PROCESS FOR PRODUCTION OF ACRYLATES FROM EPOXIDES
First Claim
1. A method for the synthesis of acrylic acid comprising the steps of:
- providing a gaseous feedstock stream comprising ethylene oxide and carbon monoxide;
directing the feedstock stream to a first reaction zone where it is contacted with a metal carbonyl compound and where at least a portion of the ethylene oxide is converted to a carbonylation product stream comprising beta propiolactone;
directing the carbonylation product stream to a second reaction zone where it is contacted with a catalyst, which catalyzes the conversion of beta propiolactone to acrylic acid;
withdrawing an acrylic acid product stream from the second reaction zone; and
isolating acrylic acid from the product stream.
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Abstract
In one aspect, the present invention encompasses integrated processes for the conversion of epoxides to acrylic acid derivatives and polyesters. In certain embodiments, the methods of the present invention comprise the steps of: providing a feedstock stream comprising an epoxide and carbon monoxide; contacting the feedstock stream with a metal carbonyl in a first reaction zone to effect conversion of at least a portion of the provided epoxide to a beta lactone; directing the effluent from the first reaction zone to a second reaction zone where the beta lactone is subjected to conditions that convert it to a compound selected from the group consisting of: an alpha beta unsaturated acid, an alpha beta unsaturated ester, an alpha beta unsaturated amide, and an optionally substituted polypropiolactone polymer; and isolating a final product comprising the alpha-beta unsaturated carboxylic acid, the alpha-beta unsaturated ester, the alpha-beta unsaturated amide or the polypropiolactone.
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Citations
41 Claims
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1. A method for the synthesis of acrylic acid comprising the steps of:
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providing a gaseous feedstock stream comprising ethylene oxide and carbon monoxide; directing the feedstock stream to a first reaction zone where it is contacted with a metal carbonyl compound and where at least a portion of the ethylene oxide is converted to a carbonylation product stream comprising beta propiolactone; directing the carbonylation product stream to a second reaction zone where it is contacted with a catalyst, which catalyzes the conversion of beta propiolactone to acrylic acid; withdrawing an acrylic acid product stream from the second reaction zone; and isolating acrylic acid from the product stream. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29)
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30. A method for the synthesis of acrylate esters comprising the steps of:
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providing a gaseous feedstock stream comprising ethylene oxide and carbon monoxide; directing the feedstock stream to a first reaction zone where it is contacted with a metal carbonyl compound and where at least a portion of the ethylene oxide is converted to a product stream comprising beta propiolactone; adding a C1-8 alcohol to the product stream comprising beta propiolactone; directing the product stream comprising beta propiolactone and the C1-8 alcohol to a second reaction zone where it is contacted with a catalyst which catalyzes the conversion of beta propiolactone and the C1-8 alcohol to the corresponding acrylic acid ester; withdrawing an acrylic acid ester product stream from the second reaction zone; and isolating an acrylate ester from the product stream. - View Dependent Claims (31, 32, 33, 36, 37, 38, 39)
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34. A method for the synthesis of polypropiolactone comprising the steps of:
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providing a gaseous feedstock stream comprising ethylene oxide and carbon monoxide; directing the feedstock stream to a first reaction zone where it is contacted with a metal carbonyl compound and at least a portion of the ethylene oxide is converted to a product stream comprising beta propiolactone; directing the product stream comprising beta propiolactone to a polymerization reactor containing a suitable solvent and a polymerization catalyst; withdrawing a polypropiolactone product stream from the polymerization reactor; and isolating polypropiolactone from the product stream.
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35. A method for the synthesis of poly-3-hydroxybutyrate comprising the steps of:
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providing a gaseous feedstock stream comprising enantio-enriched propylene oxide and carbon monoxide; directing the feedstock stream to a first reaction zone where it is contacted with a metal carbonyl compound and at least a portion of the propylene oxide is converted to a product stream comprising beta butyrolactone; directing the product stream comprising beta butyrolactone to a polymerization reactor containing a solvent and a polymerization catalyst; withdrawing a poly-3-hydroxybutyrate product stream from the polymerization reactor; and isolating poly-3-hydroxybutyrate from the product stream.
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40. A method for the synthesis of acrylic acid comprising the steps of:
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providing an ethylene stream; contacting the ethylene stream with oxygen in the presence of a catalyst to provide an ethylene oxide stream; adding carbon monoxide to the ethylene oxide stream to provide a feedstock stream; directing the feedstock stream to a first reaction zone where it is contacted with a metal carbonyl compound and where at least a portion of the ethylene oxide is converted to a carbonylation product stream comprising beta propiolactone; directing the carbonylation product stream to a second reaction zone where it is contacted with a catalyst, which catalyzes the conversion of beta propiolactone to acrylic acid; withdrawing an acrylic acid product stream from the second reaction zone; and isolating acrylic acid from the product stream. - View Dependent Claims (41)
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Specification