Abstract:
An isocyanate compound of the general formula R(NCO) n , wherein R is  her an aliphatic or an aromatic radical or a combination of both, and n is 1 or a larger integer is prepared by the process comprising dissolving in a high temperature boiling point solvent contained in an agitated, jacketed reactor vessel, an amine of the formula R(NH 2 ) n , completing a hydrochlorination and precipitation step to form a colloidal suspension of microcrystalline salt particles of amine hydrochloride salt R(NH 2 ) n .nHCl, introducing oxalyl chloride with agitation and by subsurface injection into the amine hydrochloride salt solution to form an intermediate of amine oxamyl chloride in situ which is thermally decomposed to yield an isocyanate of the general formula R(NCO) n , and separating and purifying the isocyanate by distillation. The unreacted oxalyl chloride and high temperature reaction solvent are recovered by distillation and by absorption from the HCl by-product and are recycled. The by-product HCl is also partially recycled and used for hydrochlorination.

Description:
DEDICATORY CLAUSE 
     The invention described herein was made in the course of or under a contract or subcontract thereunder with the Government and may be manufactured, used, and licensed by or for the Government for governmental purposes without the payment to me of any royalties thereon. 
    
    
     BACKGROUND OF THE INVENTION 
     Isocyanates are required by the US military as curing agents for hydroxyl-terminated polymers, which are used as binders in many cast-cured solid propellants and plastic-bonded explosives. Several factors are considered in selecting the best isocyanate for the desired application: processability and mechanical properties, pot life and cure rate, toxicity, tendency to hydrolyze, stability and aging, and availability. 
     3-Isocyanatomethyl-3,5,5-trimethylcyclohexyl isocyanate, commonly known as isophorone diisocyanate (IPDI), excels in most of these categories. Its desirable pot life and cure rate are due to two isocyanate groups with different reactivities, one hindered and the other unhindered. Generally, isocyanates are extremely toxic, but IPDI&#39;s lower volatility makes it easier and safer to handle than other candidates. The mechanical and chemical properties imparted by use of IPDI are also good. 
     Current Process for IPDI Employing a Final Phosgenation Step 
     IPDI is made from isophorone by the present commerical route shown below. All steps can be accomplished through commercially feasible routes. The final phosgenation step results in high yield, but it presents major problems and capital equipment expenditures because it involves the use of phosgene, an extremely poisonous gas. Only large-scale (millions of pounds a year) production by a continuous process renders a phosgenation route feasible. Indeed, other isocyanates made via phosgenation are available in the United States, but none offers the advantages of IPDI discussed above. ##STR1## 
     The characteristics of IPDI makes it the choice of curing agents in the isocyanate series; however, because the final step of the present commercial route from IPDA involves the use of phosgene, companies, both foreign and domestic, are reluctant at establishing a US capability because of the current small US military demand for IPDI, because of the strict OSHA and EPA regulations, and because U.S. industrial needs are currently met by Veba-Chemie&#39;s production at 3/pound. 
     Because the interest in processes for preparing isocyanates without phosgene has been an active concern of industry, particularly in recent years as regulations for handling the highly toxic gas have been tightened, much of the current literature available concerns this topic. One such source, U.S. Pat. No. 4,322,365, discloses a method wherein isocyanates are prepared by thermal decomposition of oxalic acid ester amides at not less than 300° C. The oxalic acid amides of the formula R&#39;NHCOCOOR&#34; wherein R&#39; is an aliphatic, cycloaliphatic, ar-aliphatic, aliphatic-aromatic, or aromatic radical and R&#34; is an aliphatic, cycloaliphatic, ar-aliphatic, aliphatic-aromatic, or aromatic radical yield isocyanates which are valuable starting materials for the preparation of crop protection agents, pesticides, dyes, synthetic resins, plastics, textile waterproofing agents, detergents, and adhesives. For further information about this non-phosgene process for preparing isocyanates and uses of same, refer to U.S. Pat. No. 4,322,365 and additional references contained therein. 
     Compared to the conventional processes, the process of U.S. Pat. No. 4,322,365 is said to &#34;give isocyanates more simply and economically&#34;. Also the difficulties with respect to distillation, corrosion problems, and reduced activity of the end products as compared to earlier prior art process, are said to not arise to a significant degree. Additionally, it is an advantage that the process avoids toxic and corrosive chlorocarbonic acid esters, expensive selenuim-catalyzed or noble metal-catalyzed reductible carbonylation of nitro compounds (entailing high pressures, toxic carbon monoxide, and toxic or expensive catalysts), and the involved reaction of amines with dimethyl carbonate (which form numerous by-products). 
     Although many of the disadvantages of the earlier prior art processes are obviated by the process of U.S. Pat. No. 4,322,365 which employs starting materials prepared by reacting amines with dialkyl oxalates, a one-step process under moderate reaction conditions (80° C.-180° C., less than 2 hours) would be advantageous where optimum energy considerations and the ready availability of starting materials are placed in proper perspective with the process of U.S. Pat. No. 4,322,365. Thus, a one-step process because of energy conservation, not requiring the use of phosgene, and not requiring the starting materials of oxalic acid ester amides which are prepared by reacting amines with dialkyl oxalates which are not readily available, as are the amine hydrochloride salts, is considered to be a superior process. 
     Therefore, an object of this invention is to provide a one-step process for preparing isocyanates. 
     A further object of this invention is to provide a one-step process for preparing isocyanates which does not require the use of phosgene. 
     Still a further object of this invention is to provide a one-step process for preparing isocyanates from oxalyl chloride and amines reacted under moderate reaction conditions in an appropriate high boiling point solvent in the range of 80° C.-180° C. 
     SUMMARY OF THE INVENTION 
     The process of this invention for preparing isocyanates is a one-step process comprising heating an amine or an amine hydrochloride salt with excess oxalyl chloride (OxCl) in a high boiling point solvent from about 80° C.-180° C. for a reaction time of about 0.5-2 hours. 
     An appropriate high boiling point solvent is selected from o-dichlorobenzene (DCB) and decahydronaphthalene (Decalin). 
     After forming the isocyanate, the excess oxalyl chloride and solvent are removed and the isocyanate is separated and purified by distillation. 
     The brief description of the process employing isophorone diamine (IPDA) as the amine reactant is as follows: 
     IPDA is dissolved in DCB, and dry hydrogen chloride (HCl) gas in excess is bubbled through in an agitated, jacketed reactor. The excess HCl passes through the reflux condenser, dry ice traps, oil bubbler, and liquid backup trap, and is absorbed in a water scrubber. 
     OxCl (3 times theoretical) is added to the IPDA-dihydrochloride salt mixture, and the temperature is brought up to the final target value (in the range of 80°-180° C.) over a period of 0.5 to 2 hour. An unstable intermediate is formed and is immediately thermally decomposed to form IPDI plus carbon monoxide (CO) and HCl. The excess OxCl is promptly removed by distillation at 130° C. 
     About two-thirds of the DCB solvent is next removed by vacuum distillation. The residual solution of IPDI in DCB is transferred to a smaller vacuum distillation apparatus for final purification. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     A block flow diagram for isophorone diamine (IPDA) conversion to isophorone diiscocyanate (IPDI) by the oxalyl chloride (OxCl) route, and using o-dichlorobenzene (DCB) as solvent, is depicted in FIG. 1 of the drawing. 
     FIG. 2 of the drawing depicts a block diagram of a projected commercial scale IPDI synthesis including flow streams by the oxalyl chloride route. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The one-step process of this invention for preparing isocyanates comprises reacting an amine or an amine hydrochloride salt with excess oxalyl chloride in a solvent selected from o-dichlorobenzene and decahydronaphthalene at a temperature from about 80° C.-180° C. for 0.5-2 hours. Excess oxalyl chloride and solvent are removed and the isocyanate is separated and purified by distillation. 
     The oxalyl radical --CO.CO-- of oxalyl chloride COCl.COCl (OxCl) reacts with isophrone diamine hydrochloride salt (IPDA.2HCl) to form the intermediate isophorone dioxamyl chloride which subsequently is thermally decomposed to yield isophorone diisocyanate (IPDI). The overall reaction process is represented by the equation*: ##STR2## 
    
     The block diagram shown in FIG. 1 of the drawings depicts the process of this invention for preparing isophorone diisocyanate. This process for preparing isophorone diisocyanate (IPDI) comprises dissolving IPDA in the high boiling point solvent o-dichlorobenzene (DCB) and bubbling dry HCl gas into the solution in excess to achieve hydrochlorination and precipitation. Oxalyl chloride (OxCl) (preferably 3 times theoretical) is added to the IPDA dihydrochloride salt (IPDA.2HCl) mixture, and the temperature is brought up to the final target value (in the range of 80° C.-180° C.) over a period of 0.5 to 2 hour. An unstable intermediate, isophorone dioxamyl chloride, undergoes thermal decomposition to yield IPDI+HCl+CO. IPDI is purified and separated by distillation. The excess OxCl is recycled, the DCB is recycled and the remaining tarry by-products are removed from the reactor system. 
     Table I below sets forth optimization experiments performed to establish combinations for the preferred embodiments. 
     
                                           TABLE I__________________________________________________________________________OPTIMIZATION EXPERIMENTS ON OXALYL CHLORIDE ROUTE  Salt    Maximum   Run  IPDIScale.sup.a  or  OxCl          Temperature (°C.)                    Time Yield.sup.bRun   (g) Amine      (eq.)          Oil Bath               Reaction                    (hr) (%) Comments__________________________________________________________________________ 1.sup.c   1   Salt      1.1 180  --   24.0 22  Hot addition.sup.d 2.sup.c   15  Salt      2   180  --   1.5  49  Hot,.sup.d slow addition (20 min) 3.sup.c   1   Salt      3   180  --   1.5  70  Hot addition.sup.d 4 100 Salt      3   180  --   1.5  &lt;1  Hot,.sup.d slow addition (120 min) 5 50  Salt      3   160-180               --   1.5  12  Hot,.sup.d slow addition (60 min) 6 1   Salt      1.1 180  --   1.0  5   -- 7 1   Salt      3   180  --   1.5  56  Hot addition.sup.d 8 1   Salt      3   180  --   2.0  62  -- 9 1   Amine      3   180  --   1.5  55  --10 0   Amine      3   160  --   2.0  38  --11 10  Amine      3   180  --   1.5  30  --12 10  Amine      3   180  --   1.5  28  All reagents distilled13 1   Salt      3   180  --   2.0  14  Old OxCl14 1   Amine      3   180  --   2.0  3.5 Old OxCl15 1   Amine      3   180  --   1.5  10  Distilled OxCl16 1   Salt      3   180  --   4.0  83  Old OxCl, new GC column17 1   Amine      3   180  --   4.0  40  --18 10  Salt      3   168-180               --   2.0  55  In presence of stainless steel19 1   Salt      3   180  --   2.0  80+ Old OxCl20 1   Salt      3   130  --   2.0  62  Temperature study21 1   Salt      3   155  --   2.0  63  Temperature study22 1   Salt      3   200  --   1.5  48  Temperature study23 10  Salt      3   200  176  2.5  40  Control24 10  Salt      6   190  100-120                    3.0  35  Excess OxCl lowered reaction                             temperature25 10  Salt      3   --   180  1.0  14.5                             Reaction in autoclave; sprang leak                             at 1 hr26 10  Salt      3   --   180  2.5  7   Reaction in autoclave; pressure                             reached 400 psi27 10  Salt      3   193  174  1.5  49  Condenser on stirrer to prevent                             loss of OxCl28 1   Salt      3   180  --   1.5  28  Alternative, less toxic solvent                             (decaline).sup.e29 45  Salt      3   --   165  1.5  46.9                             &#34;Tight&#34; glassware; 45.77% (18.8 g)                             isolated crude yield30 50  Salt      3   --   162  1.0  43  Salt made in situ; &#34;tight&#34; glassware;                             45.5% (22.8 g) crude yield31 100 Salt      3   --   156  2.0  50  Condenser held at -5° C.;                             exhaust gases                             trapped; &#34;tight&#34; glassare; 38.7%32 100 Salt      3   --   148  1.5  43.5                             Condenser held at -5° C.;                             exhaust gases                             trapped; &#34;tight&#34; glassware; 32.0%                             (29.1 g) isolated crude yield33 42  Salt      3   --   168  1.25 36  41% (15.7 g) isolated crude yield34 20  Salt.sup.f      3   --    80  31.0 34  Material balance study; atempt to                             favor intermediate formation; held                             at 40° C. for 4 hrs, at                             60° C. for 8 hrs35 10  Salt      3   --   167  7.75 32  High-dilution reaction, yield                             peaked at 5 hr36 7   Amine      3   --   157  29.0 40  Looked for intermediate formation in                             solution; held at 40° C. for 27                             hr, then                             heated to maximum temperature37 1   Amine      3   --   175  1.5  &lt;6  Mixed IPDA and OxCl neat, then                             heated solid in solvent to                             temperature;                             yield unknown because purity of solid                             unknown; fast injection of                             refluxed OxCl38 1   Salt      3   180  164  1.0  88  Temperature study at 1-g scale39 1   --  3   180  175  6.0                       100                         10  Demonstrates decomposition of                             IPDI heated in solution presence of                             OxCl40 7   Amine      3   180  --   1.0  4   Hot tube reaction (very low yield;                             mechanical problem)41 1   Salt      3   130  126  3.0  70  Temperature study at 1-g scale42 1   Salt      3   155  154  2.5  66  Temperature study at 1-g scale43 1   Salt      3   200  164  1.5  40  Temperature study at 1-g scale44 8.5 Salt      3   --.sup.g               168  1.5  78  New Adapter (subsurface injection                             of refluxed OxCl)45 10  Salt.sup.f      3   --.sup.g               165  1.5  55  Same as Run 44, except with in situ                             salt46 10  OLS.sup.h      2   --   165  2.3  7   Unsuccessful run; bad batch of off-                             line salt47 10  OLS.sup.h      2   --   165  0.5  1   Unsuccessful run; bad batch of off-                             line salt48 10  OLS.sup.h      2   --   167  1.5  68  New batch of off-line salt; 2 eq.                             OxCl gives lower yield than 3 eq.49 10  OLS.sup.h      3   --   165  1.5  78  Repeat of Run 44 for reproducibility                             (good check)50 10  Salt.sup.f      3   --   160  1.25 45  In situ salt formed and isolated,                             then reacted52 10  OLS.sup.g      3   --   165  1.6  70  OxCl removed after peak (40 min)  Salt                       to slow degradation of IPDI53 10  Salt.sup.f      3   --   150  1.5  45  OxCl removed after peak (30 min)  Salt                       to slow degradation of IPDI54 10  Salt.sup.f      3   --   130  1.6  72  Lower temperature increases yield  Salt                       with in situ salt (compare Run 51)55 10  Salt.sup.f      3   --   110  1.5  49  Temperature study; (in situ salt                             analyzed as 72% disalt)56 10  Salt.sup.f      3   --   110  1.5  49  Temperature study; (in situ salt                             analyzed as 76% disalt) [wet]57 10  OLF.sup.g      3   --   165  1.5  44  Run at 10% IPDI solution, to                             complete concentration study58 10  Salt.sup.f      3   --   130  1.5  60  OxCl removal after peak in IPDI yield                             with no loss of yield; (in situ salt                             analyzed at 90% disalt [wet])59 10  Salt.sup.f      3   --   130  2.0  55  OxCl addition took 5 min, OxCl removal                             after peak in IPDI yield, with little                             loss in yield; (in situ salt analyzed                             as 88% disalt [wet])60 10  Salt.sup.f      3   --   165  1.3  0   Salt formed in MeOH,  -o-DCB added,                             salt precipitated as MeOH was                             distilled                             off; no IPDI was formed.__________________________________________________________________________ .sup.a Weight of IPDA or salt charged. .sup.b Based on GC analysis. .sup.c These runs used reagent grade (99%) OxCl; all other runs used commerical (98%) OxCl. .sup.d Hot: OxCl added to reaction mixtures at ˜160° C.; cold: OxCl added at 25° C. and then heated temperature. .sup.e All other runs used DCB solvent. .sup.f In situ. .sup. g Electric heating mantle. .sup.h Offline salt. 
    
     Table II below shows the criticality of providing excess equivalents of oxalyl chloride for higher yields of isophorone diisocyanate (IPDI). 
     
                       TABLE II______________________________________Effect of Excess Oxalyl Chloride on Yield of IPDIEquivalents ofOxalyl Chloride         IPDI Yield Percent*______________________________________1.1           222.0           453.0           79______________________________________ *at 180° C. in odichlorobenzene (-oDCB) solvent for 1 hour; yield is based on IPDA charged. 
    
     Subsequent pilot plant scale runs showed that, with good agitation and efficient physical contact, a temperature of about 90° C. is optimal for rapid conversion of the in situ salt to give IPDI yields in excess of 80%. An important process feature for effecting efficient contact between the refluxed oxalyl chloride and the IPDA hydrochloride relates to subsurface injection of refluxed oxalyl chloride to prevent boil off again of the oxalyl chloride prior to chance for reaction. 
     Production Process Description 
     The procedure envisioned for a commercial scale production facility is described below in sequence and is conveniently illustrated in FIG. 2 for easy reference. IPDA is dissolved in o-DCB, and dry hydrogen chloride gas in excess is passed therein in an agitated, jacketed reactor. The excess HCl and CO (originating from the recycled incoming hydrogen chloride gas, see below) is passed to a scrubber and is scrubbed by dilute caustic soda. The final CO gas is vented. 
     The IPDA-dihydrochloride salt in o-DCB in the reactor is heated up, and oxalyl chloride is added. The heating is continued at a selected temperature in the range of 80° C. to 180° C., IPDI is thus formed, releasing HCl and CO. This gas contains oxalyl chloride. Before this gas can be used for making IPDA-hydrochloride, the oxalyl chloride has to be removed. This is achieved by passing it through an absorption column in contact with o-DCB. This scrubbed gas is then used for hydrochlorination. 
     A whole batch, starting from charging of IPDA to the discharge of IPDI solution, takes 4 hours. Two reactors are provided as shown in production relationship in FIG. 2. When one reactor is in hydrochlorination, the other reactor is in reaction with oxalyl chloride. The HCl gas stream from one reactor is used in the other reactor. Only at start-up does one have to add fresh HCl. All together, 12 batches are made in a 24-h calendar day. 
     The reaction product from the reactor is a solution of IPDI and excess unused oxalyl chloride in o-DCB. This solution is discharged to a surge tank. The o-DCB/oxalyl chloride solution from scrubbing of the HCl/CO gas is also added to the surge tank. When 12 batches have been collected, the whole content is discharged to a batch still. There it is first distilled at atmospheric pressure to recover the excess oxalyl chloride as distillate and then vacuum distilled at 20 mm Hg to recover o-DCB. After vacuum distillation removal of IPDI, the final still bottoms (containing tars and polychlorinated biphenyl, PCBs) are collected for incineration. The expected yield of IPDI is 78%, based on IPDA consumed. 
     Because this operation is projected to be attached to an existing plant, the small amount of still bottoms may be incinerated together with other solid waste in a presumably existing incinerator. If there is none, or it is not suitable for incinerating the waste from this process, a small incinerator has to be provided. The gas from the incinerator should pass to the HCl scrubber before discharging to a stack. 
     At a projected capacity of only 20,000 lb/yr., a fully continuous operation is not practical. However, a conventional batch process would need storage of HCl gas and there would be more likelihood of leakage of gas containing toxic oxalyl chloride in connection with start-up and shut-down of batches. The present design, while still a batch operation, minimizes the above disadvantages by venting all vessels to each other or to gas scrubbers. 
     Table III hereinbelow depicts calculated stream flows and compositions for IPDI synthesis by oxalyl chloride route and reaction products related thereto. The numbers above the columns correspond to the stream numbers circled and shown in FIG. 2. 
     
                                           TABLE III__________________________________________________________________________CALCULATED STREAM FLOWS AND COMPOSITIONS FORIPDI SYNTHESIS BY OxCl ROUTE     Stream Components (lb/batch*)CompnMol Wt     1 2 2a 2b              3 4  5 6 7 8 9 10 11 12                                     13 14                                          15                                            16 17__________________________________________________________________________IPDA 170.3     4.3       --         -- --              --                -- --                     --                       --                         --                           --                             -- -- --                                     -- --                                          --                                            -- --O--DCB147.   0.3         55.7            56              --                -- --                     --                       --                         10                           10                             56.                                792                                   --                                     788                                        --                                          --    --                                          --HCL  36.5 --       --         -- --              3.6                1.8                   --                     --                       3.6                         --                           --                             -- -- --                                     -- --                                          --    --                                          --Oxalyl127. --       --         -- --              --                trace                   --                     7.1                       0.3                         --                           0.3                             0.4                                8.4                                   8.3                                     -- --                                          --    --                                          --chlorideCO   28.  --       --         -- --              1.4                1.4                   1.4                     --                       1.4                         --                           --                             -- -- --                                     -- --                                          --    --                                          --IPDI 220.3     --       --         -- --              --                -- --                     --                       --                         --                           --                             5  -- --                                     -- 60                                          --    --                                          --Heavy--   --       --         -- --              --                -- --                     --                       --                         --                           --                             -- -- --                                     -- --                                          7     --                                          --endsNaOH 40.  --       --         -- --              --                -- --                     --                       --                         --                           --                             -- -- --                                     -- --                                          --    730NaCl 58.5 --       --         -- --              --                -- --                     --                       --                         --                           --                             -- -- --                                     -- --                                          --    --                                          34.7Water18.  --       --         -- --              --                -- --                     --                       --                         --                           --                             -- -- --                                     -- --                                          --    234                                          234__________________________________________________________________________ *Streams (1)-(10): 12 batches per 24h day. Streams (11)-(15): 1 batch per 24h day. Streams (16)-(17): average continuous rate per 24h day. The tabulated stream flows represent 330 days/yr operation on IPDI; to convert to operation for 5 days/yr, multiply each entry by 66. 
    
     In further reference to FIG. 2 of the drawing, the flow process of this invention is depicted for a 2 reactor system. Hydrochlorination and condensation occur in sequence for each reactor. When one reactor is in hydrochlorination, the other is in condensation, and vice-versa. The production batches illustrated in Table III, and employing the circled streams of operations shown in FIG. 2 of the drawing, are further explained in the footnotes of Table III. For example, streams 1-10 are employed for each of 12 batches per 24 hour day, streams 11-15 are employed once per 24 hour day, and streams 16-17 show average continuous rate per 24 hour day. 
     Recycle of excess oxalyl chloride and the reaction solvent is achieved by separating and scrubbing to remove reaction gases HCl and CO for recovery. Any excess oxalyl chloride contained in the HCl must be removed before this gas can be used for making IPDA-hydrochloride. This can be achieved by passing it through an absorption column in communication with the reaction solvent.