Method for producing epoxides
First Claim
1. A method for producing epoxides comprising the steps:
- (a) forming a low chlorides aqueous hypochlorous acid solution;
(b) contacting the low chlorides aqueous hypochlorous acid solution with at least one unsaturated organic compound to form an aqueous organic product comprising at least olefin chlorohydrin, wherein the unsaturated organic compound contains from 2 to about 10 carbon atoms and is selected from the group consisting of substituted and unsubstituted olefins and cyclic olefins, the substituted olefins having substituents selected from the group consisting of an alkyl radical, a phenyl radical, and an alkylphenyl radical, each radical being independently either unsubstituted or substituted;
(c) contacting at least the olefin chlorohydrin with an aqueous alkali metal hydroxide to form an aqueous salt solution product containing at least epoxide; and
(d) isolating the epoxide from the aqueous salt solution;
wherein water is recovered from the product of at least Step (b) and recycled into Step (a) for use in forming the low chlorides aqueous hypochlorous acid solution.
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Abstract
Described herein is a method for producing epoxides which is continuous, inhibits formation of chlorinated byproducts, and eliminates or substantially reduces waste water discharge. The method includes:
(a) forming a low chlorides aqueous hypochlorous acid solution;
(b) contacting the low chlorides aqueous hypochlorous acid solution with at least one unsaturated organic compound to form an aqueous organic product comprising at least olefin chlorohydrin;
(c) contacting at least the olefin chlorohydrin with an aqueous alkali metal hydroxide to form an aqueous salt solution product containing at least epoxide; and
(d) isolating the epoxide from the aqueous salt solution;
wherein water is recovered from the product of at least Step (b) and recycled into Step (a) for use in forming the low chlorides aqueous hypochlorous acid solution. In this process, not only is the water internally recycled after Step (b), but a concentrated brine solution is generated in both Steps (a) and (d) which is useful in other processes such as electrochemical production of chlorine and caustic. The chlorine and caustic, in turn, may then be recycled back to the method of this invention.
139 Citations
32 Claims
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1. A method for producing epoxides comprising the steps:
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(a) forming a low chlorides aqueous hypochlorous acid solution; (b) contacting the low chlorides aqueous hypochlorous acid solution with at least one unsaturated organic compound to form an aqueous organic product comprising at least olefin chlorohydrin, wherein the unsaturated organic compound contains from 2 to about 10 carbon atoms and is selected from the group consisting of substituted and unsubstituted olefins and cyclic olefins, the substituted olefins having substituents selected from the group consisting of an alkyl radical, a phenyl radical, and an alkylphenyl radical, each radical being independently either unsubstituted or substituted; (c) contacting at least the olefin chlorohydrin with an aqueous alkali metal hydroxide to form an aqueous salt solution product containing at least epoxide; and (d) isolating the epoxide from the aqueous salt solution; wherein water is recovered from the product of at least Step (b) and recycled into Step (a) for use in forming the low chlorides aqueous hypochlorous acid solution. - View Dependent Claims (2, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32)
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- 3. The method of claim I wherein the water is recovered from the product of Step (b) by extracting the organic product from the water with an organic solvent.
Specification