Continuous carbonylation processes
First Claim
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1. A process for continuous carbonylation of an epoxide or lactone feedstock, comprising:
- continuously reacting an epoxide or lactone feedstock with carbon monoxide in the presence of a carbonylation catalyst in a carbonylation reaction vessel,wherein the carbonylation catalyst comprises a Lewis acid and a metal carbonyl, andwherein at a start time of the process, the carbonylation reaction vessel contains an initial concentration of the Lewis acid and an initial concentration of the metal carbonyl; and
adding to the carbonylation reaction vessel, at a time after the start time of the process, a catalyst replacement component which is different from the carbonylation catalyst,wherein the catalyst replacement component comprises the Lewis acid, a precursor to the Lewis acid, the metal carbonyl, and a precursor to the metal carbonyl,wherein the precursor to the metal carbonyl is a neutral metal carbonyl complex, andwherein the precursor to the Lewis acid is;
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Abstract
Provided are processes for monitoring and maintaining continuous carbonylation of epoxides or lactones. Processes include measuring parameters affecting the rate of the carbonylation reaction and adding supplemental replacement catalyst replacement components to maintain a constant rate of carbonylation.
132 Citations
31 Claims
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1. A process for continuous carbonylation of an epoxide or lactone feedstock, comprising:
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continuously reacting an epoxide or lactone feedstock with carbon monoxide in the presence of a carbonylation catalyst in a carbonylation reaction vessel, wherein the carbonylation catalyst comprises a Lewis acid and a metal carbonyl, and wherein at a start time of the process, the carbonylation reaction vessel contains an initial concentration of the Lewis acid and an initial concentration of the metal carbonyl; and adding to the carbonylation reaction vessel, at a time after the start time of the process, a catalyst replacement component which is different from the carbonylation catalyst, wherein the catalyst replacement component comprises the Lewis acid, a precursor to the Lewis acid, the metal carbonyl, and a precursor to the metal carbonyl, wherein the precursor to the metal carbonyl is a neutral metal carbonyl complex, and wherein the precursor to the Lewis acid is; - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 29)
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14. A process for continuous carbonylation of an epoxide or lactone feedstock, comprising:
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continuously reacting an epoxide or lactone feedstock with carbon monoxide in the presence of a catalyst in a carbonylation reaction vessel, wherein the catalyst comprises a Lewis acid and a metal carbonyl; and continuously or intermittently introducing to the carbonylation reaction vessel a catalyst replacement component which is different from the carbonylation catalyst, wherein the catalyst replacement component comprises a species selected from the group consisting of the Lewis acid, a precursor to the Lewis acid, the metal carbonyl, and a precursor to the metal carbonyl, wherein the precursor to the metal carbonyl is a neutral metal carbonyl complex, and wherein the precursor to the Lewis acid is; - View Dependent Claims (15, 30)
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28. A process for continuous carbonylation of an epoxide or lactone feedstock, comprising:
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continuously reacting an epoxide or lactone feedstock with carbon monoxide in the presence of a carbonylation catalyst in a carbonylation reaction vessel to produce a carbonylation product stream, wherein the carbonylation catalyst comprises a Lewis acid and a metal carbonyl, wherein the carbonylation product stream comprises at least one carbonylation product, at least some of the Lewis acid and at least some of the metal carbonyl, and wherein at a start time of the process, the carbonylation reaction vessel contains an initial concentration of the Lewis acid and an initial concentration of the metal carbonyl; separating the carbonylation product stream from the carbonylation reaction vessel by a nanofiltration membrane, wherein the nanofiltration membrane retains at least a portion of the Lewis acid and at least a portion of the metal carbonyl, and permeates at least one carbonylation product; and adding to the carbonylation reaction vessel, at a time after the start time of the process, a catalyst replacement component which is different from the carbonylation catalyst, wherein the catalyst replacement component is added at a rate or time of addition based on a rate of depletion of one or both of the Lewis acid and the metal carbonyl in the carbonylation reaction vessel, wherein the catalyst replacement component comprises the Lewis acid, a precursor to the Lewis acid, the metal carbonyl, and a precursor to the metal carbonyl, wherein the precursor to the metal carbonyl is a neutral metal carbonyl complex, and wherein the precursor to the Lewis acid is; - View Dependent Claims (31)
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Specification