Method to obtain methylene malonate via bis(hydroxymethyl) malonate pathway
First Claim
1. A plant for producing a methylene malonate monomer comprising:
- at least one diol production unit comprising a diol reactor apparatus capable of reacting a dialkyl malonate ester and a source of formaldehyde in the presence of a catalyst,at least one diol purification unit,at least one monomer production unit comprising a plurality of catalyst columns and at least one heating apparatus for maintaining the temperature of the plurality of catalyst columns, and at least one monomer purification unit comprising a condensation apparatus, a fractional distillation apparatus, or both;
wherein the at least one diol production unit is in communication with the at least one diol purification unit, and the at least one diol purification unit is in communication with the at least one monomer production unit, and the at least one monomer production unit is in communication with the at least one monomer purification unit.
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Abstract
Method to obtain methylene malonate and related monomers following a bis(hydroxymethyl) malonate pathway. A bis(hydroxymethyl) malonate intermediary is subsequently reacted (i.e., subjected to thermolysis) to provide a methylene malonate monomer species. A source of formaldehyde (e.g., formalin) is provided in the presence of a basic catalyst (e.g., calcium hydroxide), to which a malonate (e.g., diethyl malonate) is added under suitable reaction conditions to obtain the desired intermediary (e.g., dialkyl bis(hydroxymethyl) malonate). The intermediary is reacted (i.e., subjected to thermolysis) under suitable conditions in the presence of a suitable catalyst (e.g., a zeolite) to obtain a methylene malonate monomer. In an exemplary embodiment, the thermolysis reaction includes the addition of the bis(hydroxymethyl) malonate intermediary onto a heated catalyst. The reaction product is collected and purified. The disclosed methods may be performed in a continuous operation. Discrete steps may be performed by using modular units within a plant.
207 Citations
16 Claims
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1. A plant for producing a methylene malonate monomer comprising:
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at least one diol production unit comprising a diol reactor apparatus capable of reacting a dialkyl malonate ester and a source of formaldehyde in the presence of a catalyst, at least one diol purification unit, at least one monomer production unit comprising a plurality of catalyst columns and at least one heating apparatus for maintaining the temperature of the plurality of catalyst columns, and at least one monomer purification unit comprising a condensation apparatus, a fractional distillation apparatus, or both; wherein the at least one diol production unit is in communication with the at least one diol purification unit, and the at least one diol purification unit is in communication with the at least one monomer production unit, and the at least one monomer production unit is in communication with the at least one monomer purification unit. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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Specification