Abstract:
The present invention provides a method for alkoxylating organic compounds comprising contacting an organic compound adapted to be alkoxylated with an alkylene oxide in a reaction vessel under conditions effective to alkoxylate the organic compound. The alkylene oxide is maintained in vapor form during transport to said reaction vessel, during discharge into said reaction vessel, and during contacting of the organic compound with the alkylene oxide. The result is an alkoxylated product containing less flocculant.

Description:
FIELD OF THE INVENTION 
     The present invention is a method for alkoxylating organic compounds, preferably polyalkylene glycols, by exposing the organic compounds to alkylene oxide vapor which is not compressed into a liquid phase for purposes of transport or introduction into the reactor. The method results in alkoxylation products containing less, little, or no flock. 
     BACKGROUND OF THE INVENTION 
     A variety of organic materials react under suitable conditions with an adducting material, such as an alkylene oxide—particularly ethylene oxide or propylene oxide—to form alkoxylated organic materials. Typically, the alkylene oxide adducting material is compressed into liquid form for transport to and discharge into the reactor. Unfortunately, even if the alkylene oxide is decompressed into the vapor phase before the alkoxylation reaction begins, the previous compression of the alkylene oxide into the liquid phase tends to increase flock in the alkoxylation product. A method is needed by which to form alkoxylated products containing no, little, or less flock. 
     SUMMARY OF THE INVENTION 
     The present invention provides a method comprising contacting an organic compound adapted to be alkoxylated with an alkylene oxide in a reaction vessel under conditions effective to alkoxylate the organic compound. The alkylene oxide is maintained in vapor form before and during transport to said reaction vessel, during discharge into the reaction vessel, and during contact with the organic compound. 
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention provides a method for producing an alkoxylation product with no, little, or less flock. According to the present method, the alkylene oxide adducting material is not compressed into liquid form in order to transport and/or to introduce the material into the alkoxylation reactor. The alkylene oxide is both transported and discharged into the reactor in the vapor phase. Without limiting the present invention to any particular theory or mechanism, it is believed that compression of ethylene oxide into the liquid phase produces minute amounts of oligomers or polymers which contribute to the formation of flock in the substrate. The present invention is believed to reduce flock by avoiding the formation of these oligomers or polymers in the alkylene oxide. 
     The alkoxylation reaction, itself, takes place under standard conditions. The reaction takes place at any suitable temperature, preferably from about 10° C. to about 160° C. For practical purposes, most commercial operations will be carried out in the temperature range of from about 50° C. to about 200° C. 
     The method is useful to alkoxylate any suitable alkoxylatable organic material. Suitable materials include, but are not necessarily limited to polyhydric, unsaturated, linear or branched alcohols, saturated alcohols, alkyl phenols, polyols, aldehydes, ketones, amines, amides, organic acids, and mercaptans. Preferred organic materials are normally selected from the group consisting of 
     (a) polyhydric alcohols containing a total of from about 2 to about 30 carbon atoms and having the general formula                           
      wherein R 1 , R 2 , and R 3  independently are selected from the group consisting of linear and branched acyclic groups, alicyclic groups, aryl groups, cyclic groups, and hydrogen, and may contain one or more functional groups selected from the group consisting of amine groups, carboxyl groups, hydroxy groups, halogen atoms, nitro-groups, carbonyl groups, and amide groups. Representative but non-exhaustive examples of various polyhydric alcohols which can be alkoxylated according to the present invention are: ethylene glycol, 1,2-propylene glycol 1,4-butanediol; 1,6-hexanediol; 1,10-decanediol; 1,3-butylene glycol; diethylene glycol; diethylene glycol monobutyl ether; diethylene glycol monomethyl ether; diethyl glycol monoethyl ether, dipropylene glycol; dipropylene glycol monomethyl ether ethylene glycol monomethyl ether; ethylene glycol monoethyl ether; ethylene glycol monobutyl ether; hexylene glycol; mannitol, sorbitol; pentaerythritol; dipentaerythritol, tripentaerythritol; trimethylolpropane; trimethylolethane; neopentyl glycol; diethanolamine; triethanolamine; diisopropanolamine; triisopropanolamine; 1,4-dimethylolcyclohexane; 2,2-bis(hydroxymethyl)propionic acid; 1,2-bis(hydroxymethyl)benzene; 4,5-bis(hydroxymethyl)furfural; 4,8-bis(hydroxymethyl)tricyclo-[5,2,1,0]decane; tartaric acid; 2-ethyl-1,3-hexanediol; 2-amino-2-ethyl-1,3-propanediol; triethylene glycol; tetraethylene glycol; glycerol; ascorbic acid. Representative but non-exhaustive examples of various aldehydes and ketones which can be alkoxylated according to the present invention are lauryl aldehyde benzaldehyde; 2-undecanoneacetophenone; 2,4-pentandione; acetylsalicyclic acid; ortho-chlorobenzaldehyde; para-chlorobenzaldehyde; cinnamic aldehyde; diisobutyl ketone; ethylacetoacetate; ethyl amyl ketone; camphor; para-hydroxybenzaldehyde; 2-carboxybenzaldehyde; 4-carboxybenzaldehyde; salicylaldehyde; octyl aldehyde; decyl aldehyde; p-methoxybenzaldehyde; p-aminobenzaldehyde; phenylacetaldehyde; acetoacetic acid; 2,5-dimethoxybenzaldehyde; T-naphthyl aldehyde; terephthaldehyde; 
     (b) aldehydes and ketones having from about 2 to about 30 carbon atoms and having the general formula                           
      wherein R 1  and R 2  independently are selected from the group consisting of hydrogen, linear and branched acyclic groups, alicyclic groups, cyclic groups, and aryl groups, and may contain one or more functionalities selected from the group consisting of carboxyl groups, hydroxyl groups, halogen atoms, nitro-groups, amine groups, and amide groups; 
     (c) primary, secondary and tertiary amides having from about 1 to about 30 carbon atoms and having the general formula                           
      wherein R 1 , R 2 , and R 3  independently are selected from the group consisting of hydrogen, linear and branched acyclic groups, alicyclic groups, cyclic groups, and aryl groups, and may contain one or more functionalities selected from the group consisting of hydroxyl groups, carboxyl groups, carbonyl groups, amine groups, nitro-groups, and halogen atoms. Representative but non-exhaustive examples of amides which can be alkoxylated according to the instant invention are: formamide; benzamide; acetanilide, salicylamide; acetoacetanilide; ortho-acetoacetotoluidide; acrylamide; N,N-diethyltoluamide; N,N-dimethylacetamide; N,N-dimethylformamide; phthalimide; octylamide; decylamide; laurylamide; stearylamide; N,N-dimethylollaurylamide; N,N-dimethylacrylamide; para-chlorobenzamide; para-methoxybenzamide; para-aminobenzamide; para-hydroxybenzamide; ortho-nitrobenzamide,; N-acetyl-para-aminophenol; 2-chloroacetamide; oxamide; N,N-methylene-bis-acrylamide; 
     (d) primary, secondary, and tertiary amines having from about 1 to about 30 carbon atoms, and having the general formula                           
      wherein R 1 , R 2 , and R 3  independently are selected from the group consisting of hydrogen, linear and branched acyclic groups, alicyclic groups, cyclic groups, and aryl groups, and may contain one or more functionalities selected from the group consisting of hydroxyl groups, carbonyl groups, halogen atoms, carboxyl groups, nitro-groups, and amide groups. Representative but non-exhaustive examples of amines which can be alkoxylated according to the present invention are: aniline; benzylamine; hexadecylamine, triphenylamine. aminoacetic acid anthranilic acid, cyclohexylamine, tert-octylamine; ortho-phenylenediamine; meta-phenylenediamine; para-phenylenediamine; N-acetyl-para-aminophenol; 2-amino-4-chlorophenol; 2-amino-2-ethyl-1,3-propanediol; ortho-aminophenol; para-aminophenol; para-aminosalicyclic acid, benzyl-N,N-dimethylamine; tert-butylamine; 2-chloro-4-aminotoluene; 6-chloro-2-aminotoluene; meta-chloroaniline; ortho-chloroaniline; para-chloroaniline; 4-chloro-2-nitroaniline; cyclohexylamine, dibutylamine; 2,5-dichloroaniline; 3,4-dichloroaniline; dicyclohexylamine; diethanolamine; N,N-diethylethanolamine; N,N-diethyl-meta-toluidine; N,N-diethylaniline; diethylenetriamine; diisopropanolamine; N,N-dimethylethanolamine; N,N-dimethylaniline; 2,4-dinitroaniline, diphenylamine, ethyl-para-aminobenzoate; N-ethylethanolamine; N-ethyl-1-naphthylamine; N-ethyl-ortho-toluidine, N-ethylaniline, ethylenediamine; hexamethylenetetraamine, 2,4-lutidine; N-methylaniline; methyl anthranilate; p,p′-diaminodiphenyl methane; ortho-nitroaniline; para-nitroaniline; tert-octylamine; piperazine; ethanolamine; isopropanolamine; ortho-toluidine; para-toluidine; 2,4-toluenediamine; triethanolamine; tributylamine; triisopropanolamine; 2,4-dimethylxylidine; para-methoxyaniline, nitrilotriacetic acid; N-phenyl-1-naphthylamine; 
     (e) organic acids having from about 1 to about 30 carbon atoms, and having the general formula                           
      wherein R 1  is selected from the group consisting of hydrogen, linear and branched acyclic groups, alicyclic groups, cyclic groups, aryl groups, and may contain one or more functionalities selected from the group consisting of carbonyl groups, hydroxyl groups, halogen atoms, nitro-groups, amine groups, and amide groups. Representative but non-exhaustive examples of organic acids which can be alkoxylated according to the present invention are: formic acid; acetic acid; valeric acid; heptanoic acid; 2-ethylhexanoic acid; lauric acid; stearic acid; oleic acid; tall oil acids hydrogenated tall oil acids; benzoic acid salicyclic acid; adipic acid; azelaic acid; fumaric acid; citric acid; acrylic acid; aminoacetic acid; para-aminosalicyclic acid; anthranilic acid; butyric acid; propionic acid; ricinoleic acid; chloroacetic acid; ortho-chlorobenzoic acid; 2,4-dichlorophenoxyacetic acid; tert-decanoic acid; para-aminobenzoic acid; abietic acid; itaconic acid; lactic acid; glycolic acid; malic acid; maleic acid; cinnamic acid; para-hydroxybenzoic acid; methacrylic acid; oxalic acid; myristic acid; palmitic acid; tert-pentanoic acid; phenylacetic acid; mandelic acid; sebacic acid; tallow fatty acids; hydrogenated tallow fatty acids; tartaric acid; trichloroacetic acid; 2,4,5-trichlorophenoxyacetic acid; undecylenic acid; crotonic acid; pelargonic acid; acetoacetic acid; para-nitrobenzoic acid; ascorbic acid; nitrilotriacetic acid; naphthenic acid; 1-naphthoic acid, trimellitic acid, 
     (f) alkyl phenols having from about 6 to about 30 carbon atoms, and having the general formula                           
      wherein R 1 , R 2 , R 3 , R 4 , and R 5  independently are selected from the group consisting of hydrogen, halogen atoms, hydroxyl groups, nitro-groups, carbonyl groups, linear and branched acyclic groups, alicyclic groups, cyclic groups, aryl groups, and may contain one or more functionalities selected from the group consisting of halogen atoms, ether groups, nitro-groups, carboxyl groups, carbonyl groups, amine groups, amide groups, and hydroxyl groups. Representative but non-exhaustive examples of various phenols which can be alkoxylated according to the present invention are: phenol, ortho-cresol, meta-cresol; para-cresol, 2,4-dimethylphenol 2,5-dimethylphenol; 2,6-dimethylphenol; ortho-chlorophenol; meta-chlorophenol; para-chlorophenol; para-nitrophenol; para-methoxyphenol; salicyclic acid; meta-hydroxyacetophenone; para-aminophenol; ortho-phenylphenol; nonylphenol; octylphenol; t-butyl-para-cresol; hydroquinone; catechol; resorcinol; pyrogallol, 1-naphthol, 2-naphthol; 4,4′-isopropylidenediphenol (bisphenol A); methyl salicylate; benzyl salicylate; 4-chloro-2-nitrophenol; para-t-butylphenol; 2,4-di-t-amylphenol; 2,4-dinitrophenol; para-hydroxybenzoic acid; 8-hydroxyquinoline; methyl para-hydroxybenzoate; 2-nitro-para-cresol; ortho-nitrophenol; para-phenylphenol; phenyl salicylate; salicylaldehyde; p-hydroxy benzaldehyde; 2-amino-4-chlorophenol; ortho-aminophenol; salicylamide; 
     (g) mercaptans of the general formula                           
      wherein R 1 , R 2  and R 3  independently are selected from the group consisting of hydrogen, linear and branched acyclic groups, alicyclic groups, cyclic groups, and aryl groups having from about 1 to about 30 carbon atoms, and may contain one or more functionalities selected from the group consisting of carboxyl groups, hydroxyl groups, halogen atoms, nitro-groups, amine groups, and amide groups, and 
     (h) alcohols having the general formula ROH wherein R is selected from the group consisting of a linear and branched alkyl groups having from about 1 to about 30 carbon atoms, aryl groups, cyclic groups having from about 6 to about 30 carbon atoms, and olefinic and acetylenic groups having from about 1 to about 30 carbon atoms. Representative but non-exhaustive examples of alcohols which can be alkoxylated according to the present invention are: 1-dodecanol; 1-tridecanol; 1-tetradecanol; 1-pentadecanol; 1-hexadecanol; 1-heptadecanol; 1-octadecanol; 1-nonadecanol; 1-eicosanol; 1-docosanol; 2-methyl-1-undecanol; 2-propyl-1-nonanol; 2-butyl- 1-octanol; 2-methyl-1-tridecanol; 2-ethyl-i -dodecanol; 2-propyl- 1-undecanol; 2-butyl- 1-decanol; 2-pentyl- 1-nonanol, 2-hexyl- 1-octanol; 2-methyl-1-pentadecanol, 2-ethyl-1-tetradecanol; 2-propyl- 1-tridecanol; 2-butyl- 1-dodecanol; 2-pentyl- 1-undecanol; 2-hexyl- 1-decanol; 2-heptyl- 1-decanol; 2-hexyl- 1-nonanol; 2-octyl- 1-octanol; 2-methyl-1-heptadecanol; 2-ethyl-1-hexadecanol; 2-propyl- 1-pentadecanol; 2-butyl- 1-tetradecanol; 1-pentyl- 1-tridecanol; 2-hexyl-1-dodecanol; 2-octyl-1-decanol; 2-nonyl-1-nonanol; 2-dodecanol; 3-dodecanol; 4-dodecanol; 5-dodecanol; 6-dodecanol; 2-tetradecanol; 3-tetradecanol; 4-tetradecanol; 5-tetradecanol; 6-tetradecanol; 7-tetradecanol; 2-hexadecanol; 3-hexadecanol, 4-hexadecanol; 5-hexadecanol; 6-hexadecanol; 7-hexadecanol; 8-hexadecanol; 2-octadecanol; 3-octadecanol; 4-octadecanol; 5-octadecanol; 6-octadecanol, 7-octadecanol; 8-octadecanol; 9-octadecanol; 9-octadecenol; 2,4,6-trimethyl- 1-heptanol; 2,4,6,8-tetramethyl- 1-nonanol; 3,5,5-trimethyl- 1-hexanol; 3,5,5,7,7-pentamethyl- 1-octanol; 3-butyl- 1-nonanol; 3-butyl- 1-undecanol; 3-hexyl- 1-undecanol; 3-hexyl- 1-tridecanol; 3-octyl- 1-tridecanol 2-methyl-2-undecanol; 3-methyl-3-undecanol; 4-methyl-4-undecanol; 2-methyl-2-tridecanol; 3-methyl-3-tridecanol; 4-methyl-3-tridecanol; 4-methyl-4-tridecanol; 3-ethyl-3-decanol; 3-ethyl-3-dodecanol; 2,4,6,8-tetramethyl-2-nonanol; 2-methyl-3-undecanol; 2-methyl-4-undecanol; 4-methyl-2-undecanol; 5-methyl-2-undecanol; 4-ethyl-2-decanol; 4-ethyl-3-decanol; tetracosanol; hexacosanol; octacosanol; triacontanol; dotriacontanol; hexatriacontanol; 2-decyltetradecanol; 2-dodecylhexadecanol; 2-tetradecyloctadecanol; 2-hexadecyleicosanol, and unsaturated alcohols such as 1-hexyn-3-ol; oleyl alcohol (technically cis-9-octadecene 1-ol); 2,5-dimethyl-4-octyne-3,6-diol 2,4,7,9-tetramethyl-n-decyne-4,7-diol;, 3-dodecene-1-ol; and 3,6- dimethyl-8-dodecene- 1-ol. 
     While the invention is effective to alkoxylate all classes of alcohols, including but not necessarily limited to saturated and unsaturated alcohols, saturated alcohols are preferred. Of these, polyalkylene glycols are preferred, with polyethylene glycol being most preferred. 
     The alkoxylation reaction may be catalyzed using any suitable catalyst. Both basic and acidic catalysts may be used. Suitable catalysts include, but are not neesaily limited to: potassium hydroxide sodium hydroxide; alkylated alumfinum fluorides, alkylated aluminum halides organoaluminum zinc compounds, calcium, strontium and barium acetates and naphthanatesI BF 3  or SiF 4  and metal alkyls or metal alkoxides; and, hydrotluoric acids and metal alkoxides. 
     The alkoxylation may be carried out at ambient pressure or at pressures above or below ambient, as long as the alkylene oxide is maintained in the vapor phase. Normally, the pressure is from about −14 to about 30 pounds per square inch (psi). Pressures below about 20 psi are preferred. Referring to FIG. 1, in order to conduct the reaction, a suitable reactor that can hold vacuum and pressure may be modified to receive gas or vapor into the top of the reactor. The top of the stainless steel receptacle 16 containing liquid and gaseous ethylene oxide is connected with a tube, hose, or pipe 12 to the vent hole 14 on the reactor head 15. The flow of ethylene oxide gas or vapor is controlled by the valves on the tube 12. The tube 12 preferably includes a “tee” with two valves 18 so that the existing vent hole 14 on the reactor head 15 can be used both for charging ethylene oxide vapor into the reactor 10 through the tube 12 and for venting the reactor 10. A more preferred alternative is to use a reactor with a separate vent hole for venting reactor pressure. Ethylene oxide vapors are allowed to diffuse from the receptacle 16 into the reactor 10 through the tube 12. The separate vent hole is used to release residual inert atmosphere in the reactor once all of the charged ethylene oxide has reacted. 
     Suitable alkylene oxide adducting materials are alpha and beta alkylene oxides, preferably ethylene oxide, propylene oxide or mixtures thereof most preferably ethylene oxide. The alkoxylated product may have any desired content of the alkoxy adducting material. Where an alcohol is ethoxylated, ethylene oxide will normally comprise from about 20 to about 90 wt% of the alkoxylated product. 
     A suitable amount of catalyst for use in the reaction is from about 0.05 to about 10.0 weight percent catalyst based upon the weight of the total reaction mixture. Preferred levels of catalyst are from about 0.1 to about 6.0 wt% based on the total reaction mixture weight. 
    
    
     The invention will be better understood with reference to the following examples, which are provided to illustrate the invention, but not to limit the invention. 
     EXAMPLE 1 
     After observing undesirable flock in batches of ethoxylated heavy ethylene glycol (EHEG), a series of experiments was performed to determine the cause for flocculation. No correlation could be observed between the percentage of flock and: the percentage of catalyst (in this case, KOH); the reaction temperature (100-160° C.); the oxide addition rate; or the hydroxyl number. 
     EXAMPLE 2 
     Experiments were undertaken to determine whether ethoxylation using only ethylene oxide vapors would prevent flock formation. In the following reaction, ethylene oxide vapor was allowed to diffuse through a tube into a Parr reactor and into contact with the substrate—flash heavy ethylene glycol (FHEG, a stream of PEG produced by Oxychem from which light ends were stripped out). The following 
     
       
         
               
               
               
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
               
               
               
             
           
               
                   
               
               
                   
                 FHEG 
                   
                 EO 
                 Total 
                 Total 
                 Sample 
                 % 
                 Base 
                 Th Base 
               
               
                 Rxn. # 
                 (g) 
                 KOH 
                 added 
                 EO 
                 Product 
                 (g) 
                 H 2 O 
                 # 1   
                 # 1   
                 ° F. 2   
                 hr. 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 1319-147 
                 957.03 
                   
                   
                   
                 957.03 
                 a. 110.12 
                 .03 
                   
                   
                 230 
                   
               
               
                 (liq. EO) 
               
               
                   
                 846.91 
                 5 (aq) 
                   
                   
                 851.91 
                   
                   
                   
                   
                 320 
               
               
                   
                 846.91 
                 1.528 
                   
                   
                 848.4- 
                 b. 64.39 
                 0.11 
                 2.08 
                 2.65 
                 320 
                 0.7 
               
               
                   
                 782.64 
                 1.41 
                 250 
                 250 
                 1034 
                 c. 204.1 
                   
                   
                 2.01 
                 320 
                 0.4 
               
               
                   
                 628.2 
                 1.13 
                   
                 200.7 
                 829.95 
                 d. 800.01 
               
               
                 1319-149 
                 1029.2 
                   
                   
                   
                 1029.2 
               
               
                 (liq. EO) 
               
               
                   
                 1029.2 
                 0.6 
                   
                   
                 1029.8 
                   
                   
                   
                 0.262 
               
               
                   
                 1029.2 
                 0.183 
                   
                   
                 1029.4 
                 a. 116.9 
                   
                   
                 0.262 
                 320 
                 0.08 
               
               
                   
                 912.32 
                 0.163 
                  20 
                   
                 932.48 
                   
                   
                   
                 0.257 
                 320 
                 0.75 
               
               
                 1319-151 
                 1028.1 
                   
                   
                   
                   
                   
                   
                   
                   
                  82 
               
               
                 (EO gas 
               
               
                 or vap.) 
               
               
                   
                 1028.1 
                 3 
                   
                   
                 1031.1 
                   
                   
                   
                 1.31 
               
               
                   
                 1028.1 
                 0.917 
                   
                   
                 1029 
                 a. 33.93 
                 0.102 
                 0.969 
                 1.312 
                 223 
                 2.75 
               
               
                   
                 994.2 
                 0.887 
                   
                   
                 995.1 
                 b. 62.91 
                 0.06 
                 0.985 
                 1.312 
                 225 
                 1.08 
               
               
                   
                 931.35 
                 0.831 
                  20 
                  20 
                 952.18 
                   
                   
                   
                 1.28 
                 267 
                 1.08 
               
               
                   
                 931.35 
                 0.831 
                  90 
                 110 
                 1042.2 
                   
                   
                   
                 1.17 
                 270 
                 6.8 
               
               
                   
                 931.35 
                 0.831 
                 185 
                 295 
                 1227.2 
                 c. 12.0 
                   
                   
                 0.997 
                 270 
                 8? 
               
               
                   
               
               
                   1 In equivalency in terms of mg of KOH per g of sample.  
               
               
                   2 Reactor temperature.  
               
             
          
         
       
     
     The last listed sample 1319-151 exhibited an OH# of 435.6. The samples from reaction 1319-151 remained clear without any trace of flock throughout an observation period of several months. Both 1319-147 and 1319-149 were synthesized with liquid ethylene oxide, and both developed flock. 
     EXAMPLE 3 
     To demonstrate that using liquid ethylene oxide for ethoxylation would promote flock formation, a clear sample of PEG 200 (from a commercial vendor, similar to FHEG) was ethoxylated with liquid ethylene oxide under the following conditions: 
     
       
         
               
               
               
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
               
               
               
             
           
               
                   
               
               
                 PEG 
                   
                   
                   
                   
                   
                   
                   
                   
                 Th 
                   
                   
               
               
                 200 
                   
                 EO 
                 Total 
                 Total 
                 Sample 
                 % 
                   
                 Base 
                 Base 
               
               
                 (g) 
                 KOH 
                 added 
                 EO 
                 Product 
                 (g) 
                 H 2 O 
                 OH # 
                 # 1   
                 # 1   
                 ° F. 2   
                 hr 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 848.3 
                 2.5 
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                   
                 0.764 
                   
                   
                   
                 A. 30.13 
                 0.026 
                 574.4 
                 1.12 
                 1.33 
                 230 
                 23 
               
               
                 818.2 
                 0.74 
                 200 
                 200 
                 1018.9 
                 B. 172.1 
                   
                 439.9 
                 0.74 
                 1.07 
                 230 
                  1 
               
               
                 680 
                 0.61 
                   
                 166.22 
                 846.9 
                 C. 96.73 
                   
                   
                   
                   
                 230 
               
               
                 602.3 
                 0.54 
                   
                 147.23 
                 750.1 
                 D. 713 
               
               
                   
               
               
                   1 In equivalency in terms of mg of KOH per g of sample  
               
               
                   2 Reactor temperature.  
               
             
          
         
       
     
     All samples developed flock within 24 hours. 
     EXAMPLE 4 
     In order to confirm the results in Example 2, another reaction was conducted. The ethylene oxide vapors were added through the dip tube (20 in FIG.  1 ). The reaction is summarized below: 
     
       
         
               
               
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
               
               
             
           
               
                   
               
               
                 Rxn. 
                   
                   
                 Total 
                   
                   
                 % 
                 Base 
                   
                   
                   
               
               
                 # 
                 FHEG 
                 KOH 
                 EO 
                 Total 
                 Sample 
                 H 2 O 
                 # 
                 ° F. 
                 hr. 
                 Appearance 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 1319-159 
                 1001.9 
                 2.92 
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 (EO vap.) 
                 (aq) 
               
               
                   
                 1001.9 
                 0.89 
                   
                 1002.8 
                 a. 39.95 
                 0.3 
                 1.87 
                 230 
                 1.1 
                 clear 
               
               
                   
                 961.99 
                 0.857 
                   
                  962.8 
                 b. 31.8 
                 0.07 
                 0.87 
                 230 
                 1.25 
                 clear 
               
               
                   
                 930.2 
                 0.829 
                 286 
                 1217 
                 c. 55.04 
                   
                 0.78 
                 260 
                   
                 clear 
               
               
                   
                 887.53 
                 0.791 
                 272.9 
                 1161.2 
                 d. 1121.5 
                   
                   
                   
                   
                 clear 
               
               
                   
               
             
          
         
       
     
     The OH# of the sample with 930.2 FHEG was 448.7. 
     Samples and products from all previous reactions in which ethylene oxide liquid was charged to the reactor developed flock in less than 24-48 hours. In contrast, all of the samples from reaction 1319-159 were sparkling clear with no flock after 5 days at ambient temperature, and remained clear throughout an observation period of several months. 
     EXAMPLE 5 
     Seven more ethoxylations were conducted in Parr reactors using ethylene oxide in the vapor phase. The conditions and results are given in the following Table: 
     
       
         
               
               
               
               
               
               
               
               
               
               
               
               
             
               
             
               
               
               
               
               
               
               
               
               
               
               
               
             
               
             
               
               
               
               
               
               
               
               
               
               
               
               
             
               
             
               
               
               
               
               
               
               
               
               
               
               
               
             
               
             
               
               
               
               
               
               
               
               
               
               
               
               
             
               
             
               
               
               
               
               
               
               
               
               
               
               
               
             
               
             
               
               
               
               
               
               
               
               
               
               
               
               
             
               
             
               
               
               
               
               
               
               
               
               
               
               
               
             
           
               
                   
               
               
                   
                   
                 EO 
                 Total 
                   
                   
                 % 
                 BASE 
                   
                   
                   
                   
               
               
                 FHEG 
                 KOH 
                 add. 
                 EO 
                 Total 
                 Sample 
                 H 2 O 
                 # 
                 OH # 
                 ° F. 
                 hr. 
                 Appearance 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Reaction 1319-163 (EO vapors to vapor space with about 30″ of vacuum initially) 
               
             
          
           
               
                 995.1 
                 2.95 
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 995.1 
                 0.902 
                   
                   
                 996 
                 A. 58.78 
                 0.09 
                 0.9 
                   
                 230 
                   
                 clear 
               
               
                 936.4 
                 0.85 
                   
                   
                 937.22 
                 B. 41.25 
                 0.05 
                 0.9 
                   
                 230 
                 0.5 
                 clear 
               
               
                 895.2 
                 0.81 
                 260 
                 260 
                 1156 
                 C. 74.67 
                   
                   
                   
                 260 
                 2.5 
                 sl. hazy 
               
               
                 837.34 
                 0.76 
                   
                 243.2 
                 1081.3 
                 D. 1034.8 
                   
                   
                   
                   
                   
                 sl. hazy 
               
             
          
           
               
                 Reaction 1319-165 (EO vapor to vapor space with about 30″ of vacuum initially) 
               
             
          
           
               
                 990.4 
                 2.85 
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 990.4 
                 0.87 
                   
                   
                 991.27 
                 A. 39.9 
                   
                   
                   
                 230 
                 1.75 
                 clear 
               
               
                 950.5 
                 0.84 
                   
                   
                 951.4 
                 B. 35.12 
                   
                   
                   
                   
                   
                 clear 
               
               
                 915.5 
                 0.805 
                 275 
                 275 
                 1191.3 
                 C. 55.93 
                   
                   
                   
                 266 
                 2.7 
                 clear 
               
               
                 872.5 
                 0.767 
                   
                 262.09 
                 1135.3 
                 D. 1009 
                   
                 0.63 
                 443.8 
                   
                   
                 clear 
               
             
          
           
               
                 1319-167 (EO vapor to vapor phase with about 30″ vacuum initially) 
               
             
          
           
               
                 995.8 
                 2.95 
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 995.8 
                 0.902 
                   
                   
                 996.7 
                 A. 25.56 
                 0.05 
                 0.8 
                   
                 230 
                 1.25 
                 clear 
               
               
                 970.26 
                 0.878 
                   
                   
                 971.14 
                 B. 32.3 
                 0.02 
                 0.81 
                   
                 230 
                   
                 clear 
               
               
                 937.99 
                 0.849 
                 291 
                 291 
                 1229.8 
                 C. 52.51 
                   
                   
                   
                 230 
                 3.38 
                 sl.hazy 
               
               
                 897.9 
                 0.81 
                   
                 278.6 
                 1177.3 
                 D. 1107 
                   
                 0.65 
                 437.1 
                   
                   
                 sl. hazy 
               
             
          
           
               
                 1319-169 (EO vapor through dip tube with about 30″ of vacuum initially--the EO cylinder was 
               
               
                 very full) 
               
             
          
           
               
                 940.3 
                 2.87 
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 940.3 
                 0.877 
                   
                   
                   
                 A. 32.33 
                 0.1 
                   
                   
                 230 
                 1 
                 clear 
               
               
                 907.98 
                 0.847 
                   
                   
                 908.8 
                 B. 32.56 
                 0.05 
                 0.89 
                   
                 230 
                 1 
                 clear 
               
               
                 875.45 
                 0.817 
                 115 
                 115 
                 991.3 
                 C. 64.46 
                   
                 0.79 
                 522.1 
                 230 
                 1 
                 clear 
               
               
                 818.08 
                 0.763 
                 125 
                 232.5 
                 1051.3 
                 D. 64.3 
                   
                 0.75 
                 456.1 
                 230 
                 0.75 
                 clear 
               
               
                 768.04 
                 0.717 
                   
                 218.3 
                 987.01 
                 E. 233.5 
                   
                   
                   
                   
                   
                 clear 
               
               
                 586.35 
                 0.547 
                  50 
                 216.61 
                 803.5 
                 F. 740.3 
                   
                   
                   
                   
                   
                 clear 
               
             
          
           
               
                 Reaction 1319-171 (EO vapors via diptube with about 30″ of vacuum initially) 
               
             
          
           
               
                 783.3 
                 2.4 
                   
                   
                 785.7 
                   
                   
                   
                   
                   
                   
                   
               
               
                   
                 0.73 
                   
                   
                 784.03 
                 a. 44 
                 0.12 
                 0.9 
                   
                 230 
                 1.1 
               
               
                   
                   
                   
                   
                   
                 b. 63.2 
                 0.06 
                 0.9 
                   
                 230 
                 0.4 
                 — 
               
               
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                 purge 
               
               
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                 and vac. 
               
               
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                 30″ 
               
               
                 676.2 
                 0.63 
                 200 
                 200 
                 876.8 
                 c. 107.4 
                   
                   
                   
                 230 
                 2.25 
                 ? 
               
               
                 593.4 
                 0.556 
                   
                 175.5 
                 769.4 
                 d. 727.4 
                   
                   
                 451.5 
                   
                   
                 sl. flock 
               
             
          
           
               
                 1319-173 (EO vapors through diptube with about 30″ of vacuum initially) 
               
             
          
           
               
                 805.1 
                 2.5 
                   
                   
                 807.6 
                   
                   
                   
                   
                   
                   
                   
               
               
                 805.1 
                 0.76 
                   
                   
                 803.86 
                 a. 27.7 
                 0.15 
                 1 
                   
                 230 
                 1 
               
               
                   
                   
                   
                   
                   
                 b. 16.2 
                 0.07 
                 0.95 
                   
                 230 
                 1.25 
                 N 2  purge 
               
               
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                 vac. 30″ 
               
               
                 761.24 
                 0.722 
                 228 
                 228 
                 989.96 
                 c. 110 
                   
                   
                   
                 230 
                 1.25 
                 EO in 
               
               
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                 continu- 
               
               
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                 ously 
               
               
                 676.7 
                 0.64 
                 202.7 
                 202.7 
                 879.96 
                 d. 830.1 
                   
                   
                   
                   
                   
                 clear 
               
             
          
           
               
                 1319-175 (EO vapors to vapor space with vacuum) 
               
             
          
           
               
                 767.9 
                 2.38 
                   
                   
                 770.3 
                   
                   
                   
                   
                   
                   
                   
               
               
                 767.9 
                 0.73 
                   
                   
                 768.6 
                 a. 16.83 
                 0.18 
                 0.96 
                   
                 230 
                 1 
               
               
                 751.1 
                 0.71 
                   
                   
                 751.8 
                 b. 18.1 
                 0.08 
                 0.96 
                   
                 230 
                 1 
                 N 2   
               
               
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                 purge 
               
               
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                 vac. 
               
               
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                 30″ 
               
               
                 732.99 
                 0.694 
                 220 
                 220 
                 953.7 
                 c. 106.2 
                   
                   
                   
                   
                   
                 EO 
               
               
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                 in 
               
               
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                 intermit- 
               
               
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                 tently 
               
               
                 651.37 
                 0.617 
                   
                 195.5 
                 847.49 
                 d. 
                   
                   
                   
                   
                   
                 clear 
               
               
                   
               
             
          
         
       
     
     The samples from 1319-163, -165, -167, -169, -173, and -175 largely remained clear throughout an observation period of several months. A number of the samples developed a slight flock later and appeared slightly hazy. The amounts of flock in these samples were less than those present in samples synthesized with liquid EO. Also, the flock was finer and was more evenly distributed. It was believed that if the EO vapor is pulled from the EO container too fast, rapid effervescence or flash boiling of EO liquid would cause fine liquid droplets of EO to be carried into the reactor, thereby incorporating liquid EO in the reactions. 
     EXAMPLE 6 
     An experiment (1319-177) was performed using an atomizer to discharge EO vapors into the Parr reactor. The atomizer was installed onto the diptube of one of the Parr reactors in which the length of the dip tube was shortened by cutting off about two inches. In another experiment using a different reactor (1319-179), EO vapors were charged into the reactor vapor phase with an initial vacuum pressure of about 5″ mercury. The conditions and results are summarized in the following Table: 
     
       
         
               
               
               
               
               
               
               
               
               
               
               
               
             
               
             
               
               
               
               
               
               
               
               
               
               
               
               
             
               
             
               
               
               
               
               
               
               
               
               
               
               
               
             
           
               
                   
               
               
                   
                   
                 EO 
                 Total 
                   
                   
                 % 
                 Base 
                   
                   
                   
                   
               
               
                 FHEG 
                 KOH 
                 added 
                 EO 
                 Total 
                 Sample 
                 H 2 O 
                 # 
                 OH # 
                 ° F. 
                 hr. 
                 Appearance 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Reaction 1319-177 (EO vapor through diptube and atomizer, 30″ var.) 
               
             
          
           
               
                 1334 
                 4.13 
                   
                   
                 1338.1 
                   
                   
                   
                   
                   
                   
                   
               
               
                 1334 
                 1.26 
                   
                   
                 1335.3 
                 a. 32.33 
                 0.4 
                 0.92 
                   
                 230 
                 2.1 
                 Drying 
               
               
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                 without 
               
               
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                 nitrogen 
               
               
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                 sparge 
               
               
                 1301.7 
                 1.23 
                   
                   
                 1302.9 
                 b. 76.3 
                 0.1 
                 0.95 
                   
                 230 
                 1.3 
               
               
                 1225.5 
                 1.16 
                 255 
                 1481.6 
                   
                   
                   
                   
                   
                 230 
                 3.611 
               
               
                 1225.1 
                 1.16 
                 100 
                 355 
                 1581.6 
                   
                   
                   
                   
                 230 
                 1.6 
               
               
                 1225.1 
                 1.16 
                   
                 355 
                 1581.6 
                 c. 1540.1 
                   
                   
                 453.3 
                   
                   
                 clear (4 
               
               
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                 days) 
               
             
          
           
               
                 Reaction 1319-179 (EO vapors to vapor phase w/5″ vacuum pressue initially) 
               
             
          
           
               
                 831.7 
                 2.43 
                   
                   
                 834.13 
                   
                   
                   
                   
                   
                   
                   
               
               
                 831.7 
                 0.743 
                   
                   
                 832.44 
                 a. 44.3 
                 0.11 
                 0.94 
                   
                 230 
                 1.1 
               
               
                 787.4 
                 0.703 
                   
                   
                 788.14 
                 b. 45.3 
                 0.01 
                 0.92 
                   
                 230 
                 1 
               
               
                 742.18 
                 0.663 
                 134 
                 134 
                 874.84 
                   
                   
                   
                   
                 230 
                 1.2 
               
               
                 742.18 
                 0.663 
                  88 
                 220 
                 962.84 
                   
                   
                   
                   
                 230 
                 1.2 
               
               
                 742.18 
                 0.663 
                   
                 220 
                 962.84 
                 c. 926.7 
                   
                   
                 444.7 
                   
                   
                 clear 
               
               
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                 (4 days) 
               
               
                   
               
             
          
         
       
     
     The products were clear initially and remained clear throughout an observation period of several months. 
     EXAMPLE 7 
     In reaction 1319-183, liquid EO was added or charged into the reactor containing FHEG via the same atomizer used for reaction 1319-177. The resulting product had flock. 
     EXAMPLE 8 
     The procedures of Example 2 were repeated. No vacuum was used. The conditions and results are summarized in the following Table: 
     
       
         
               
               
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
               
               
             
           
               
                   
               
               
                   
                   
                 EO 
                 Total 
                   
                   
                   
                   
                   
                   
                 Appear- 
               
               
                 FHEG 
                 KOH 
                 added 
                 EO 
                 Total 
                 Sample 
                 % H 2 O 
                 Base # 
                 ° F. 
                 hr. 
                 ance 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 551.5 
                 1.61 
                   
                   
                 553.11 
                   
                   
                   
                 220 
                   
                   
               
               
                 551.5 
                 0.49 
                   
                   
                 551.99 
                 a. 24.18 
                 0.095 
                 10.6 
                 215 
                 2.3 
               
               
                 527.34 
                 0.47 
                 48 
                  48 
                 575.81 
                   
                   
                   
                 265 
                 2.1 
               
               
                 527.34 
                 0.47 
                 89 
                 137 
                 664.81 
                   
                   
                   
                 265 
                 6 
               
               
                 527.34 
                 0.47 
                 30 
                 167 
                 194.81 
                   
                   
                   
                 260 
                 2.5 
               
               
                 527.34 
                 0.47 
                   
                 167 
                 694.81 
                 b. 38.2 
                   
                   
                 260 
                 2.5 
                 clear 
               
               
                   
               
             
          
         
       
     
     The samples were clear and remained clear throughout an observation period of several months. 
     EXAMPLE 9 
     A mixture of PEG 200 and KOH flakes was charged into a Parr reactor and dried. The procedures of Example 2 then were repeated. The conditions and results are summarized in the following Table: 
     
       
         
               
               
               
               
               
               
               
               
               
               
               
             
               
             
               
               
               
               
               
               
               
               
               
               
               
             
           
               
                   
               
               
                 PEG 
                   
                 EO 
                 Total 
                   
                   
                   
                 Base 
                   
                   
                   
               
               
                 200 
                 KOH 
                 added 
                 EO 
                 Total 
                 Sample 
                 % H 2 O 
                 # 
                 ° F. 
                 hr. 
                 Appearance 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Reaction 1318-155 (EO vapor to reactor head space) 
               
             
          
           
               
                 803.54 
                 2.34 
                   
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 803.54 
                 0.715 
                   
                   
                   
                 a. 31.2 
                 0.22 
                   
                 230 
                 1.6 
               
               
                   
                   
                   
                   
                   
                 b. 8.7 
                 0.14 
                   
                 230 
                 2.5 
               
               
                   
                   
                   
                   
                   
                 c. 12.3 
                 0.19 
                   
                 230 
                 1.2 
               
               
                   
                   
                   
                   
                   
                 d. 16 
                 0.16 
                   
                 240 
                 1.6 
               
               
                 735.4 
                 0.654 
                   
                   
                 736.06 
                 e. 16.8 
                 0.23 
                   
                 240 
                 1.6 
               
               
                 718.6 
                 0.64 
                 122  
                 122 
                 841.3 
                 f. 238.9 
                   
                   
                 230 
                 2.5 
                 clear 
               
               
                 514.5 
                 0.46 
                 38 
                 125.4 
                 640.6 
                 g. 202.1 
                   
                   
                 230 
                 1.6 
                 clear 
               
               
                 352.2 
                 0.31 
                 32 
                 117.8 
                 470.3 
                 h. 204.4 
                   
                   
                 230 
                 1.7 
                 clear 
               
               
                 199.1 
                 0.18 
                 20 
                 86.6 
                 285.9 
                 i. 283 
                   
                   
                 230 
                 1.95 
                 clear 
               
               
                   
               
             
          
         
       
     
     The samples were clear and remained clear throughout an observation period of several months. 
     EXAMPLE 10 
     The procedures of Example 9 were repeated using an initial vacuum of 10″ inside the reactor. The reaction (1318-157) and results are summarized in the following Table: 
     
       
         
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
             
           
               
                   
               
               
                 PEG 
                   
                 EO 
                 Total 
                   
                   
                 % 
                   
                   
               
               
                 200 
                 KOH 
                 added 
                 EO 
                 Total 
                 Sample 
                 H 2 O 
                 ° F. 
                 hr. 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 835.33 
                 2.43 
                   
                   
                 837.76 
                   
                   
                   
                   
               
               
                 835.33 
                 0.743 
                   
                   
                 836.07 
                 a. 14.7 
                 0.06 
                 230 
                 5.3 
               
               
                 820.64 
                 0.73 
                   
                   
                 821.37 
               
               
                 820.64 
                 0.73 
                 128 
                 128 
                 949.37 
                   
                   
                 230 
                 2.2 
               
               
                 820.64 
                 0.73 
                 132 
                 260 
                 1081.4 
                 b. 1018.6 
                   
                 230 
                 4.3 
               
               
                   
               
             
          
         
       
     
     The samples were clear and remained clear throughout an observation period of several months. 
     EXAMPLE 11 
     Finally, an ethoxylation with EO vapor was conducted in a 60-gallon reactor in the pilot plant. The reaction (1318-159) is summarized below: 
     
       
         
               
               
               
               
               
               
               
               
               
               
             
           
               
                   
               
               
                   
                 KOH 
                 EO 
                 Total 
                   
                 % 
                   
                   
                   
                 Appear- 
               
               
                 FHEG 
                 (g) 
                 added 
                 EO 
                 Sample 
                 H 2 O 
                 Base # 
                 ° F. 
                 hr. 
                 ance 
               
               
                   
               
             
             
               
                 248 lb 
                 148 
                   
                   
                 a. 6 oz 
                 0.38 
                   
                 220 
                 5 
                 clear 
               
               
                   
                   
                   
                   
                 b. 16 oz 
                 0.08 
                 5927 
                 220 
                 7 
                 clear 
               
               
                   
                   
                 78 lb. 
                 78 lb. 
                 c. 16 oz 
                   
                 4685 
                   
                   
                 clear 
               
               
                   
                   
                 13 lb. 
                 19 lb. 
                 d. 336 lb. 
                   
                  433 
                   
                   
                 clear 
               
               
                   
               
             
          
         
       
     
     All samples remained clear for at least one month. 
     Persons of ordinary skill in the art will appreciate that many modifications may be made to the embodiments described herein without departing from the spirit of the present invention. Accordingly, the embodiments described herein are illustrative only and are not intended to limit the scope of the present invention.