Method for producing 2-octyl acrylate by direct esterification

1. A process for continuously producing 2-octyl acrylate, the process comprising the steps of (1) reacting acrylic acid and a branched secondary alcohol which is 2-octanol in the presence of a sulfuric acid esterification catalyst and at least one polymerization inhibitor in a reactor, (2) entraining water formed by the esterification reaction by distillation in a column surmounting the reactor in the form of a heteroazeotropic mixture with the 2-octanol which is condensed and then separated in a decanter to produce an upper organic phase and a lower aqueous phase, (3) purifying by separation a reaction mixture comprising reaction product and residual by-products to obtain, pure 2-octyl acrylate, unreacted 2-octanol, acrylic acid compounds, and catalyst, wherein said unreacted 2-octanol, acrylic acid compounds and catalyst are recyclable and wherein:

the aqueous phase derived from the decanter is continuously removed and not returned to the reactor;

the organic phase derived from the decanter is continuously recycled at the bottom of the distillation column surmounting the reactor; and

the treatment for purification of the reaction mixture comprises the steps of (i) separating a catalyst-rich stream which is at least partly recycled to the reaction step, (ii) separating a stream rich in unreacted 2-octanol which is at least partly recycled to the reaction step, and (iii) recovering pure 2-octyl acrylate.

2. The process as claimed in claim 1 , wherein the treatment for purification of the reaction mixture comprises steps of:

first separating the catalyst using a film evaporator, at the end of which are separated, at the bottom, a stream rich in catalyst and polymerization inhibitors, said stream being at least partly recycled to the reaction, and, at the top, a stream rich in 2-octyl acrylate; and

second, sending the stream rich in 2-octyl acrylate to a first distillation column to recover, at the top, a stream rich in 2-octanol which is recycled to the reaction and, at the bottom, a stream rich in 2-octyl acrylate which is sent to a second distillation column to separate, at the top, the pure 2-octyl acrylate and, at the bottom, a fraction containing heavy impurities and polymerization inhibitors which is either recycled to the first distillation column, or removed.

3. The process as claimed in claim 1 , wherein the treatment for purification of the reaction mixture comprises steps of:

flash evaporating the reaction mixture resulting in separation of a first stream rich in 2-octyl acrylate reaction product and of a reaction mixture residue;

bringing, with stirring, the reaction mixture residue into contact with water or an aqueous stream so as to form a two-phase system consisting of an aqueous phase comprising the catalyst, and an organic phase rich in heavy by-products resulting from the reaction;

separating said aqueous phase and recycling thereof to the reaction;

separating said organic phase which is sent to a film evaporator to separate a second stream of reaction products and unreacted reagents which is mixed with the first stream;

sending the first stream rich in 2-octyl acrylate to a distillation column to recover:

at the top, a third stream rich in 2-octanol which is recycled to the reaction,

pure 2-octyl acrylate via side take-off, and

at the bottom, a fourth stream rich in heavy by-products and containing 2-octyl acrylate which is sent to the film evaporator from which a fraction containing the heavy by-products is separated from reaction products and unreacted reagents and removed.

4. The process as claimed in claim 1 , wherein the treatment for purification of the reaction mixture comprises steps of:

bringing the reaction mixture into contact with water or an aqueous stream so as to form a two-phase system consisting of an aqueous phase comprising the catalyst, and of an organic phase rich in reaction product;

separating said aqueous phase and recycling thereof to the reaction;

separating said organic phase which is sent to a first distillation column to obtain:

at the top, a stream rich in reaction product; and

at the bottom, a stream rich in heavy by-products and containing 2-octyl acrylate, said stream being sent to a film evaporator from which a fraction containing the heavy by-products is separated and removed from reaction products and unreacted reagents which are recycled to the first distillation column;

sending the stream rich in reaction product to a second distillation column to recover:

at the top, a stream rich in 2-octanol which is recycled to the reaction;

the pure 2-octyl acrylate via a side take-off; and

at the bottom, a stream rich in 2-octyl acrylate with polymerization inhibitors, which is at least partly recycled to the first distillation column.

5. The process of claim 1 wherein the catalyst is methanesulfonic acid.

6. The process of claim 1 wherein the reaction is carried out in a single reactor, the 2-octanol being introduced partly directly into the reactor and partly by means of the distillation column surmounting the reactor.

7. The process of claim 1 wherein the aqueous phase from the decanter is subjected to a distillation whereby any 2-octanol present is recovered before the aqueous phase is removed.

8. The process of claim 2 wherein the film evaporator is a falling film or wiped film evaporator operating under the conditions of the first distillation column.

9. The process of claim 1 wherein the acrylic acid is of renewable origin.