PROCESSSES USING MULTIFUNCTIONAL CATALYSTS

• US 20190076835A1
• Filed: 09/11/2017
• 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:
  US15/701,410
• Publication Number:
  US 20190076835A1
• Time in Patent Office: Days
• CPC Class Codes: B01J 21/04 Alumina
• CPC Class Codes: B01J 21/08 Silica
• CPC Class Codes: B01J 2231/127 Anionic (co)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 2231/30 Addition reactions at carbon centres, i.e. to either C-C or C-X multiple bonds
• CPC Class Codes: B01J 2231/321 Hydroformylation, metalformylation, carbonylation or hydroaminomethylation
• CPC Class Codes: B01J 2231/48 Ring-opening reactions
• CPC Class Codes: B01J 23/18 Arsenic, antimony or bismuth
• CPC Class Codes: B01J 23/26 Chromium
• CPC Class Codes: B01J 23/28 Molybdenum
• CPC Class Codes: B01J 23/31 combined with bismuth
• CPC Class Codes: B01J 23/8432 Arsenic
• CPC Class Codes: B01J 2531/0213 Complexes without C-metal linkages
• 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 2531/31 Aluminium
• CPC Class Codes: B01J 2531/845 Cobalt
• CPC Class Codes: B01J 2540/20 Non-coordinating groups comprising halogens
• CPC Class Codes: B01J 29/146 Y-type faujasite
• CPC Class Codes: B01J 29/46 Iron group metals or copper
• CPC Class Codes: B01J 31/0202 : Alcohols or phenols
• CPC Class Codes: B01J 31/0215 : Sulfur-containing compounds
• CPC Class Codes: B01J 31/0218 : Sulfides
• CPC Class Codes: B01J 31/0229 : also containing elements or functional groups covered by B01J31/0201 - B01J31/0214
• CPC Class Codes: B01J 31/0244 : with nitrogen contained as ring member in aromatic compounds or moieties, e.g. pyridine
• CPC Class Codes: B01J 31/0265 : Phosphazenes, oligomers thereof or the corresponding phosphazenium salts polyphosphazenes per se C07F9/067
• CPC Class Codes: B01J 31/0271 : also containing elements or functional groups covered by B01J31/0201 - B01J31/0231
• 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 31/2213 : At least two complexing oxygen atoms present in an at least bidentate or bridging ligand
• 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 253/00 : Preparation of carboxylic acid nitriles of cyanogen or compounds thereof C01C3/00
• CPC Class Codes: C07C 255/08 : Acrylonitrile; Methacrylonitrile
• 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: C07C 67/37 : by reaction of ethers with carbon monoxide
• CPC Class Codes: C07D 305/12 : Beta-lactones
• CPC Class Codes: C07D 307/60 : Two oxygen atoms, e.g. succinic anhydride
• CPC Class Codes: C08G 63/08 : Lactones or lactides
• CPC Class Codes: C08G 63/16 : Dicarboxylic acids and dihydroxy compounds
• 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 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 process for producing a product with a multifunctional catalyst comprising:

a. introducing at least an epoxide reagent and a carbon monoxide reagent to a reaction vessel containing a multifunctional catalyst;

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

c. contacting a second portion of the multifunctional catalyst with the one or more intermediates to produce a product;

d. removing the product from the reaction vessel.

2. The process from claim 1, wherein the at least one epoxide reagent includes an ethylene oxide reagent.

3. The process from claim 1, wherein the one or more intermediates includes a beta-lactone intermediate.

4. The process from claim 1, wherein the one or more intermediates includes a succinic anhydride intermediate.

5. The process from claim 1, wherein the first portion of the multifunctional catalyst comprises a metal carbonyl-Lewis acid.

6. The process from claim 1, wherein the product includes succinic anhydride.

7. The process from claim 1, wherein the second portion of the multifunctional catalyst has a ring-opening polymerization functionality.

8. The process from claim 1, wherein the second portion of the multifunctional catalyst includes a polymerization initiator.

9. The process from claim 1, wherein the second portion of the multifunctional catalyst has modification functionality useful for modification of a beta-lactone intermediate.

10. The process from claim 9, wherein the second portion comprises Cr2O3/Al2O3, KNaMoP/Al2O3, NaMo/Al2O3, AsFeO, SbSnO, FeBiPO, BiMoO, MoO3, MoO3/SiO2, and/or NaMo/Al2O3

11. The process from claim 1, wherein the product is a polylactone homopolymer comprising beta-propiolactone monomers.

12. The process from claim 1, wherein the product is a polylactone heteropolymer comprising a beta-propiolactone monomer and one or more other beta-lactone monomers.

13. The process from claim 1, wherein the product is a co-polymer comprising a beta-propiolactone monomer and a succinic anhydride monomer.

14. The process from claim 1, wherein the multifunctional catalyst comprises a heterogenous support.

15. The process from claim 1, wherein the multifunctional catalyst comprises a metal carbonyl-Lewis acid and a heterogenous support.

16. The process from claim 1, wherein the multifunctional catalyst comprises metal carbonyl-Lewis acid, and ionic initiator, and a heterogenous support.

17. The process form claim 5, wherein the process further includes:

a. introducing an ammonia reagent to the reaction vessel; and

b. contacting the beta-lactone intermediate and the ammonia reagent with the second portion of the multifunctional catalyst to produce an acrylonitrile product, wherein the second portion of the multifunctional catalyst includes a moiety comprising a dehydration agent chosen from the following;

a phosphorous pentoxide, an organophosphorous compound, a carbodiimide compound, a triazine compound, an organosilicon compound, a transition metal complex, an aluminum complex, or a mixture thereof.

18. The process form claim 17, wherein the process further comprises a step for contacting the acrylonitrile product with a third portion of the multifunctional catalyst to produce polyacrylonitrile, wherein the third portion comprising a metal complex bonded to a heterogenous support.

19. The process from claim 18, 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.