Method for the preparation of a hydroxyalkyl hindered phenolic antioxidant

1. A method of making a hindered phenolic antioxidant comprising:

reacting an ester of the formula:

 wherein

R 1 , R 2 , and R 3 are independently selected alkyl groups and n is 0, 1, or 2, with an aliphatic polyhydroxyl alcohol of the general formula R(OH) n wherein R is an aliphatic group of from 2 to about 12 carbon atoms and n is an integer of from 2 to 7, provided that one hydroxyl is primary and the others are secondary or tertiary, in the presence of a strong acid catalyst;

then, neutralizing the strong acid catalyst with an overbased detergent; and

isolating the hindered phenolic antioxidant after the neutralization step.

2. A method of making a hindered phenolic antioxidant comprising:

providing an ester of the formula:

 wherein

R 1 , R 2 , and R 3 are independently selected alkyl groups and n is 0, 1, or 2;

providing an aliphatic polyhydroxyl alcohol of the general formula R(OH) n wherein R is an aliphatic group of from 2 to about 12 carbon atoms and n is an integer of from 2 to 7, provided that one hydroxyl is primary and the others are secondary or tertiary;

providing a strong acid catalyst;

heating the ester and the aliphatic polyhydroxyl alcohol in the presence of the strong acid catalyst to react the primary hydroxyl group of the aliphatic polyhydroxyl alcohol with the ester to transesterify said ester to form a product mixture comprising a mono-ester;

neutralizing the strong acid catalyst with an overbased detergent; and

isolating the hindered phenolic antioxidant after the neutralization step.

3. The method of claim 2 wherein the aliphatic polyhydroxyl alcohol is selected from the group consisting of ethylene glycol, 1,2-propane diol, 1,3-propane diol, 1,2-butane diol, 1,3-butane diol, 1,4-butane diol, 2,3-butane diol, 1,2-pentane diol, 1,3-pentane diol, 1,4-pentane diol, 1,5-pentane diol, 2,3-pentane diol, 2,4-pentane diol, 1,2-hexane diol, 1,3-hexane diol, 1,4-hexane diol, 1,5-hexane diol, 1,6-hexane diol, 2,3-hexane diol, 2,4-hexane diol, 2,5-hexane diol, glycerol, trimethylol propane, and pentaerythritol.

4. The method of claim 2 wherein the aliphatic polyhydroxyl alcohol is employed at a level in excess of the stoichiometric amount required for reaction with the ester.

5. The method of claim 4 further including the step of removing any residual aliphatic polyhydroxyl alcohol after the step of neutralizing the strong acid catalyst.

6. The method of claim 2 wherein the aliphatic polyhydroxyl alcohol is 1,3-butane diol.

7. The method of claim 2 wherein the strong acid catalyst is para-toluene sulfonic acid.

8. The method of claim 2 wherein the overbased detergent is an overbased calcium sulfonate detergent.

9. The method of claim 2 wherein R 1 and R 2 are both tert-butyl, n is 2, and R 3 is methyl.

10. A method of making making a hindered hydroxyalkyl phenolic antioxidant comprising the steps of:

reacting methyl-(3,5-di-t-butyl(4-hydroxyphenyl)) propionate with a stoichiometric excess of 1,3-butanediol in the presence of a para-toluene sulfonic acid catalyst;

neutralizing the para-toluene sulfonic acid catalyst with an overbased detergent; and

removing any residual aliphatic polyhydroxyl alcohol after the neutralization step to isolate the product mixture.

11. The method of claim 10 wherein the overbased detergent is an overbased calcium sulfonate detergent.