Processes Using Multifunctional Catalysts

• US 20190076834A1
• Filed: 08/08/2018
• Published: 03/14/2019
• Est. Priority Date: 09/11/2017
• Status: Abandoned Application

• Current Assignee: Novomer, Inc (Danimer Scientific, Inc.)
• Original Assignee: Novomer, Inc (Danimer Scientific, Inc.)
• Inventors: Sookraj, Sadesh H.
• Application Number:
  US16/058,716
• Publication Number:
  US 20190076834A1
• Time in Patent Office: Days
• CPC Class Codes: B01J 21/04 Alumina
• CPC Class Codes: B01J 2231/10 Polymerisation reactions involving at least dual use catalysts, e.g. for both oligomerisation and polymerisation
• CPC Class Codes: B01J 2231/14 Other (co) polymerisation, e.g. of lactides, epoxides "ROMP", i.e. ring-opening metathesis polymerisation B01J2231/54
• CPC Class Codes: B01J 2231/321 Hydroformylation, metalformylation, carbonylation or hydroaminomethylation
• CPC Class Codes: B01J 23/28 Molybdenum
• CPC Class Codes: B01J 2531/0205 Bi- or polynuclear complexes, i.e. comprising two or more metal coordination centres, without metal-metal bonds, e.g. Cp(Lx)Zr-imidazole-Zr(Lx)Cp
• CPC Class Codes: B01J 2531/025 Ligands with a porphyrin ring system or analogues thereof, e.g. phthalocyanines, corroles
• CPC Class Codes: B01J 2531/0252 Salen ligands or analogues, e.g. derived from ethylenediamine and salicylaldehyde
• CPC Class Codes: B01J 2531/22 Magnesium
• CPC Class Codes: B01J 2531/26 Zinc
• CPC Class Codes: B01J 2531/31 Aluminium
• CPC Class Codes: B01J 2531/32 Gallium
• CPC Class Codes: B01J 2531/33 Indium
• CPC Class Codes: B01J 2531/38 Lanthanides other than lanthanum
• CPC Class Codes: B01J 2531/42 Tin
• CPC Class Codes: B01J 2531/46 Titanium
• CPC Class Codes: B01J 2531/48 Zirconium
• CPC Class Codes: B01J 2531/62 Chromium
• CPC Class Codes: B01J 2531/64 Molybdenum
• CPC Class Codes: B01J 2531/66 Tungsten
• CPC Class Codes: B01J 2531/821 : Ruthenium
• CPC Class Codes: B01J 2531/822 : Rhodium
• CPC Class Codes: B01J 2531/824 : Palladium
• CPC Class Codes: B01J 2531/827 : Iridium
• CPC Class Codes: B01J 2531/845 : Cobalt
• CPC Class Codes: B01J 2540/12 : Carboxylic acid groups
• CPC Class Codes: B01J 2540/62 : Activating groups
• CPC Class Codes: B01J 29/084 : Y-type faujasite
• CPC Class Codes: B01J 31/1616 : Coordination complexes, e.g. organometallic complexes, immobilised on an inorganic support, e.g. ship-in-a-bottle type catalysts catalysts comprising molecular sieves B01J29/00
• CPC Class Codes: B01J 31/1815 : with more than one complexing nitrogen atom, e.g. bipyridyl, 2-aminopyridine
• CPC Class Codes: B01J 31/183 : with more than one complexing nitrogen atom, e.g. phenanthroline
• CPC Class Codes: B01J 31/20 : Carbonyls
• CPC Class Codes: B01J 31/22 : Organic complexes
• CPC Class Codes: B01J 31/2243 : At least one oxygen and one nitrogen atom present as complexing atoms in an at least bidentate or bridging ligand
• CPC Class Codes: B01J 35/19 : Catalysts containing parts with different compositions
• CPC Class Codes: C07C 253/22 : by reaction of ammonia with carboxylic acids with replacement of carboxyl groups by cyano groups
• CPC Class Codes: C07C 255/08 : Acrylonitrile; Methacrylonitrile
• CPC Class Codes: C07D 303/04 : containing only hydrogen and carbon atoms in addition to the ring oxygen atoms
• CPC Class Codes: C07D 487/22 : in which the condensed system contains four or more hetero rings
• CPC Class Codes: C08G 63/82 : characterised by the catalyst used
• CPC Class Codes: C08G 63/823 : for the preparation of polylactones or polylactides
• CPC Class Codes: Y02P 20/50 : Improvements relating to the production of bulk chemicals
• CPC Class Codes: Y02P 20/52 : using catalysts, e.g. selective catalysts

Abstract

The present invention is directed to catalysts and processes for catalyzing two or more chemical reactions with a multifunctional catalyst in a reaction vessel. The processes include steps for introducing one or more reagents to a reaction vessel containing a multifunctional catalyst; contacting the one or more reagents with a first portion of the multifunctional catalyst to produce an intermediate; contacting the intermediate with a second portion of the multifunctional catalyst to produce a product; and removing the product from the reaction vessel. In certain embodiments, the multifunctional catalyst may have a first portion with carbonylation functionality for catalyzing the production of a beta-lactone intermediate from an epoxide reagent and a carbon monoxide reagent. In certain embodiments, the multifunctional catalyst may have a second portion with a functionality suitable for polymerization, co-polymerization, and/or modification of a beta-lactone intermediate. In preferred embodiments, the first portion and second portion are bonded to a heterogenous support.

Claims

1. A multifunctional catalyst, comprising:

a substrate;

a multifunctional catalyst supported on the substrate,

wherein a first portion of the multifunctional catalyst has carbonylation functionality with at least one epoxide reagent and at least one carbon monoxide reagent to produce one or more intermediates; and

wherein a second portion of the multifunctional catalyst has polymerization functionality to polymerize one or more intermediates to form a polymer.

2. The multifunctional catalyst of claim 1, wherein the carbonylation functionality of the multifunctional catalyst includes a carbonylation catalyst wherein the carbonylation catalyst comprises a metal carbonyl-Lewis acid catalyst.

3. The multifunctional catalyst of claim 1, wherein the substrate comprises a heterogeneous support.

4. The multifunctional catalyst of claim 1, wherein the second portion of the multifunctional catalyst includes a moiety comprising an ionic initiator.

5. The multifunctional catalyst of claim 4, wherein the carbonylation functionality of the multifunctional catalyst and the ionic initiator form a mixture on the substrate.

6. The multifunctional catalyst of claim 4, wherein the substrate has a first zone and a second zone downstream of the first zone, wherein at least about 90 weight percent of the carbonylation functionality of the multifunctional catalyst is located in the first zone and at least about 90 weight percent of the polymerization functionality is located in the second zone.

7. The multifunctional catalyst of claim 6, wherein a volume ratio between the first and second zones is from about 1:

10 to about 10;

1.

8. The multifunctional catalyst of claim 3, wherein the heterogeneous support is selected from the group comprising silica, magnesia, alumina, titania, silica/alumina, pyrogenic silica, high purity silica, zirconia, zincate, carbon, zeolites and mixtures thereof.

9. The multifunctional catalyst of claim 1, wherein the at least one epoxide reagent comprises an ethylene oxide reagent.

10. The multifunctional catalyst of claim 1, wherein the one or more intermediates comprises a beta-lactone intermediate.

11. The multifunctional catalyst of claim 1, wherein the one or more intermediates comprises a succinic anhydride intermediate.

12. A multifunctional catalyst, comprising:

a substrate;

a catalyst supported on the substrate, wherein the catalyst has a first portion of carbonylation functionality designed to catalyze at least one epoxide reagent and at least one carbon monoxide reagent to produce one or more first intermediates; and

a second portion of the catalyst designed to convert the one or more first intermediates to a product or a second intermediate.

13. The multifunctional catalyst of claim 12 further comprising a third portion of polymerization functionality designed to polymerize acrylic nitrile.

14. The multifunctional catalyst of claim 13, wherein the third portion comprises a metal complex bonded to the substrate.

15. The multifunctional catalyst of claim 14, wherein the metal complex comprises a metal chosen from Ti, Cr, Mn, Fe, Ru, Co, Rh, Sm, Re, Ir, Zr, Ni, Pd, Co, Zn, Mg, Al, Ga, Sn, In, Mo, W.

16. The multifunctional catalyst of claim 12, wherein the second portion of the catalyst includes a moiety comprising a dehydration agent.

17. The multifunctional catalyst of claim 16, wherein the dehydration agent is chosen from the group consisting of a phosphorous pentoxide, an organophosphorous compound, a carbodiimide compound, a triazine compound, an organosilicon compound, a transition metal complex, an aluminum complex, and a mixture thereof.

18. The multifunctional catalyst of claim 12, wherein the first portion of the carbonylation functionality includes a moiety comprising a carbonylation catalyst wherein the carboxylation catalyst comprises a metal carbonyl-Lewis acid catalyst.

19. The multifunctional catalyst of claim 12, wherein the substrate comprises a heterogeneous support.

20. The multifunctional catalyst of claim 18, wherein the second portion of the multifunctional catalyst includes a moiety comprising a polymerization initiator.

21. The multifunctional catalyst of claim 20, wherein the polymerization initiator comprises an ionic initiator.

22. The multifunctional catalyst of claim 20, wherein the carbonylation catalyst and the polymerization initiator form a mixture on the substrate.

23. The multifunctional catalyst of claim 20, wherein the substrate has a first zone and a second zone downstream of the first zone, wherein at least 90 weight percent of the carbonylation catalyst is located in the first zone and at least about 90 weight percent of the polymerization initiator is located in the second zone.

24. The multifunctional catalyst of claim 23, wherein a volume ratio between the first and second zones is from about 1:

10 to about 10;

1.

25. The multifunctional catalyst of claim 19, wherein the heterogeneous support is selected from the group comprising silica, magnesia, alumina, titania, silica/alumina, pyrogenic silica, high purity silica, zirconia, zincate, carbon, zeolites and mixtures thereof.

26. The multifunctional catalyst of claim 12, wherein the at least one epoxide reagent includes an ethylene oxide reagent.

27. The multifunctional catalyst of claim 12, wherein the one or more first intermediates includes a beta-lactone intermediate.

28. The multifunctional catalyst of claim 12, wherein the one or more first intermediates includes a succinic anhydride intermediate.

29. The multifunctional catalyst of claim 12, wherein the second intermediate comprises acrylic acid.