SYSTEMS AND PROCESSES FOR PRODUCING ORGANIC ACIDS DIRECT FROM BETA-LACTONES
Provided herein are reactor systems and processes for producing organic acids directly from beta-lactones. Such reactor systems and processes involve the use of a heterogeneous catalyst, such as a zeolite at vapor phase conditions. The reactor systems and processes may use a fixed bed, moving bed or fluidized contacting zone as reactor configurations.
1 . A process for producing at least one organic acid product directly from at least one beta-lactone reagent comprising the steps: introducing at least one beta-lactone reagent to at least one reaction vessel; contacting the at least one beta-lactone reagent with at least one heterogenous catalyst in the at least one reaction vessel to produce at least one organic acid; and removing the at least one organic acid from the at least one reaction vessel to provide at least one organic acid product.
2 . The process from claim 1 , wherein the heterogenous catalyst comprises a microporous solid selected from the group including alkaline-earth phosphates, supported phosphate salts, calcium hydroxyapatites, inorganic salts, metal oxides, and zeolites, or combinations thereof.
3 . The process from claim 1 , wherein the heterogenous catalyst comprises an alumina-silicate molecular sieve having Lewis or Brönsted acidity.
4 . The process from claim 1 , wherein the heterogenous catalyst comprises a zeolite.
5 . The process from claim 4 , wherein the heterogenous catalyst comprises Zeolite Y, beta Zeolite, ZSM-5, ZSM-11 ZSM-22, MCM-22, ZSM-35, Zeolite A, or combinations thereof.
6 . The process from claim 2 , wherein the zeolite catalyst is in a hydrogen form or in metal cation exchanged form
7 . The process from claim 6 , wherein the metal cations are Na+, K+, Ca2+, Mg2+, Cu2+, Cu+.
8 . The process from claim 1 , wherein organic acid is produced continuously.
9 . The process from claim 1 , wherein the at least one beta-lactone reagent is introduced to the at least one reaction vessel combined with a solvent.
10 . The process from claim 1 , wherein the at least one reaction vessel further comprises a continuous fixed-bed reactor operating at a reduced pressure.
11 . The process from claim 1 , wherein the at least one reaction vessel further comprises a continuous fixed-bed reactor configured for receiving at least one beta-lactone reagent diluted with inert gas
12 . The process from claim 1 , wherein the least one reaction vessel further comprises a fluidized bed reactor configured to receive at least one beta-lactone reagent diluted with inert gas such as nitrogen.
13 . The process from claim 1 , wherein the least one reaction vessel further comprises a tubular shell-and-tube reactor with a heterogenous catalyst loaded into the tubes and heat transfer fluid fed to the shell side to facilitate temperature control and removal of the heat produced during the reactions.
14 . The process from claim 1 , wherein the beta-lactone reagent is provided at a weight hourly space velocity of 0.1 h −1 to 2.1 h −1 .
15 . The process from claim 1 , wherein the beta-lactone reagent is provided at a weight hourly space velocity of 0.3 h-1 to 0.9 h-1.
16 . The process from claim 1 , wherein the organic acid product is continuously isolated.
17 . The process from claim 1 , wherein the organic acid product is produced at a yield of at least 50%.
18 . The process from claim 1 , wherein the organic acid product is produced at a temperature between 100° C. and 300° C.
19 . A reactor system for producing at least one organic acid product directly from at least one beta-lactone reagent, wherein the reactor system comprises: at least one reaction vessel configured as a continuous fixed-bed reactor or a fluidized bed reactor defining at least one feed stream inlet and at least one product stream outlet; said at least one reaction vessel further defining an interior volume for receiving the at least one beta-lactone reagent from said at least one feed stream inlet and a retaining volume adapted for retaining the at least one beta-lactone reagent in solid, liquid, and gaseous phases.
20 . The reactor from claim 19 , wherein the at least one reaction vessel further comprises a fixed-bed reactor.
21 . The reactor system from claim 19 , wherein the at least one reaction vessel further comprises a continuous fixed-bed reactor operating at a reduced pressure for production of at least one organic acid product.
22 . The reactor system from claim 19 , wherein the at least one reaction vessel further comprises a continuous fixed-bed reactor configured for receiving at least one beta-lactone reagent diluted with inert solvent or gas.
23 . The reactor system from claim 19 , wherein the at least one reaction vessel further comprises a fluidized bed reactor configured to receive at least one beta-lactone reagent diluted with inert gas.
24 . The reactor system from claim 19 , wherein the at least one reaction vessel further comprises two or more sections separated by one or more heaters.
25 . The reactor system from claim 19 , wherein the at least one reaction vessel further comprises a tubular shell-and-tube reactor with a heterogenous catalyst loaded into the tubes and heat transfer fluid fed to the shell side to facilitate temperature control and removal of the heat produced during the reactions.
26 . The reactor system from claim 19 , wherein the at least one reaction vessel further comprises a regeneration vessel for the regeneration of at least one heterogenous catalyst.