Process for production of acrylates from epoxides
First Claim
1. A method for producing acrylic acid, comprising:
- contacting ethylene oxide with carbon monoxide in the presence of a metal carbonyl compound supported on a solid support in a first reaction zone;
carbonylating at least a portion of the ethylene oxide in the first reaction zone to produce beta-propiolactone;
directing the beta-propiolactone to a second reaction zone; and
converting at least a portion of the beta-propiolactone in the second reaction zone to acrylic acid in the presence of a catalyst, wherein the conversion of the beta-propiolactone to the acrylic acid is performed in a continuous flow format.
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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
57 Claims
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1. A method for producing acrylic acid, comprising:
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contacting ethylene oxide with carbon monoxide in the presence of a metal carbonyl compound supported on a solid support in a first reaction zone; carbonylating at least a portion of the ethylene oxide in the first reaction zone to produce beta-propiolactone; directing the beta-propiolactone to a second reaction zone; and converting at least a portion of the beta-propiolactone in the second reaction zone to acrylic acid in the presence of a catalyst, wherein the conversion of the beta-propiolactone to the acrylic acid is performed in a continuous flow format. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. A method for producing an acrylate ester, comprising:
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contacting ethylene oxide with carbon monoxide in the presence of a metal carbonyl compound supported on a solid support in a first reaction zone; carbonylating at least a portion of the ethylene oxide in the first reaction zone to produce beta-propiolactone; directing the beta-propiolactone and a C1-20 alcohol to a second reaction zone; and converting at least a portion of the beta-propiolactone and the C1-20 alcohol in the second reaction zone to an acrylate ester in the presence of a catalyst, wherein the conversion of the beta-propiolactone and C1-20 alcohol to the acrylate ester is performed in a continuous flow format. - View Dependent Claims (16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30)
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31. A method for producing polypropiolactone, comprising:
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contacting ethylene oxide with carbon monoxide in the presence of a metal carbonyl compound supported on a solid support in a first reaction zone; carbonylating at least a portion of the ethylene oxide in the first reaction zone to produce beta-propiolactone; directing the beta-propiolactone to a second reaction zone; and converting at least a portion of the beta-propiolactone in the second reaction zone to polypropiolactone in the presence of a catalyst, wherein the conversion of the beta-propiolactone to the polypropiolactone is performed in a continuous flow format. - View Dependent Claims (32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43)
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44. A method for producing an acrylamide, comprising:
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contacting ethylene oxide with carbon monoxide in the presence of a metal carbonyl compound supported on a solid support in a first reaction zone; carbonylating at least a portion of the ethylene oxide in the first reaction zone to produce beta-propiolactone; directing the beta-propiolactone and an organic amine to a second reaction zone; and converting at least a portion of the beta-propiolactone and the organic amine in the second reaction zone to an acrylamide, wherein the conversion of the beta-propiolactone and the organic amine to the acrylamide is performed in a continuous flow format. - View Dependent Claims (45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57)
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Specification