
recovered is at a level of at least. 90% excluding the
iodide added in an excess amount and the remaining
solvent, and therefore, it can be recycled to the
reaction step for reuse, as it is or as dissolved in a
suitable solvent such as ethylene glycol. However,
preferably, the recovered solid is washed with water to
remove the remaining iodide and the solvent, before being
recycled to the reaction step for reuse. For such
washing with water, washing water may be added to the
recovered solid to form a slurry, which may be subjected
to filtration or centrifugal separation. In such a case,
the amount of washing water to be added is preferably
made to be at most twice by weight to the recovered solid,
taking the dissolution loss in the washing water into
consideration.
As another method for removing the inorganic
chloride in the above process, it is possible that
without subjecting the inorganic chloride to filtration,
removal of the solvent is carried out by a similar
operation, and then, the above-mentioned washing with
water is carried out to have the inorganic compound
dissolved in water and removed.
The following process may be mentioned as another
embodiment of the present invention.
APPLICATION EXAMPLE II
In Application Example I, a pre-recovery is carried
out wherein water is added to and mixed with a highly
concentrated catalyst solution wherein the concentration
of a quaternary phosphonium iodide is at least 1/2 0 time
by mol to ethylene glycol or which is concentrated to
such a concentration, followed by cooling to have the
quaternary phosphonium iodide selectively precipitated
and recovered. Here, the amount of water to be added is
optional, but if it is too small, no adequate
precipitation effect can be obtained, and therefore it is
necessary to add at least 0.1 time by weight of the
dissolved quaternary phosphonium iodide. The upper limit
of the amount of water to be added, is not particularly
limited, but in order not to increase the treating volume
excessively, the amount is preferably adjusted to be at
most about 5 times by weight to the dissolved quaternary
phosphonium iodide. The temperature for this
precipitation operation is preferably low, whereby the
remaining amount of the quaternary phosphonium iodide in
water will be small. The operation is preferably carried
out at a temperature of from 0 to 3 0°C.
In the aqueous solution remaining after the recovery
of the precipitated quaternary phosphonium iodide, an
unprecipitated quaternary phosphonium iodide and a
quaternary phosphonium chloride will be present. Such an
aqueous solution remaining after the recovery of the
quaternary phosphonium iodide may be used as the mixture
to be treated, and it may be concentrated as the case .
requires, and then an iodide is added to carry out the
conversion of the quaternary phosphonium chloride to a
quaternary phosphonium iodide, and precipitation. It is
preferred to carry out the concentration so that the
quaternary phosphonium chloride concentration in the
mixture to be treated prior to addition of the iodide
becomes to be at least 1 wt%, from the viewpoint of the
conversion efficiency of the quaternary phosphonium
chloride and the recovery efficiency of the quaternary
phosphonium iodide.
The type of the iodide to be added, and the
concentration and method for addition, the method for
filtration of the precipitate, the subsequent treatment,
etc. may be the same as in the above-mentioned
Application Example I.
However, in this case, water is already present in
the system, and the iodide may be added in a solid form,
whereby the amount of water to be used will consequently
be reduced, and the dissolution loss of the quaternary
phosphonium iodide in waste water can be reduced.
Further, after carrying out the pre-recovery, the
inorganic chloride precipitation operation can be carried
out by using, as the mixture to be treated, one obtained
by evaporating and removing preferably at least 90%, more
preferably at least 99%, of water in the aqueous solution
containing the quaternary phosphonium chloride and iodide.
Namely, such a mixture to be treated is dissolved in an
organic solvent in an amount of from 1 to 10 times by
weight to the sum of the quaternary phosphonium chloride
and iodide in the mixture to be treated, and an iodide is
added thereto. The type of the iodide to be added, the
concentration and method for addition, the method for
filtration of the precipitate, the subsequent treatment,
etc., may be the same as in the above-described process
of Application Example I.
Further, in this process, it is possible to add an
aqueous iodide solution instead of water added to
precipitate the quaternary phosphonium iodide in the
highly concentrated catalyst solution, and in such a case,
addition of the iodide in the later stage will be
unnecessary.
In either case, by removing the organic solvent from
the organic solvent solution after subjecting the
precipitate of the inorganic chloride to solid-liquid
separation, it is possible to further recover the
quaternary phosphonium iodide, which may be re-used
together with the previously recovered quaternary
phosphonium iodide.
The following process may be mentioned as a still
another embodiment.
APPLICATION EXAMPLE III
In Application Example I, the highly concentrated
catalyst solution wherein the concentration of the
quaternary phosphonium iodide is at least 1/2 0 time to
ethylene glycol or which is concentrated to such a
concentration, is further concentrated, and at least 90%
of the solvent is distilled off. In such a case, the
residue (the distillation residue) will solidify as it is
cooled. The solidified residue may be washed with a
suitable amount of water, whereby the quaternary
phosphonium chloride in the residue may be eluted to the
water side and removed. Also in such a case, the
temperature of water for washing is preferably low, as
the dissolution amount of the quaternary phosphonium
iodide in the water for washing will be small. Washing
is carried out preferably at a temperature of from 0 to
3 0°C.
The amount of the water to be used for washing is
not particularly limited. However, taking the washing
efficiency and the loss of the quaternary phosphonium
iodide in waste water into consideration, it is
preferably from 0.5 to 10 times by weight to the solid
residue to be washed. Water to be used for washing is
not required to be pure water, and it is possible to use
recycled water within the process. Further, it may be
repeatedly recycled for use. Especicilly, an aqueous
solution containing the quaternary phosphonium iodide is
preferred, since the dissolution loss of the quaternary
phosphonium iodide in water can thereby be reduced.
In water after washing, the eluted quaternary
phosphonium chloride and a slight amount of dissolved
quaternary phosphonium iodide will be present.
This may be used as a mixture to be treated, and as
mentioned above, it is concentrated as the case requires,
and then an iodide is added to carry out conversion of
the quaternary phosphonium chloride to the quaternary
phosphonium iodide, and precipitation. Also in this case,
the concentration of the quaternary phosphonium chloride
in the mixture to be treated before adding the iodide, is
preferably at least 1 wt%, and the type of the iodide to
be added, the concentration and method for addition, the
method for filtration of the precipitate, the subsequent
treatment, etc., may be the same as in the above-
mentioned process of Application Example I.
Also in this case, water is already present in the
system, and the iodide may be added in a solid form,
whereby the amount of water to be used will be
consequently reduced, and it is possible to reduce the
dissolution loss of the quaternary phosphonium iodide in
waste water.
Further, in the above-mentioned process wherein the
washing operation is carried out, water after washing is
used as a mixture to be treated, and an iodine is added
thereto, the aqueous iodide solution may be used as water
for washing, as a mode for carrying out the process as
shortened. In this case, the concentration of the
aqueous iodide solution to be used, nay be a
concentration such that the concentration of the iodine
in water after washing will be the concentration in the
above-mentioned added and mixed state.
The inorganic chloride precipitation operation can
be carried out by using, as the mixture to be treated,
one obtained by evaporating and removing preferably at
least 90%, more preferably at least 99%, of water in this
aqueous solution containing the quaternary phosphonium
chloride and iodide. Namely, this mixture to be treated
is dissolved in an organic solvent in an amount of from 1
to 10 times by weight to the sum of the quaternary
phosphonium chloride and iodide in the mixture to be
treated, and an iodide is added thereto.
The type of the iodide to be added, the
concentration and method for addition, the method for
filtration of the precipitate, the subsequent treatment,
etc. may be the same as in the above-described process of
Application Example I.
Further, also in this process, an aqueous iodide
solution may be used instead of water for washing, and in
such a case, addition of the iodide at a later stage will
be unnecessary.
In either case, by removing the organic solvent from
the organic solvent solution after subjecting the
precipitate of the inorganic chloride to solid-liquid
separation, it is possible to further recover the
quaternary phosphonium iodide, which may be reused
together with the previously recovered quaternary
phosphonium iodide.
Further, a highly concentrated catalyst solution
wherein the concentration of the quaternary phosphonium
iodide is at least 1/20 time to the ethylene glycol or
which is concentrated to such a concentration, may be
further concentrated, and after distilling off at least
90% of the solvent, the solution may be maintained at a
temperature of at least 9 0°C, whereby the liquid state
can be maintained. Water is added thereto, followed by
cooling to from 0 to 40°C, whereby it is possible to
precipitate the quaternary phosphonium iodide. Otherwise,
the above-mentioned concentrated residue may be
continuously supplied alone or together with water to the
already existing cool water or slurry, to carry out.
precipitation. Also in this case, in the aqueous
solution remaining after separation and recovery of the
precipitated quaternary phosphonium iodide, an
unprecipitated quaternary phosphonium iodide and chloride
will be present.
This may be used as a mixture to be treated, and as
mentioned above, after concentrating it as the case
requires, an iodide may be added to carry out conversion
of the quaternary phosphonium chloride to the quaternary
phosphonium iodide, and precipitation.
Also in this case, the concentration of the
quaternary phosphonium chloride in the mixture to be
treated prior to the addition of the iodide is preferably
at least 1 wt%, and the type of the iodide to be added,
the concentration and method for addition, the method for
filtration of the precipitate, the subsequent treatment,
etc. may be the same as in the above-described process of
Application Example I.
Thus, also in this case, water is already present in
the system, and the iodide may be added in a solid form,
whereby the amount of water to be used is consequently
reduced, and the dissolution loss of the quaternary
phosphonium iodide in waste water can be reduced.
Further, as a mode to carry out the above process as
shortened, it is also possible to use an aqueous iodide
solution as heated, instead of water.
The inorganic chloride precipitation operation may
be carried out by using, as the mixture to be treated,
one obtained by evaporating and removing preferably at
least 90%, more preferably at least 99%, of water in this
aqueous solution containing the quaternary phosphonium
chloride and iodide. Namely, such a mixture to be
treated is dissolved in an organic solvent in an amount
of from 1 to 10 times by weight to the sum of the
quaternary phosphonium chloride and iodide in the mixture
to be treated, and an iodide is added thereto.
The type of the iodide to be added, the
concentration and method for addition, the method for
filtration of the precipitate, the subsequent treatment,
etc. may be the same as in the above-described process of
Application Example I.
Also in this process, it is possible to use an
aqueous iodide solution instead of waiter, and in such a
case, addition of an iodide in the later stage will be
unnecessary.
In all embodiments, it is also possible to apply the
present invention to the quaternary phosphonium chloride
and iodide still remaining in the separated liquid after
solid-liquid separation of the inorganic chloride
precipitated by adding an iodide. Namely, it is also
possible to repeatedly carry out addition of the iodide
and removal of the inorganic chloride until the desired
recovery rate is reached.
In the application of the present invention, at
least a part of the reaction solution and/or the catalyst
solution is continuously or intermittently withdrawn from
the reaction process which is continuously operated, and
after carrying out concentration and/or pre-recovery as
the case requires, conversion of the quaternary
phosphonium chloride to a quaternary phosphonium iodide
and recovery of the quaternary phosphonium iodide, are
carried out, and the recovered quaternary phosphonium
iodide catalyst may be recycled to the reactor. In such
a case, the amount of the reaction solution and/or the
catalyst solution withdrawn to recover the quaternary
phosphonium iodide is not particularly limited. However,
in order to maintain the reaction efficiency at a high
level by removing the quaternary phosphonium chloride
within a range not to excessively increase the cost for
the recovery of the catalyst, it is preferred to
continuously or intermittently withdraw the reaction
solution and/or the catalyst solution for treatment when
the weight ratio of the quaternary phosphonium chloride
to the iodide in the reactor becomes within a range of
from 0.01 to 1.0. The amount for the withdrawal is not
particularly limited, but it is preferably within a range
of from about 0.1 to 100 wt%, based on the amount of the
reaction solution or the catalyst solution in the
respective system.
EXAMPLES
Now, the present invention will be described in
further detail with reference to Examples. However, it
should be understood that the present invention is by no
means restricted to such Examples.
EXAMPLE 1-1
Into a first reactor pressurized to 2.0 MPa by
carbon dioxide for a retention time of 1 hour at 100°C, 5
parts by weight/hr of tributylmethylphosphonium iodide as
a catalyst, 0.8 part by weight/hr of potassium carbonate,
and 78 parts by weight/hr of the starting material
ethylene oxide aqueous solution (60 wt%), were supplied
to obtain a reaction solution comprising ethylene
carbonate and ethylene glycol (EG). This solution was
transferred in its entire amount to a second reactor for
a retention time of 2 hours under a pressure of 0.5 MPa
at a temperature of 150°C to have the contained ethylene
carbonate hydrolyzed to obtain 66.5 parts by weight/hr of
an aqueous solution of ethylene glycol, containing the
catalyst.
The obtained reaction solution was distilled by a
vacuum distillation column having a bottom temperature of
14 0°C under a pressure of 11 kPa (80 mmHg) to obtain a
dehydrated liquid from the bottom, and the liquid was
further subjected to a vacuum evaporator operated at
140°C under a pressure of 8 kPa (60 mmHg) to evaporate
the majority of ethylene glycol and to recover 13 parts
by weight/hr of a catalyst solution having the catalyst
concentrated, from the bottom of the evaporator. The
recovered catalyst solution was recycled as a catalyst to
the first reactor for reuse. The composition of the
catalyst solution after the continuous operation for 1
year was as follows:
Composition of the Catalyst Solution
Ethylene glycol: about 59 wt%
Iodide (quaternary phosphonium iodide): about 33 wt%
Chloride (quaternary phosphonium chloride):
about 6 wt%
Potassium carbonate: about 2 wt%
After the above composition was reached, the
operation was changed so that a part of this catalyst
solution was withdrawn at a rate of 0.02 part by
weight/hr. The withdrawn catalyst solution (hereinafter
referred to as "withdrawn liquid A") was supplied to a
flush vessel, and under conditions of 3 Torr (400 Pa) and
12 8°C, about 93 wt% of ethylene glycol contained in the
liquid was removed.
The liquid after the removal of ethylene glycol
(hereinafter referred to as "concentrated liquid A") was
maintained at 95°C, and a 3 wt% potassium iodide aqueous
solution was added, and the mixture was cooled to 20°C
with stirring and mixing, whereupon it was left to stand
for 1 hour. The potassium iodide added here was
equimolar to the chloride in the concentrated liquid A,
and the amount of water used was equal weight to the
concentrated liquid A.
The precipitate was separated by a vacuum filter and
analyzed, whereby the composition of this precipitate was
as follows. This indicates that it was possible to
efficiently separate 90 wt% of the iodide and chloride in
the withdrawn liquid A, as the quaternary phosphonium
iodide catalyst.
Composition of Precipitate
Water: about 18 wt%
Ethylene glycol: about 2 wt%
Iodide (quaternary phosphonium iodide): about 80 wt%
Chloride (quaternary phosphonium chloride):
about 2 wt%
Potassium carbonate: at most 1 wt%
This precipitate was dissolved in ethylene glycol
and recycled to the reactor.
Thus, the operation was continued while recovery and
recycling of the catalyst were carried out, whereby it
was possible to continue the operation efficiently
without a problem of a decrease in the reaction
efficiency in the process for production of ethylene
glycol.
EXAMPLE 1-2
In Example 1-1, instead of the potassium iodide
aqueous solution, distilled water in the same amount as
the concentrated liquid A, was added to the concentrated
liquid A after separation and removal of ethylene glycol,
and a similar operation was carried out to have a solid
precipitated.
The precipitate was separated and analyzed, whereby
it was confirmed that this precipitate contained 94 wt%
of the iodide and about 13 wt% of the chloride in the
withdrawn liquid A, and it was possible to efficiently
separate the quaternary phosphonium iodide catalyst from
the chloride.
In the liquid separated from the precipitate
(hereinafter referred to as "separated liquid A"), about
6 wt% of the iodide and about 87 wt% of the chloride in
the withdrawn liquid A were dissolved. To such a
separated liquid A, potassium iodide in an amount of 1.2
times by mol to the chloride in the liquid was added in
the form of a 50 wt% aqueous solution, and the mixture
was left to stand still at 20°C for 1 hour. The
precipitate was separated and analyzed, whereby it was
confirmed that in this precipitate, it was possible to
efficiently separate 50 wt% of the chloride in the
withdrawn liquid A as the quaternary phosphonium iodide
catalyst.
EXAMPLE 1-3
The separated liquid A obtained in Example 1-2 was
distilled, and 50 wt% of water in the separated liquid A
was distilled off for concentration. To such a
concentrated liquid, potassium iodide in an amount of 1.2
times by mol to the chloride in the liquid was added in
the form of a 50 wt% aqueous solution, and the mixture
was left to stand still at 2 0°C for 1 hour. The
precipitate was separated and analyzed, whereby it was
confirmed that in this precipitate, it was possible to
efficiently separate about 7 5 wt% of the chloride in the
withdrawn liquid A as the quaternary phosphonium iodide
catalyst.
EXAMPLE 2-1
Into a first reactor pressurized to 2.0 MPa by
carbon dioxide for a retention time of 1 hour at 100°C, 5
parts by weight/hr of tributylmethylphosphonium iodide as
a catalyst, 0.8 part by weight/hr of potassium carbonate,
and 7 8 parts by weight/hr of a starting material ethylene
oxide aqueous solution (60 wt%), were supplied to obtain
a reaction solution comprising ethylene carbonate and
ethylene glycol (EG) . This solution was in its entire
amount transferred to a second reactor for a retention
time of 2 hours, under a pressure of 0.5 MPa at a
temperature of 150°C to have the contained ethylene
carbonate hydrolyzed to obtain 66.5 parts by weight/hr of
an aqueous solution of ethylene glycol, containing the
catalyst.
The obtained reaction solution was distilled by a
vacuum distillation column at a bottom temperature of
140°C under a pressure of 11 kPa (80 mmHg) to obtain a
dehydrated liquid from the bottom, and the liquid was
further subjected to a vacuum evaporator operated at
140°C under a pressure of 8 kPa (60 mmHg) to evaporate
the majority of ethylene glycol and to recover 13 parts
by weight/hr of the catalyst solution having the catalyst,
concentrated, from the bottom of the evaporator. The
recovered catalyst solution was recycled as a catalyst to
the first reactor for reuse. The composition of the
catalyst solution after a continuous operation for 1 year,
was as follows.
Composition of the Catalyst Solution
Ethylene glycol: about 59 wt%
Iodide (quaternary phosphonium iodide): about 3 3 wt%
Chloride (quaternary phosphonium chloride):
about 6 wt%
Potassium carbonate: about 2 wt%
After the above composition was reached, the
operation was changed so that a part of this catalyst
solution was withdrawn at a rate of 0.02 part by
weight/hr. The withdrawn catalyst solution (hereinafter
referred to as "withdrawn liquid A") was supplied to a
flush vessel, and about 93 wt% of ethylene glycol
contained in the liquid was removed under conditions of 3
Torr (40 0 Pa) and 12 8°C. The liquid after removal of
ethylene glycol (hereinafter referred to as "concentrated
product A") was maintained at 9 5°C, and water in the same
amount as the concentrated product A was added, and the
mixture was cooled to 2 0°C with stirring and mixing,
whereupon it was left to stand still for 1 hour.
The precipitate (hereinafter referred to as
"precipitate A") was separated by a vacuum separator, and
the obtained filtrate (hereinafter referred to as
"filtrate A") was analyzed, whereby the composition of
this filtrate A was as follows and was one containing
about 8 0 wt% of the chloride in the withdrawn liquid A.
Composition of Filtrate A
Water: about 7 8 wt%
Ethylene glycol: about 7 wt%
Iodide (quaternary phosphonium iodide): about 1 wt%
Chloride (quaternary phosphonium chloride):
about 10 wt%
Potassium carbonate: 4 wt%
On the other hand, the above precipitate A was
analyzed, whereby the composition of the precipitate A
was as follows, and this was one containing about 98 wt%
of the iodide in the above withdrawn liquid A.
Composition of Precipitate A
Water: about 16 wt%
Ethylene glycol: about 1 wt%
Iodide (quaternary phosphonium iodide): about 80 wt%
Chloride (quaternary phosphonium chloride):
about 2 wt%
Potassium carbonate: at most 1 wt%
Water and ethylene glycol contained in the filtrate
A were removed by means of an evaporator operated at
140°C. Along with the removal of water and ethylene
glycol, the pressure was reduced, and finally, 5 Torr
(660 Pa) was maintained for 3 0 minutes. By this
operation, the amount of water and ethylene glycol
contained in the distillation residue became at most 10
wt%. To the residue after thus removing water and
ethylene glycol, acetone in the same amount by weight was
added. Then, the obtained liquid was transferred to a
vessel equipped with a stirrer, and sodium iodide in an
amount of 1.2 times by mol to the contained chloride was
added in the form of a solid, followed by stirring at
room temperature for 1 hour. The precipitate formed by
this inorganic chloride precipitation operation was
separated by a vacuum filter and analyzed, whereby in
this precipitate, sodium chloride corresponding to at
least 98 wt% of the chloride in the filtrate A, was
present.. On the other hand, the filtrate obtained by
this solid-liquid separation (hereinafter referred to as
"filtrate B") was introduced into an evaporator operated
under 5 Torr (660 Pa) at 110°C, and substantially all
amounts of acetone and ethylene glycol in the filtrate B
were evaporated, and the obtained solid was mixed with
water in the same amount by weight and washed, followed
by solid-liquid separation by a vacuum filter. The
obtained solid (hereinafter referred to as "solid B") was
analyzed and found to have the following composition.
Composition of Solid B
Water: about 17 wt%
Ethylene glycol: at most 1 wt%
Iodide (quaternary phosphonium iodide): about 81 wt%
Chloride (quaternary phosphonium chloride):
at most 1 wt%
Sodium iodide: about 1 wt%
One having this solid B and the above precipitate A
combined, contains about 9 8 wt% of the iodide and the
chloride in the withdrawn liquid A, as the quaternary
phosphonium iodide, which was dissolved in ethylene
glycol in the same amount by weight and recycled to the
reactor for reuse.
Thus, while recovery and recycling of the catalyst
were carried out, the operation was continued, whereby it
was possible to continue the operation efficiently
without a problem of a decrease in the reaction
efficiency in the process for producing ethylene glycol.
EXAMPLE 2-2
In Example 2-1, to the concentrated product A after
separation and removal of ethylene glycol, n-butanol in
the same amount by weight was added as an organic solvent
for dissolution. This solution was transferred to a
vessel equipped with a stirrer, and potassium iodide in
the same molar amount as the chloride contained in the
liquid, was added, followed by mixing at room temperature
for 2 hours.
The precipitate was separated by a vacuum filter and
analyzed, whereby in this precipitate, potassium chloride
corresponding to at least 95 wt% of the chloride
contained in the concentrated product A, was present.
On the other hand, the filtrate was introduced into
an evaporator operated under 5 Torr (660 Pa) at 110°C,
and substantially all amounts of butanol and ethylene
glycol in the filtrate were evaporated. The obtained
solid was mixed with water in the same amount by weight
and washed, followed by solid-liquid separation by a
vacuum filter. The obtained solid was analyzed and found
to have the following composition, and it was one
containing about 9 5 wt% of the iodide and the chloride in
the withdrawn liquid A in the form of the quaternary
phosphonium iodide.
Composition of Solid
Water: about 18 wt%
Ethylene glycol: 2 wt%
Iodide (quaternary phosphonium iodide): about 80 wt%
Chloride (quaternary phosphonium chloride):
at most 1 wt%
Potassium iodide: at most about 1 wt%
This solid was dissolved in ethylene glycol in the
same amount by weight and recycled to the reactor for
reuse.
Thus, while recovery and recycling of the catalyst
were carried out, the operation was continued, whereby it
was possible to continue the operation efficiently
without a problem of a decrease in the reaction
efficiency in the process for producing ethylene glycol.
COMPARATIVE EXAMPLE 1
In Example 1-1, 100 g of the dehydrated reaction
solution was withdrawn from the bottom of the vacuum
distillation column. The ratio of ethylene glycol to the
catalyst contained therein was 87%. Water in the same
amount by weight was added thereto, and the mixture was
cooled to 0°C, but no precipitate was formed.
EXAMPLE 1-4
To the filtrate obtained in Example 1-2, potassium
iodide in an amount of 1 time by mol to the chloride in
the liquid, was added in the form of a 50 wt% aqueous
solution, and the mixture was left to stand still at 20°C
for 1 hour. The precipitate was sepcirated and analyzed.
As a result, it was confirmed that in this precipitate,
it was possible to effectively separate about 87 wt% of
the chloride in the filtrate, as the quaternary
phosphonium iodide catalyst.
INDUSTRIAL APPLICABILITY
According to the present invention, in a process for
producing an alkylene derivative, such as an alkylene
glycol such as ethylene glycol, or an alkylene carbonate
such as ethylene carbonate, which comprises reacting an
alkylene oxide such as ethylene oxide with water or
carbon dioxide, in the presence of carbon dioxide, by
means of a quaternary phosphonium iodide and/or bromide
catalyst, it is possible to efficiently recover the
quaternary phosphonium iodide or bromide catalyst from
the reaction system and to recycle it for use, or it is
possible to convert the quaternary phosphonium chloride
formed in the reaction system, efficiently to a
quaternary phosphonium iodide and/or bromide, which can
be recycled to the reaction system for reuse. Thus, it
is possible to prevent accumulation in the system of the
quaternary phosphonium chloride having a low catalytic
activity and at the same time to convert it to a
quaternary phosphonium iodide and/or bromide having a
high catalytic activity and to recycle it for use,
whereby it is possible to maintain the catalytic activity
in the system at a high level and to carry out the
reaction to form the alkylene derivative constantly and
effectively over a long period of time.
The present invention is based on Japanese Patent
Application No. 2003-031391 (filed on February 7, 2003),
Japanese Patent Application No. 2003-078178 (filed on
March 20, 2003) and Japanese Patent Application No. 2003-
088281 (filed on March 27, 2003), and their entireties
are hereby included by reference.
We Claim :
1. A process for producing an alkylene derivative, which
comprises a reaction step of reacting an alkylene oxide
with water in the presence of carbon dioxide by means of
a quaternary phosphonium iodide or bromide catalyst to
form an alkylene glycol, characterized in that from at
least a part of the reaction solution and/or the catalyst
solution, the alkylene glycol is removed so that the
molar ratio of the alkylene glycol to the catalyst
becomes at most 20 times, followed by mixing with water
to recover the catalyst, wherein the molar ratio of the
alkylene glycol to the catalyst is made to be at most
twice and the operation temperature at the time of mixing
with water to recover the catalyst is at most 30°C.
2. The process as claimed in Claim 1, wherein the amount
of water to be mixed is at least 0.1 time by weight,
based on the catalyst to be recovered.
3. The process as claimed in Claim 1, wherein after
mixing with water, solid-liquid separation is carried out
to separate the catalyst, which is recycled to the
reaction step.
4. The process as claimed in Claim 3, wherein the liquid
separated by the solid-liquid separation is recycled and
used as water for washing the catalyst.
5. The process as claimed any one of the preceeding
Claims 1 to 4, wherein the alkylene oxide is ethylene
oxide.
6.The process as claimed in any of the preceding claims 1
to 5, wherein the catalyst is regenerated from a mixture
comprising a quaternary phsphonium chloride and a
quaternary phosphonim iodide and/or bromide, obtained
from a reaction step of reacting an alkylene oxide
containing a chlorinated compound as an impurity, by
mixing with an iodide and/or bromide to have the
quaternary phosphonium chloride converted to a quaternary
phosphonium iodide and/or bromide, which is precipitated
in water.
7. The process as claimed in Claim 6, wherein the
mixture comprising a quaternary phosphonium chloride and
a quaternary phosphonium iodide and/or bromide, is a
reaction solution withdrawn from the above reaction step,
or a residue after distilling water and/or at least a
part of the alkylene derivative as the desired product,
from such a reaction solution.
8. The process as claimed in claim 6, wherein the
mixture comprising a quaternary phosphonium chloride and
a quaternary phosphonium iodide and/or bromide, is an
aqueous solution obtained by mixing the reaction solution
withdrawn from the above reaction step or the residue
after distilling off water and/or at least a part of the
alkylene derivative as the desired product from such a
reaction solution, with water to let the catalyst
precipitate as solid, and separating the precipitated
catalyst.
9. The process as claimed in any one of the Claims 6 to
8, wherein the precipitated quaternary phosphonium iodide
and/or bromide is recovered and recycled to the above
reaction step.
10. The process as claimed in any of the preceding
claims 1 to 5, wherein the catalyst is regenerated by
adding an iodide and/or a bromide to a mixture
comprising a quaternary phosphonium chloride and a
quaternary phosphonium iodide and/or bromide, obtained
from the reaction step of reacting an alkylene oxide
containing a chlorinated compound as an impurity, with
water in the presence of carbon dioxide by means of a
quaternary phosphonium iodide and/or bromide as a
catalyst, to let chlorine derived from the quaternary
phosphonium chloride precipitate as an inorganic chloride
in an organic solvent, thereby to recover the quaternary
phosphonium iodide and/or bromide.
11. The process as claimed in Claim 10, wherein the
mixture comprising a quaternary phosphonium chloride and
a quaternary phosphonium iodide and/or bromide, is any
one of the following (a) to (c) :
(a) A liquid or solid obtained by adding water to the
reaction solution withdrawn from the above reaction step
to precipitate the catalyst and dehydrating an aqueous
solution after separating the precipitated catalyst,
(b) A liquid or solid obtained by adding water to a
residue after distilling off water and/or at least a part
of the alkylene derivative as the desired product from
the reaction solution withdrawn from the reaction step,
to precipitate the catalyst as solid, and dehydrating an
aqueous solution after separating the precipitated
catalyst,
(c) A liquid obtained by dissolving the liquid or
solid obtained by the dehydration in (a) or (b) , in an
organic solvent.
12. The process as claimed in Claim 10, wherein the
mixture comprising a quaternary phosphonium chloride and
a quaternary phosphonium iodide and/or bromide, is either
one of the following (d) and (e):
(d) A liquid obtained by diluting the reaction
solution withdrawn from the reaction step, with an
organic solvent,
(e) A residue after distilling off water and/or at
least a part of the alkylene derivative as the desired
product from the reaction solution withdrawn from the
above reaction step, or a liquid obtained by dissolving
such a residue in an organic solvent.
13. The process as claimed in any one of Claims 10-12,
wherein the recovered quaternary phosphonium iodide
and/or bromide is recycled to the above reaction step.
A process for producing an alkylene derivative such
as ethylene glycol or ethylene carbonate wherein ethylene
oxide is reacted with water or carbon dioxide in the
presence of carbon dioxide by means of a quaternary
phosphonium iodide or bromide catalyst, characterized in
that the quaternary phosphonium iodide or bromide
catalyst is recovered efficiently from the reaction
system and is recycled for use, and in that quaternary
phosphonium chloride formed in the reaction system is
converted efficiently to a quaternary phosphonium iodide
or bromide, and the resultant iodide or bromide is
recovered and recycled to the reaction system for use.

Documents:

01499-kolnp-2005-abstract.pdf

01499-kolnp-2005-claims.pdf

01499-kolnp-2005-description complete.pdf

01499-kolnp-2005-form 1.pdf

01499-kolnp-2005-form 3.pdf

01499-kolnp-2005-form 5.pdf

01499-kolnp-2005-international publication.pdf

1499-kolnp-2005-granted-abstract.pdf

1499-kolnp-2005-granted-assignment.pdf

1499-kolnp-2005-granted-claims.pdf

1499-kolnp-2005-granted-correspondence.pdf

1499-kolnp-2005-granted-description (complete).pdf

1499-kolnp-2005-granted-examination report.pdf

1499-kolnp-2005-granted-form 1.pdf

1499-kolnp-2005-granted-form 18.pdf

1499-kolnp-2005-granted-form 3.pdf

1499-kolnp-2005-granted-form 5.pdf

1499-kolnp-2005-granted-gpa.pdf

1499-kolnp-2005-granted-letter patent.pdf

1499-kolnp-2005-granted-reply to examination report.pdf

1499-kolnp-2005-granted-specification.pdf


Patent Number 216056
Indian Patent Application Number 01499/KOLNP/2005
PG Journal Number 10/2008
Publication Date 07-Mar-2008
Grant Date 06-Mar-2008
Date of Filing 29-Jul-2005
Name of Patentee MITSUBISHI CHEMICAL CORPORATION
Applicant Address 33-8, SHIBA 5-CHOME, MINATO-KU, TOKYO 108-0014, JAPAN.
Inventors:
# Inventor's Name Inventor's Address
1 YAMAGISHI MASAHIKO C/O MITSUBISHI CHEMICAL CORPORATION, 1, TOHO-CHO, YOKKAI CHI-SHI, MIE 5100848, JAPAN.
2 KAWABE KAZUKI C/O MITSUBISHI CHEMICAL CORPORATION, 1, TOHO-CHO, YOKKAI CHI-SHI, MIE 5100848, JAPAN.
PCT International Classification Number C07C 29/10
PCT International Application Number PCT/JP2004/001322
PCT International Filing date 2004-02-09
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 2003-078178 2003-03-20 Japan
2 2003-031391 2003-02-07 Japan
3 2003-088281 2003-03-27 Japan