IMPROVED METHOD OF CARBONYLATING AN EPOXIDE
A continuous method of carbonylating an epoxide and/or lactone with carbon monoxide with improved catalyst efficiency and reactor productivity is comprised of reacting the epoxy and/or lactone in a solvent with carbon monoxide in the presence of a catalyst at a temperature of at least 80° C. and an amount of water that is at most about 150 ppm of the effluent from the reactor. The amount of water in any of the ingredients used in a method of the invention is desirably substantially below the aforementioned water concentration in the effluent from the reactor. Likewise, in a method of the invention, the amount of polyether byproduct is substantially absent. The methods may be performed without recycling of the catalyst.
1 . A method of carbonylating an epoxide or lactone comprising reacting, continuously, the epoxide or lactone in a liquid solvent with carbon monoxide in the presence of a catalyst at a temperature of at least 85° C. to at most 130° C., a carbon monoxide pressure of 700 psi to 2000 psi to form a carbonylation product in an effluent having a concentration of water of at most 150 ppm and the catalyst being present at a molar ratio of epoxide/catalyst greater than 2000.
2 . The method of claim 1 , wherein the pressure is at least 800 psi, the temperature is at least 90° C., the molar ratio of CO/epoxide is from 1.2 to 20, and the epoxide and catalyst are present in amounts such that the epoxide and catalyst have a molar ratio of epoxide/catalyst from 2200 to 25,000.
3 - 6 . (canceled)
7 . The method of claim 2 , wherein the pressure is at least 1000 psi and the temperature is greater than 90 at least 100° C.
8 . The method of claim 1 , wherein the epoxide is carbonylated and the epoxide is ethylene oxide, propylene oxide or combination thereof.
9 - 13 . (canceled)
14 . The method of claim 1 , wherein the catalyst is comprised of a homogeneous catalyst, and the solvent is an ether, hydrocarbon, aprotic polar solvent or mixture thereof.
15 . The method of claim 14 , wherein the catalyst is a metal carbonyl catalyst, represented by [QMy(CO)w]x where: Q is any ligand; M is a metal atom; y is an integer from 1 to 6 inclusive; w is a number that renders the metal carbonyl stable; x is an integer from −3 to +3 inclusive.
16 - 18 . (canceled)
19 . The method of claim 15 , wherein the metal carbonyl catalyst is anionic and further comprised of a cationic Lewis acid, wherein the cationic Lewis acid is a metal complex represented by [M′(L)b]c+, where, M′ is a metal; each L is a ligand; b is an integer of 1 to 6; c is 1, 2, or 3; and where, if more than one L is present, each L may be the same or different.
20 . (canceled)
21 . The method of claim 19 , wherein the ligand L is a dianionic tetradentate ligand, and M′ is a translation metal or group 13 metal.
22 . The method of claim 21 , wherein the dianionic tetradentate ligand is a porphyrin derivative; and wherein M′ is aluminum, chromium, indium, gallium or combination thereof.
23 - 29 . (canceled)
30 . The method of claim 1 , wherein the method is performed in a continuously stirred reactor or plug flow reactor.
31 - 32 . (canceled)
33 . The method of claim 14 , wherein the solvent is 14 , tetrahydrofuran (“THF”), tetrahydropyran, 2,5-dimethyl tetrahydrofuran, sulfolane, N-methyl pyrrolidone, 1,3 dimethyl-2-imidazolidinone, diglyme, triglyme, tetraglyme, diethylene glycol dibutyl ether, isosorbide ethers, methyl tertbutyl ether, diethylether, diphenyl ether, 1,4-dioxane, ethylene carbonate, propylene carbonate, butylene carbonate, dibasic esters, diethyl ether, acetonitrile, ethyl acetate, propyl acetate, butyl acetate, 2-butanone, cyclohexanone, toluene, difluorobenzene, dimethoxy ethane, acetone, methylethyl ketone, or mixture thereof.
34 . The method of claim 33 , wherein the solvent is comprised of THF.
35 . The method of claim 1 , wherein the concentration of water is at most about 75 ppm.
36 - 38 . (canceled)
39 . The method of claim 1 , wherein any one or more of the epoxide, lactone, solvent, carbon monoxide are dried prior to reacting.
40 - 41 . (canceled)
42 . The method of claim 30 , wherein the method is performed in a plug flow reactor, wherein the plug flow reactor is a vertical plug flow reactor.
43 . (canceled)
44 . The method of claim 1 , wherein the carbonylation product is a beta lactone in the substantial absence of an anhydride.
45 - 46 . (canceled)
47 . A method of carbonylating an epoxide or lactone, comprising reacting, continuously the epoxide or lactone in a liquid solvent with carbon monoxide in the presence of a catalyst at a temperature of at least 85° C., a carbon monoxide pressure of at least 700 psi, the catalyst being present at a molar ratio of epoxide/catalyst greater than 2000, to form a carbonylation product in an effluent, the effluent being substantially in the absence of a by-product polymer and having a water concentration of at most 150 ppm.
48 . The method of claim 47 , wherein the reacting is performed in the absence of recycling of the catalyst; and the concentration of the by-product polymer is comprised of a polyether that is present in an amount of at most 0.2% by weight.
49 - 53 . (canceled)
54 . A method of carbonylating an epoxide or lactone, comprising reacting, continuously the epoxide or lactone in a liquid solvent with carbon monoxide in the presence of a catalyst at a temperature of at least 85° C., a carbon monoxide pressure of at least 700 psi, wherein the epoxide, lactone, carbon monoxide and solvent have a total water concentration of at most 40 ppm and the catalyst being present at a molar ratio of epoxide/catalyst greater than 2000.
55 - 59 . (canceled)
60 . The method of claim 54 , wherein the total water concentration is at most 20 ppm.