Methods for producing lactide with recycle of meso-lactide

1. A process for producing a polymerizable lactide stream, comprising:

a) forming a low molecular weight poly(lactic acid);

b) depolymerizing the low molecular weight poly(lactic acid) to form a crude lactide that includes meso-lactide, S,S-lactide and R,R-lactide, wherein either S,S-lactide or R,R-lactide is the non-predominant lactide;

c) separating meso-lactide from the crude lactide in one or more steps such that

1) a meso-lactide-enriched stream is formed in which the mole fraction of meso-lactide is at least 0.8; and

2) a purified S,S- and R,R-lactide stream is formed; and

d) recycling at least a portion of the meso-lactide stream directly or indirectly back into step a) or step b),

whereby at least a portion of the meso-lactide in the recycled meso-lactide stream is converted to a mixture of S,S-, meso- and R,R-lactide and the mole fraction of the non-predominant lactide in the crude lactide produced in step b) is increased relative to when step d) is not performed,

wherein during step b), the recycled meso-lactide stream is subjected to a temperature of from 180 to 250° C., hydroxylic species and a lactic acid polymerization/depolymerization catalyst are present, and the residence time in step b) is at least 15 minutes.

2. A process for producing a polymerizable lactide stream, comprising:

a) forming a low molecular weight poly(lactic acid);

b) depolymerizing the low molecular weight poly(lactic acid) to form a crude lactide that includes meso-lactide, S,S-lactide and R,R-lactide, wherein either S,S-lactide or R,R-lactide is the non-predominant lactide;

c) separating meso-lactide from the crude lactide in one or more steps such that

1) a meso-lactide-enriched stream is formed in which the mole fraction of meso-lactide is at least 0.8; and

2) a purified S,S- and R,R-lactide stream is formed; and

d) recycling at least a portion of the meso-lactide stream directly or indirectly back into step a) or step b),

whereby at least a portion of the meso-lactide in the recycled meso-lactide stream is converted to a mixture of S,S-, meso- and R,R-lactide and the mole fraction of the non-predominant lactide in the crude lactide produced in step b) is increased relative to when step d) is not performed,

wherein the meso-lactide stream is recycled into step a) or upstream of step a), and the recycled meso-lactide becomes mixed into a liquid phase that is present in the step a).

3. A process for producing a polymerizable lactide stream, comprising:

a) forming a low molecular weight poly(lactic acid);

b) depolymerizing the low molecular weight poly(lactic acid) to form a crude lactide that includes meso-lactide, S,S-lactide and R,R-lactide, wherein either S,S-lactide or R,R-lactide is the non-predominant lactide;

c) separating meso-lactide from the crude lactide in one or more steps such that

1) a meso-lactide-enriched stream is formed in which the mole fraction of meso-lactide is at least 0.8; and

2) a purified S,S- and R,R-lactide stream is formed; and

d) recycling at least a portion of the meso-lactide stream directly or indirectly back into step a) or step b),

whereby at least a portion of the meso-lactide in the recycled meso-lactide stream is converted to a mixture of S,S-, meso- and R,R-lactide and the mole fraction of the non-predominant lactide in the crude lactide produced in step b) is increased relative to when step d) is not performed, wherein the meso-lactide stream is recycled into step b), and the meso-lactide stream is recycled by (1) introducing the meso-lactide stream into step b) as a sub-cooled liquid, (2) pre-blending the meso-lactide stream with the low molecular weight poly(lactic acid) formed in step a) and introducing them together into step b), (3) introducing the meso-lactide stream at or below the surface of the low molecular weight poly(lactic acid) in step b), (4) providing for a separate hydrolysis step of the meso-lactide stream prior to recycling the meso-lactide stream into step b) or (5) a combination of any two or more thereof.

4. A process for producing a polymerizable lactide stream, comprising:

a) forming a low molecular weight poly(lactic acid);

b) depolymerizing the low molecular weight poly(lactic acid) to form a crude lactide that includes meso-lactide, S,S-lactide and R,R-lactide, wherein either S,S-lactide or R,R-lactide is the non-predominant lactide;

c) separating meso-lactide from the crude lactide in one or more steps such that

1) a meso-lactide-enriched stream is formed in which the mole fraction of meso-lactide is at least 0.8; and

2) a purified S,S- and R,R-lactide stream is formed; and

d) recycling at least a portion of the meso-lactide stream directly or indirectly back into step a) or step b),

whereby at least a portion of the meso-lactide in the recycled meso-lactide stream is converted to a mixture of S,S-, meso- and R,R-lactide and the mole fraction of the non-predominant lactide in the crude lactide produced in step b) is increased relative to when step d) is not performed,

wherein the low molecular weight poly(lactic acid) is formed in step a) by polymerizing lactic acid or a lactic acid derivative, wherein the lactic acid or lactic acid derivative contains at least 90% of either the S- or R-enantiomer, and no more than 10% of the other enantiomer and further wherein enough of the meso-lactide stream is recycled to provide from 0.015 to 0.5 moles of lactic units per mole of lactic units contributed by the lactic acid or lactic acid derivative that is polymerized in step a).

5. The process of claim 4 wherein the lactic acid or lactic acid derivative contains at least 99% of either the S- or R-enantiomer, and no more than 1% of the other enantiomer.

6. A process for producing a polymerizable lactide stream, comprising:

a) forming a low molecular weight poly(lactic acid);

b) depolymerizing the low molecular weight poly(lactic acid) to form a crude lactide that includes meso-lactide, S,S-lactide and R,R-lactide, wherein either S,S-lactide or R,R-lactide is the non-predominant lactide;

c) separating meso-lactide from the crude lactide in one or more steps such that

1) a meso-lactide-enriched stream is formed in which the mole fraction of meso-lactide is at least 0.8; and

2) a purified S,S- and R,R-lactide stream is formed; and

d) recycling at least a portion of the meso-lactide stream directly or indirectly back into step a) or step b),

whereby at least a portion of the meso-lactide in the recycled meso-lactide stream is converted to a mixture of S,S-, meso- and R,R-lactide and the mole fraction of the non-predominant lactide in the crude lactide produced in step b) is increased relative to when step d) is not performed,

wherein the mole fraction of the non-predominant lactide in the crude lactide produced in step b) is increased by 0.01 to 0.05 relative to when step d) is not performed.

7. The process of claim 3 wherein the mole fractions of lactides contained in the crude lactide produced in step b) are from 0.67 to 0.80 S,S-lactide, from 0.19 to 0.30 meso-lactide and from 0.01 to 0.03 R,R-lactide, or from 0.67 to 0.80 R,R-lactide, from 0.19 to 0.30 meso-lactide and from 0.01 to 0.03 S,S-lactide.

8. The process of claim 7 wherein the mole fractions of lactides contained in the purified S,S- and R,R-lactide stream produced in step c) are at least 0.95 S,S-lactide, from 0.005 to 0.05 R,R-lactide and from 0 to 0.025 meso-lactide, and the mole fraction of meso-lactide is less than or equal that of R,R-lactide.

9. The process of claim 8 wherein the mole fraction of meso-lactide in the purified S,S- and R,R-lactide stream is from 0 to 0.01.

10. The process of claim 7 wherein the mole fractions of lactides contained in the purified S,S- and R,R-lactide stream produced in step c) are at least 0.95 R,R-lactide, from 0.005 to 0.05 S,S-lactide and from 0 to 0.025 meso-lactide, and the mole fraction of meso-lactide is less than or equal that of S,S-lactide.

11. The process of claim 10 wherein the mole fraction of meso-lactide in the purified S,S- and R,R-lactide stream is from 0 to 0.01.

12. A process for producing a polymerizable lactide stream, comprising:

a) forming a low molecular weight poly(lactic acid);

b) depolymerizing the low molecular weight poly(lactic acid) to form a crude lactide that includes meso-lactide, S,S-lactide and R,R-lactide, wherein either S,S-lactide or R,R-lactide is the non-predominant lactide;

c) separating meso-lactide from the crude lactide in one or more steps such that

1) a meso-lactide-enriched stream is formed in which the mole fraction of meso-lactide is at least 0.8; and

2) a purified S,S- and R,R-lactide stream is formed; and

d) recycling at least a portion of the meso-lactide stream directly or indirectly back into step a) or step b),

whereby at least a portion of the meso-lactide in the recycled meso-lactide stream is converted to a mixture of S,S-, meso- and R,R-lactide and the mole fraction of the non-predominant lactide in the crude lactide produced in step b) is increased relative to when step d) is not performed,

wherein in step c), intermediate boiling impurities become concentrated in the meso-lactide-enriched stream and further wherein the meso-lactide-enriched stream contains succinic anhydride, and succinic anhydride is separated from the meso-lactide before step d).

13. The process of claim 3 , further comprising polymerizing the purified S,S- and R,R-lactide stream produced in step c).

14. The process of claim 3 , wherein step c) includes a melt crystallization step.

15. The process of claim 4 , wherein step c) includes a melt crystallization step.

16. The process of claim 4 wherein the low molecular weight poly(lactic acid) is formed in step a) by polymerizing lactic acid or a lactic acid derivative, wherein the lactic acid or lactic acid derivative contains at least 90% of either the S- or R-enantiomer, and no more than 10% of the other enantiomer.

17. The process of claim 15 wherein enough of the meso-lactide stream is recycled to provide from 0.015 to 0.5 moles of lactic units per mole of lactic units contributed by the lactic acid or lactic acid derivative that is polymerized in step a).

18. The process of claim 17 wherein the lactic acid or lactic acid derivative contains at least 99% of either the S- or R-enantiomer, and no more than 1% of the other enantiomer.

19. The process of claim 4 wherein the mole fractions of lactides contained in the crude lactide produced in step b) are from 0.67 to 0.80 S,S-lactide, from 0.19 to 0.30 meso-lactide and from 0.01 to 0.03 R,R-lactide, or from 0.67 to 0.80 R,R-lactide, from 0.19 to 0.30 meso-lactide and from 0.01 to 0.03 S,S-lactide and the mole fractions of lactides contained in the purified S,S- and R,R-lactide stream produced in step c) are at least 0.95 S,S-lactide, from 0.005 to 0.05 R,R-lactide and from 0 to 0.025 meso-lactide, and the mole fraction of meso-lactide is less than or equal that of R,R-lactide.

20. The process of claim 19 wherein the mole fraction of meso-lactide in the purified S,S- and R,R-lactide stream is from 0 to 0.01.

21. The process of claim 4 wherein the mole fractions of lactides contained in the crude lactide produced in step b) are from 0.67 to 0.80 S,S-lactide, from 0.19 to 0.30 meso-lactide and from 0.01 to 0.03 R,R-lactide, or from 0.67 to 0.80 R,R-lactide, from 0.19 to 0.30 meso-lactide and from 0.01 to 0.03 S,S-lactide and the mole fractions of lactides contained in the purified S,S- and R,R-lactide stream produced in step c) are at least 0.95 R,R-lactide, from 0.005 to 0.05 S,S-lactide and from 0 to 0.025 meso-lactide, and the mole fraction of meso-lactide is less than or equal that of S,S-lactide.

22. The process of claim 21 wherein the mole fraction of meso-lactide in the purified S,S- and R,R-lactide stream is from 0 to 0.01.

23. The process of claim 4 , further comprising polymerizing the purified S,S- and R,R-lactide stream produced in step c).

24. The process of claim 5 , wherein step c) includes a melt crystallization step.

25. The process of claim 5 wherein the low molecular weight poly(lactic acid) is formed in step a) by polymerizing lactic acid or a lactic acid derivative, wherein the lactic acid or lactic acid derivative contains at least 90% of either the S- or R-enantiomer, and no more than 10% of the other enantiomer.

26. The process of claim 25 wherein enough of the meso-lactide stream is recycled to provide from 0.015 to 0.5 moles of lactic units per mole of lactic units contributed by the lactic acid or lactic acid derivative that is polymerized in step a).

27. The process of claim 26 wherein the lactic acid or lactic acid derivative contains at least 99% of either the S- or R-enantiomer, and no more than 1% of the other enantiomer.

28. The process of claim 5 wherein the mole fractions of lactides contained in the crude lactide produced in step b) are from 0.67 to 0.80 S,S-lactide, from 0.19 to 0.30 meso-lactide and from 0.01 to 0.03 R,R-lactide, or from 0.67 to 0.80 R,R-lactide, from 0.19 to 0.30 meso-lactide and from 0.01 to 0.03 S,S-lactide and the mole fractions of lactides contained in the purified S,S- and R,R-lactide stream produced in step c) are at least 0.95 S,S-lactide, from 0.005 to 0.05 R,R-lactide and from 0 to 0.025 meso-lactide, and the mole fraction of meso-lactide is less than or equal that of R,R-lactide.

29. The process of claim 28 wherein the mole fraction of meso-lactide in the purified S,S- and R,R-lactide stream is from 0 to 0.01.

30. The process of claim 5 wherein the mole fractions of lactides contained in the crude lactide produced in step b) are from 0.67 to 0.80 S,S-lactide, from 0.19 to 0.30 meso-lactide and from 0.01 to 0.03 R,R-lactide, or from 0.67 to 0.80 R,R-lactide, from 0.19 to 0.30 meso-lactide and from 0.01 to 0.03 S,S-lactide and the mole fractions of lactides contained in the purified S,S- and R,R-lactide stream produced in step c) are at least 0.95 R,R-lactide, from 0.005 to 0.05 S,S-lactide and from 0 to 0.025 meso-lactide, and the mole fraction of meso-lactide is less than or equal that of S,S-lactide.

31. The process of claim 30 wherein the mole fraction of meso-lactide in the purified S,S- and R,R-lactide stream is from 0 to 0.01.

32. The process of claim 5 , further comprising polymerizing the purified S,S- and R,R-lactide stream produced in step c).

33. The process of claim 6 , wherein step c) includes a melt crystallization step.

34. The process of claim 6 wherein the low molecular weight poly(lactic acid) is formed in step a) by polymerizing lactic acid or a lactic acid derivative, wherein the lactic acid or lactic acid derivative contains at least 90% of either the S- or R-enantiomer, and no more than 10% of the other enantiomer.

35. The process of claim 34 wherein enough of the meso-lactide stream is recycled to provide from 0.015 to 0.5 moles of lactic units per mole of lactic units contributed by the lactic acid or lactic acid derivative that is polymerized in step a).

36. The process of claim 35 wherein the lactic acid or lactic acid derivative contains at least 99% of either the S- or R-enantiomer, and no more than 1% of the other enantiomer.

37. The process of claim 6 wherein the mole fractions of lactides contained in the crude lactide produced in step b) are from 0.67 to 0.80 S,S-lactide, from 0.19 to 0.30 meso-lactide and from 0.01 to 0.03 R,R-lactide, or from 0.67 to 0.80 R,R-lactide, from 0.19 to 0.30 meso-lactide and from 0.01 to 0.03 S,S-lactide and the mole fractions of lactides contained in the purified S,S- and R,R-lactide stream produced in step c) are at least 0.95 S,S-lactide, from 0.005 to 0.05 R,R-lactide and from 0 to 0.025 meso-lactide, and the mole fraction of meso-lactide is less than or equal that of R,R-lactide.

38. The process of claim 37 wherein the mole fraction of meso-lactide in the purified S,S- and R,R-lactide stream is from 0 to 0.01.

39. The process of claim 6 wherein the mole fractions of lactides contained in the crude lactide produced in step b) are from 0.67 to 0.80 S,S-lactide, from 0.19 to 0.30 meso-lactide and from 0.01 to 0.03 R,R-lactide, or from 0.67 to 0.80 R,R-lactide, from 0.19 to 0.30 meso-lactide and from 0.01 to 0.03 S,S-lactide and the mole fractions of lactides contained in the purified S,S- and R,R-lactide stream produced in step c) are at least 0.95 R,R-lactide, from 0.005 to 0.05 S,S-lactide and from 0 to 0.025 meso-lactide, and the mole fraction of meso-lactide is less than or equal that of S,S-lactide.

40. The process of claim 39 wherein the mole fraction of meso-lactide in the purified S,S- and R,R-lactide stream is from 0 to 0.01.

41. The process of claim 6 , further comprising polymerizing the purified S,S- and R,R-lactide stream produced in step c).