PROCESS FOR PRODUCTION OF ACRYLIC ACID

• US 20180354881A1
• Filed: 08/21/2018
• Published: 12/13/2018
• Est. Priority Date: 02/13/2015
• Status: Active Grant

• Current Assignee: Novomer, Inc (Danimer Scientific, Inc.)
• Original Assignee: Novomer, Inc (Danimer Scientific, Inc.)
• Inventors: FARMER, Jay J., GALEBACH, Peter, SHERRY, Kyle, SOOKRAJ, Sadesh H.
• Granted Patent: US 10,626,073 B2
• Time in Patent Office: Days
• CPC Class Codes: C07C 51/09 from carboxylic acid esters or lactones
• CPC Class Codes: C07C 57/04 Acrylic acid; Methacrylic acid
• CPC Class Codes: Y02P 20/10 Process efficiency

Abstract

Provided are integrated processes for the conversion of beta propiolactone to acrylic acid. Systems for the production of acrylic acid are also provided.

Claims

1-3. -3. (canceled)

4. A method for producing acrylic acid, comprising:

(a) providing a feedstock stream comprising beta propiolactone;

(b) directing the feedstock stream to a first reaction zone;

(c) contacting the feedstock stream with a polymerization catalyst;

(d) polymerizing at least a portion of the beta propiolactone to a poly(propiolactone) product stream, wherein the first reaction zone is maintained at a temperature to promote formation of poly(propiolactone);

(e) directing the poly(propiolactone) product stream to a second reaction zone, wherein the second reaction zone is maintained at a temperature at or above the pyrolysis temperature of poly(propiolactone) such that the thermal decomposition of poly(propiolactone) produces acrylic acid; and

(f) withdrawing an acrylic acid product stream from the second reaction zone.

5. The method of claim 4, wherein the first reaction zone and second reaction zone are in an extruder reactor.

6. The method of claim 5, wherein the extruder reactor provides a temperature gradient between the first reaction zone and second reaction zone.

7. The method of claim 5, wherein the extruder reactor has a terminal temperature at or above the pyrolysis temperature of poly(propiolactone).

8. The method of claim 4, further comprising capturing heat generated from the first reaction zone, and directing the heat to other processes.

9. The method of claim 8, wherein the heat is directed to the second reaction zone.

10-18. -18. (canceled)

19. A system for converting beta propiolactone to acrylic acid, comprising:

(a) a beta propiolactone source;

(b) a catalyst source; and

(c) a reactor comprising;

at least one inlet to receive beta propiolactone from the beta propiolactone source and a polymerization catalyst from the catalyst source, wherein the polymerization catalyst comprises a carboxylate salt, and

an outlet to output an acrylic acid stream,

wherein the reactor is configured to (i) polymerize the beta propiolactone to produce poly(propiolactone) in the presence of the polymerization catalyst, at or above the pyrolysis temperature of poly(propiolactone), and (ii) concurrently thermally decompose the poly(propiolactone) to produce acrylic acid in situ, and wherein the acrylic acid produced in situ maintains the polymerization of beta propiolactone to poly(propiolactone).

21. The system of claim 19, wherein the carboxylate salt is:

a salt of a compound of formula;

22. The system of claim 19, wherein the carboxylate salt is:

a salt of a compound of formula;

20. A system for converting beta propiolactone to acrylic acid, comprising:

(a) a reaction zone comprising beta propiolactone and a cationic solid catalyst comprising a carboxylate salt,

wherein the reaction zone is configured to (i) polymerize the beta propiolactone to poly(propiolactone), at or above the pyrolysis temperature of poly(propiolactone), (ii) concurrently thermally decompose the poly(propiolactone) to acrylic acid, and (iii) output the acrylic acid; and

(b) a return loop configured to return a portion of the acrylic acid to the reaction zone to maintain polymerization of the beta propiolactone to poly(propiolactone) in the reaction zone.

23. The system of claim 20, wherein the carboxylate salt is:

a salt of a compound of formula;

24. The system of claim 20, wherein the carboxylate salt is:

a salt of a compound of formula;