Promoter catalyst system with solvent purification
View Patent ↗Methods for performing a condensation reaction are disclosed. Specifically, various methods for the production of highly-pure bisphenol-A are disclosed in which an attached promoter ion exchange resin catalyst system is combined with a solvent crystallization step.
1. A process for a chemical condensation reaction comprising contacting at least two chemical reagents comprising at least one of a phenol and a ketone, with an attached promoter ion exchange resin catalyst system to produce an effluent stream, and then subjecting the effluent stream to a solvent crystallization step, wherein the attached promoter ion exchange resin catalyst system comprises a cross-linked, sulfonated ion exchange resin having sulfonic groups, wherein the effluent stream comprises an aromatic solvent, and wherein process has a ketone conversion rate of at least about 90%.
2. The process of claim 1 , wherein the attached promoter ion exchange resin catalyst system has a degree of cross-linking of from about 1% to about 4%.
3. The process of claim 2 , wherein the degree of cross-linking is from about 1.5% to about 2.5%.
4. The process of claim 2 , wherein the degree of cross-linking is about 2%.
5. The process of claim 1 , wherein the attached promoter ion exchange resin catalyst system comprises a dimethyl thiazolidine promoter.
6. The process of claim 1 , wherein the attached promoter ion exchange resin catalyst system comprises a pyridyl ethylmercapton promoter.
7. The process of claim 2 , wherein the attached promoter ion exchange resin catalyst system comprises a promoter that is ionically bound to from about 18% to about 25% of sulfonic acid groups present on the ion exchange resin.
8. The process of claim 2 , wherein the attached promoter ion exchange resin catalyst system comprises a promoter that is ionically bound to from about 20% to about 24% of sulfonic acid groups present on the ion exchange resin.
9. The process of claim 1 , wherein the sulfonated ion exchange resin is a sulfonated polystyrene ion exchange resin.
10. The process of claim 1 , wherein the process does not comprise a bulk promoter.
11. The process of claim 1 , wherein prior to the solvent crystallization step, a reactor effluent is subjected to at least one of a separate ion exchange resin bed, a water removal step, a phenol recovery step, or a combination thereof.
12. The process of claim 1 , further comprising a water removal step.
13. The process of claim 12 , further comprising a phenol recovery step.
14. The process of claim 1 , further comprising a phenol recovery step.
15. The process of claim 1 , wherein the solvent crystallization step removes at least a portion of one or more bisphenol-A byproducts.
16. The process of claim 1 , wherein the solvent crystallization step removes a bisphenol-A byproduct.
17. The process of claim 1 , wherein the aromatic solvent is selected from one or more of a toluene, xylene, benzene, or a combination thereof.
18. The process of claim 1 , wherein the aromatic solvent comprises toluene.
19. The process of claim 1 , wherein the effluent stream comprises bisphenol-A.
20. The process of claim 1 , wherein the phenol comprises an aromatic hydroxy compound having at least one unsubstituted position.
21. The process of claim 1 , wherein the reaction has a p,p-bisphenol A selectivity of at least about 90%.
22. The process of claim 12 , wherein the effluent stream has a water content of less than about 0.5 wt %.
23. The process of claim 1 , wherein the sulfonated ion exchange resin is cross-linked with polycyclic aromatic divinyl monomers, divinyl benzene, divinyl toluene, divinyl biphenyl monomers, or a combination thereof.
24. The process of claim 1 , wherein the ion exchange resin is cross-linked with divinyl benzene.
25. A process to produce a bis-phenol A isomer comprising:
a) contacting at least two chemical reagents comprising at least one of a phenol and at least one of a ketone, an aldehyde, or a combination thereof, to produce a reactant feed;
b) contacting the reactant feed with an attached promoter ion exchange resin catalyst system to produce an effluent stream, wherein the attached promoter ion exchange resin catalyst system comprises a cross-linked, sulfonated ion exchange resin having sulfonic groups, and wherein the effluent stream comprises a bisphenol A isomer and an aromatic solvent, wherein the reaction has a p,p-bisphenol A selectivity of at least about 90%;
c) passing the effluent stream through a phenol flash unit to remove a phenol reactant from the effluent stream; and
d) subjecting the effluent stream to a solvent crystallization step.
26. The process of claim 25 , wherein the attached promoter ion exchange resin catalyst system comprises polystyrene, polysiloxane, or derivatives thereof.
27. The process of claim 25 , wherein the sulfonated ion exchange resin is cross-linked with polycyclic aromatic divinyl monomers, divinyl benzene, divinyl toluene, divinyl biphenyl monomers, or a combination thereof.
28. The process of claim 25 , wherein the sulfonated ion exchange resin is cross-linked with divinyl benzene.
29. The process of claim 25 , wherein the attached promoter ion exchange resin catalyst system comprises a dimethyl thiazolidine promoter.
30. A process for preparing polycarbonate comprising:
a) contacting at least two chemical reagents comprising at least one of a phenol and at least one of a ketone, an aldehyde, or a combination thereof, to produce a reactant feed;
b) contacting the reactant feed with an attached promoter ion exchange resin catalyst system to produce an effluent stream, wherein the attached promoter ion exchange resin catalyst system comprises a cross-linked, sulfonated ion exchange resin having sulfonic groups, and wherein the effluent stream comprises a bisphenol A isomer and an aromatic solvent, wherein the reaction has a p,p-bisphenol A selectivity of at least about 90%;
c) passing the effluent stream through a phenol flash unit to remove a phenol reactant from the effluent stream; and
d) subjecting the effluent stream to a solvent crystallization step, wherein the bisphenol A isomer has no inorganic, sulfur, or thermally degraded components; and
e) polymerizing the bisphenol A isomer to form a polycarbonate.
31. A process for a chemical condensation reaction comprising contacting at least two chemical reagents comprising at least one of a phenol and at least one of a ketone, an aldehyde, or a combination thereof, with an attached promoter ion exchange resin catalyst system to produce an effluent stream, and then subjecting the effluent stream to a solvent crystallization step, wherein the attached promoter ion exchange resin catalyst system comprises a cross-linked, sulfonated ion exchange resin having sulfonic groups, wherein the effluent stream comprises an aromatic solvent, and wherein the reaction has a p,p-bisphenol A selectivity of at least about 90%.
32. The process of claim 31 , wherein the attached promoter ion exchange resin catalyst system has a degree of cross-linking of from about 1% to about 4%.
33. The process of claim 32 , wherein the degree of cross-linking is from about 1.5% to about 2.5%.
34. The process of claim 32 , wherein the degree of cross-linking is about 2%.
35. The process of claim 31 , wherein the attached promoter ion exchange resin catalyst system comprises a dimethyl thiazolidine promoter.
36. The process of claim 31 , wherein the attached promoter ion exchange resin catalyst system comprises a pyridyl ethylmercapton promoter.
37. The process of claim 32 , wherein the attached promoter ion exchange resin catalyst system comprises a promoter that is ionically bound to from about 18% to about 25% of sulfonic acid groups present on the ion exchange resin.
38. The process of claim 32 , wherein the attached promoter ion exchange resin catalyst system comprises a promoter that is ionically bound to from about 20% to about 24% of sulfonic acid groups present on the ion exchange resin.
39. A process for a chemical condensation reaction comprising contacting at least two chemical reagents comprising at least one of a phenol and at least one of a ketone, an aldehyde, or a combination thereof, with an attached promoter ion exchange resin catalyst system to produce an effluent stream, and then subjecting the effluent stream to a solvent crystallization step, wherein the attached promoter ion exchange resin catalyst system comprises a cross-linked, sulfonated ion exchange resin having sulfonic groups, wherein the sulfonated ion exchange resin is cross-linked with polycyclic aromatic divinyl monomers, divinyl benzene, divinyl toluene, divinyl biphenyl monomers, or a combination thereof, and wherein the effluent stream comprises an aromatic solvent.
40. The process of claim 39 , wherein the attached promoter ion exchange resin catalyst system has a degree of cross-linking of from about 1% to about 4%.
41. The process of claim 40 , wherein the degree of cross-linking is from about 1.5% to about 2.5%.
42. The process of claim 40 , wherein the degree of cross-linking is about 2%.
43. The process of claim 39 , wherein the attached promoter ion exchange resin catalyst system comprises a dimethyl thiazolidine promoter.
44. The process of claim 39 , wherein the attached promoter ion exchange resin catalyst system comprises a pyridyl ethylmercapton promoter.
45. The process of claim 40 , wherein the attached promoter ion exchange resin catalyst system comprises a promoter that is ionically bound to from about 18% to about 25% of sulfonic acid groups present on the ion exchange resin.
46. The process of claim 40 , wherein the attached promoter ion exchange resin catalyst system comprises a promoter that is ionically bound to from about 20% to about 24% of sulfonic acid groups present on the ion exchange resin.
47. A process for a chemical condensation reaction comprising contacting at least two chemical reagents comprising at least one of a phenol and at least one of a ketone, an aldehyde, or a combination thereof, with an attached promoter ion exchange resin catalyst system to produce an effluent stream, and then subjecting the effluent stream to a solvent crystallization step, wherein the attached promoter ion exchange resin catalyst system comprises a cross-linked, sulfonated ion exchange resin having sulfonic groups, wherein the effluent stream comprises an aromatic solvent, and wherein the effluent stream has a water content of less than about 0.5 wt %.
48. The process of claim 47 , wherein the attached promoter ion exchange resin catalyst system has a degree of cross-linking of from about 1% to about 4%.
49. The process of claim 48 , wherein the degree of cross-linking is from about 1.5% to about 2.5%.
50. The process of claim 48 , wherein the degree of cross-linking is about 2%.
51. The process of claim 47 , wherein the attached promoter ion exchange resin catalyst system comprises a dimethyl thiazolidine promoter.
52. The process of claim 47 , wherein the attached promoter ion exchange resin catalyst system comprises a pyridyl ethylmercapton promoter.
53. The process of claim 48 , wherein the attached promoter ion exchange resin catalyst system comprises a promoter that is ionically bound to from about 18% to about 25% of sulfonic acid groups present on the ion exchange resin.
54. The process of claim 48 , wherein the attached promoter ion exchange resin catalyst system comprises a promoter that is ionically bound to from about 20% to about 24% of sulfonic acid groups present on the ion exchange resin.