PROTON-CATALYSED REACTIONS CATALYSED BY HYDROGEN ION-EXCHANGED LAYERED CLAYS

Abstract: The invention relates to the use of hydrogen ion-exchan­ ged layered clays in organic reactions which are catalysed by protons. Such organic reactions include the reaction of an ole­ fin with a carboxylic acid in the liquid or vapour phase to pro­ duce an ester, e. g. reaction of ethylene with acetic acid to pro­ duce acetate, reaction of an alkanol with a linear olefin at tem­ peratures above 100°C to produce an ether, the conversion of primary or secondary aliphatic alcohols or polyols into ethers, the conversion of primary or secondary amines into secondary and tertiary amines respectively and the reaction of an olefin with benzene to produce an alkyl benzene.

Description: Proton-catalysed reactions catalysed by hydrogen ion-exchanged layered clays The present invention relates generally to proton-catalysed organic reactions and in particular to the use of hydrogen ion-exchanged layered clays as catalysts in organic reactions catalysed by protons. Many different types of organic reaction are catalysed by protons or, to give them another name, hydrogen ions. Typical of such reactions are olefin hydration in which the product is an alcohol, esterification of an alcohol with an acid in which the product is an ester and the decomposition of organic hydroperoxides, e.g. cumene hydroperoxide in which the products are phenol and acetone. Generally the protons are provided by the dissociation of a strong mineral acid or a strong organic acid. Thus sulphuric acid and para-toluene sulphonic acid have been used extensively as catalysts in the industrial production of esters, and phosphoric acid, usually supported on silica, is a catalyst commonly employed in the commercial production of ethanol. Comparatively recently hydrogen ion-exchanged resins have been employed as catalysts in, for example, the production of alkanols. In the Journal of Physical Chemistry, Volume 44, No. 2, February, 1940, pp 180 to 184, there is disclosed the preparation of an acid bentonite by electrodialyzing a 4 per cent suspension of Wyoming bentonite in a cell of the Mattson type until the catholyte liquor is no longer alkaline and the use of the acid bentonite so-prepared as catalyst in the decomposition of hydrogen peroxide. In the complete specification of British Patent No 905,854 there is disclosed a process for the production of tertiary butyl acetate which comprises reacting isobutene with acetic acid at a temperature within the range 0° to 100°C in the presence of an acid-activated silicate, which may be, for example, a Fuller's earth, montmorillonite, bleaching earth, clay or kaolin, activated by treatment with mineral acid. US Patent No 3,096,365 discloses a process for the condensation of a tertiary olefin with a carboxylic acid to form the corresponding ester in a reaction zone wherein the improvement comprises contacting said reactants in the liquid phase at a temperature not above about 300°F, and in the presence of a Period 3 polyvalent metal silicate catalyst which is substantially free from fugitive acid and consists essentially of 5 to 50 weight per cent Period 3 polyvalent metal oxide and 50 to 95 weight per cent silica. The effective catalysts are said to be acid-type synthetic and naturally-occurring cracking catalysts, clays, of which bentonite and montmorillonite are specifically referred to, selected zeolites and talc, the natural products ordinarily having been washed with strong mineral leaching acids such as HCl or H₂SO₄, then washed with water and calcined at an elevated temperature, eg 1000°F. USP 3,492,341 discloses a process for preparing carboxylic acid esters by reacting a mono-olefinic hydrocarbon containing about 1 to 8 carbon atoms with a hydrocarbon carboxylic acid containing from 1 to about 20 carbon atoms at a temperature of about 100 to 800° F in the presence of a catalyst wherein the improvement comprises conducting said reaction in the presence of a catalytic amount of a mordenite type crystalline aluminosilicate catalyst in predominantly the hydrogen form. Thereafter in the Journal of Catalysis 58 , 238-252 (1979) Adams et al disclosed that metal cation-exchanged water-intercalated clays such as metal cation-exchanged water-intercalated montmorillonites will convert alkenes to the corresponding bis-sec-alkyl ethers. Although the catalytic activity of a variety of metal cation-exchanged clays is described, there is no disclosure of a hydrogen ion-exchanged clay. We have now found that hydrogen ion-exchanged layered clays catalyse those organic reactions which are catalysed by protons. Hydrogen ion-exchanged layered clays are to be distinguished from acid-activated clays as disclosed in GB 905854 in that their layered structure is essentially intact and they do not contain residual mineral acid. They are to be distinguished from the clays treated in the manner of USP 3,096,365 in that their layered structure has not been substantially impaired by calcination at elevated temperatures of the order of 1000°F. Accordingly the present invention provides a process for carrying out a proton-catalysed organic reaction selected from the group consisting of (a) producing an ester by reacting either an olefin or an epoxide with a carboxylic acid under reaction conditions which result in the formation of an ester, (b) producing an ether by reacting an alcohol with either an olefin or an epoxide under reaction conditions which result in the formation of an ether, (c) producing an ether by reacting at elevated temperature and a pressure such that the reactants are maintained in the liquid phase a primary or secondary aliphatic alcohol or a polyol, (d) producing an ether by reacting an epoxide at elevated temperature, (e) producing an alkyl aromatic compound by reacting at elevated temperature an aromatic compound with an olefin, (f) producing an alcohol by the hydration of an olefin at elevated temperature, employing as catalyst a source of protons characterised in that as the source of protons there is used a hydrogen ion-exchanged layered clay in which the layered structure is essentially intact and which is free from residual mineral acid. A layered clay within the context of the present specification is a clay having a lamellar structure with interlamellar spaces disposed between the lamellar layers. Typical of such clays is montmorillonite which has an idealised stoichiometric composition corresponding to Na 0.67 [Al 3.33 Mg 0.67 ](Si₈)O₂₀(OH)₄. Structurally it comprises a central octahedral co-ordination layer containing aluminium and magnesium oxides and hydroxides sandwiched between two tetrahedral coordination layers containing silicon oxide. Normally in nature cations are present to compensate for the charge imbalance caused by isomorphous substitution of Mg²⁺ for Al³⁺ in the octahedral layer, and/or Al³⁺ or other ions for Si⁴⁺ in the tetrahedral layers. The octahedral and tetrahedral regions are tightly bound together to form a lamellar layer. The space between the lamellar layers, i.e. the interlamellar space, is normally occupied by exchangeable Ca²⁺ or Na⁺ ions. The distance between the interlamellar layers can be substantially increased by absorption of a variety of polar molecules such as water, ethylene glycol, amines etc., which enter the interlamellar space and in doing so push apart the lamellar layers. The interlamellar spaces tend to collapse when the molecules occupying the space are removed, for example by heating the clay at a high temperature. Both natural and synthetic clays having a layered structure are well known and may be used in the process of the invention after exchange of the metal cations normally associated therewith with hydrogen ions. Besides montmorillonites such as bentonite and Fullers Earth, other types of suitable clays include hectorites, beidellites, vermiculites and nontronite. Preferably the clay is a bentonite, such as Wyoming bentonite. Techniques for obtaining a hydrogen ion-exchanged material from a cation-exchangeable material are well known and include:- (i) exchange with excess hydrogen ions in solution, customarily an aqueous solution of a mineral acid, and (ii) exchange with an aqueous solution of an ammonium compound to produce the ammonium ion-exchanged material followed by calcination to decompose the ammonium moiety thereby converting the material to the hydrogen ion-exchanged form. In the preparation of hydrogen ion-exchanged layered clays we have found that there are disadvantages associated with the aforesaid technique (ii) arising from the use of elevated temperatures in the calcination step. The use of too low a temperature risks incomplete decomposition of the ammonium moiety resulting in a clay containing both ammonium and hydrogen ions. The catalytic activity of the clay so-produced tends to diminish as the proportion of ammonium ions remaining in the clay increases. On the other hand, the use of too high a calcination temperature tends to collapse the lamellar structure and produce an inactive catalyst. Accordingly, it is preferred to produce a hydrogen ion-exchanged layered clay for use in the process of the present invention by contacting the clay containing exchangeable cations with a solution of a mineral acid under ion-exchange conditions. Preferably the solution of the mineral acid is an aqueous solution. Suitable mineral acids include sulphuric acid and hydrochloric acid. The acid may suitably be from 0.5 to 10 molar. Although contact of the clay with the mineral acid is preferably effected at ambient temperature, elevated temperatures may be employed. The period of contact will depend to some extent on the temperature. Typically at ambient temperature the contact period may be in the range ½ hour to 3 days, preferably about 2 days. Techniques for separating the fully exchanged clay from the ion-exchange media and excess ions are well known. Any suitable solid/liquid separation procedure can be used. Decantation or centrifugation are two preferred methods for solid/liquid separation. After exchange it is preferred to wash the exchanged clay until all extraneous acid and cations are removed. Thereafter the clay is preferably dried. Although drying is preferably effected at elevated temperature, temperatures which cause collapse of the lamellar structure should be avoided. Hydrogen ion-exchanged layered clays may be used as catalysts in all organic reactions catalysed by protons. Advantages arising from their use are that they can be readily separated from the reaction mixture which renders them useful in continuous processes, and they are less corrosive than the strong acids conventionally employed. We have found the clays to be particularly useful catalysts in certain specific organic reactions, such as the production of esters by the reaction of an olefin with a carboxylic acid and the production of ethers by reaction of an alcohol and a linear alkene. In a particular aspect therefore the present invention provides a process for the production of esters which process comprises reacting one or more olefins with one or more carboxylic acids in the presence as catalyst of a hydrogen ion-exchanged layered clay under reaction conditions which result in the formation of an ester. With regard to the olefin reactant any suitable olefin may be employed. Suitable olefins include ethylene, propylene, butenes, pentenes and hexenes, diolefins such as butadiene and cyclic olefins such as cyclohexene. Mixtures of olefins such as those commonly encountered in refinery streams may also be used if so desired. The amount of olefin employed may be greater or less than the stoichiometric amount required to react completely with the acid. Both aromatic and aliphatic carboxylic acids may be used. Suitable aliphatic acids include formic, acetic, propionic and butyric acids. Of the aromatic acids phthalic acids, especially orthophthalic acid, may be employed. Mixtures of acids may also be employed is so desired. Preferably the olefin is ethylene, the carboxylic acid is acetic acid and the ester produced is ethyl acetate. A preferred hydrogen ion-exchanged layered clay for use in this process is a hydrogen ion-exchanged sodium bentonite. The catalyst may suitably be activated before use by heating in air at a temperature up to 220°C, preferably from 140 to 160°C. The process may be carried out in the liquid phase or in the vapour phase, preferably in the liquid phase. Reaction conditions which result in the formation of an ester will depend on whether the process is carried out in the liquid or the vapour phase and to some extent on the nature of the reactants. In the liquid phase the pressure is suitably that pressure which maintains a liquid phase at the reaction temperature. In the case of olefins with suitably high boiling points, e.g. hexene-1, the reaction may for example be conveniently carried out at the reflux temperature of the reactants and under atmospheric pressure, or at higher temperatures and pressures if so desired. In the case of ethylene, for example, initial pressures in the range 25 to 150 bar may suitably be employed. Generally the temperature may suitably be in the range 100 to 300°C, preferably 150 to 250°C. Solvents may be employed if desired. Suitable solvents include hydrocarbons, e.g. alkanes such as ethane, hexane and octane. In the vapour phase the conditions must be chosen so that the reactants do not liquefy; for example acetic acid must be fed at atmospheric or slightly higher pressure otherwise it would liquefy at higher pressures. Generally the temperature will suitably be in the range 120 to 180°C, preferably 140 to 160°C. The residence time which is defined as:- Volume of catalyst in mls Vapour flow rate (in mls/sec at NTP) may suitably be in the range 10 to 60 secs, preferably 20 to 40 secs. The process may be carried out batchwise or continuously, preferably continuously. The batchwise liquid phase production of ethyl acetate, for example, may conveniently be carried out by charging acetic acid and catalyst to an autoclave, pressurising the autoclave with ethylene and maintaining the autoclave at the reaction temperature. The reaction time should not be unduly protracted otherwise the selectivity for the conversion of acetic acid to ethyl acetate may be adversely affected. Thus at an approximately 2:1 molar ratio of ethylene to acetic acid, an initial ethylene pressure of 55 bar and a temperature of 200°C, the reaction time should preferably not exceed 5 hours. At the completion of the reaction the catalyst may be recovered from the product, suitably by filtration, centrifugation or decantation and the product worked up in known manner to recover ethyl acetate therefrom. The catalyst may thereafter be re-used in a further batch reaction with or without intervening treatment. The invention also provides a process for the production of ethers which process comprises reacting one or more alcohols with one or more olefins under reaction conditions which result in the formation of ethers in the presence of a hydrogen ion-exchanged layered clay as catalyst. Suitable alcohols include methanol, ethanol, propanols, butanols, pentanols and hexanols, of which linear alcohols are preferred. Diols, polyols and arylalcohols may also be employed. With regard to the olefin any suitable olefin may be employed. Suitable olefins include ethylene, propylene, butenes, pentenes and hexenes, diolefins such as butadiene and cyclic olefins such as cyclohexene. Preferably the olefin is a C₃ to C₆ linear or branched olefin. Mixtures of olefins such as those commonly encountered in refinery streams may also be used if so desired. The amount of olefin employed may be greater or less then than stoichiometric amount required to react completely with the alcohol. A preferred hydrogen ion-exchanged layered clay for use in this process is a hydrogen ion-exchanged sodium bentonite. The catalyst may suitably be activated before use by heating in air at a temperature up to 220°C, preferably from 140 to 160°C. The process may be carried out in the liquid phase or in the vapour phase, preferably in the liquid phase. Reaction conditions which result in the formation of an ether will depend on whether the process is carried out in the liquid or the vapour phase and to some extent on the nature of the reactants. In the liquid phase the pressure is suitably that pressure which maintains a liquid phase at the reaction temperature. In the case of olefins with suitably high boiling points, e.g. hexene-1, the reaction may for example be conveniently carried out at the reflux temperature of the reactants and under atmospheric pressure, or at higher temperatures and pressures if so desired. Generally the temperature may be up to 300°C, preferably 50 to 250°C, even more preferably 100 to 200°C. The particular temperature employed within the aforesaid ranges will depend upon the nature of the olefin. For example the temperatures employed for linear olefins will be higher than those employed for the corresponding branched olefins. Solvents may be employed if so desired. Suitable solvents include hydrocarbons, e.g. alkanes such as ethane, hexane and octane. The process may be carried out batchwise or continuously, preferably continuously. Other proton-catalysed reactions which are catalysed by hydrogen ion-exchanged layered clays include:- (i) the production of ethers by reacting at elevated temperature and a pressure such that the reactants are maintained in the liquid phase a primary or second aliphatic alcohol or a polyol in the presence of a hydrogen ion-exchanged layered clay. The ethers are believed to be produced by condensation of two alcohol functions accompanied by elimination of water. With regard to the primary aliphatic alcohol reactant suitable alcohols include methanol, ethanol, propan-1-ol, butan-1-ol, pentan-1-ol, hexan-1-ol, heptan-1-ol and octan-1-ol. The principal ether in the product resulting from the reaction of a primary aliphatic alcohol in the presence of the lamellar clays is the corresponding 1,1-ether, though the corresponding 1,2-ether, may also be formed. Alkenes and alkene dimers may also be formed. Generally the proportion of alkene in the product increases as the carbon number of the reactant alcohol increases. With regard to the secondary aliphatic alcohol reactant suitable alcohols include straight-chain alcohols such as propan-2-ol, butan-2-ol, pentan-2-ol, hexan-2-ol and hexan-3-ol and cyclohexanol, of which propan-2-ol and butan-2-ol are preferred. The ethers predominating in the product resulting from the reaction of alkan-2-ol and alkan-3-ols are the 2,2- and 3,3-ethers respectively. Alkenes and alkene dimers are also formed. The reactant may also be a polyol such as an alkylene glycol. A suitable alkylene glycol is ethylene glycol which produces a mixture of dioxan, and di-, tri-, tetra- etc., ethylene glycol. A preferred alkylene glycol is diethylene glycol which produces dioxan in high conversions in the presence of the lamellar clay. Additionally mixtures of alcohols and/or polyols may be used if so desired. The elevated temperature may suitably be in the range 100 to 300°C, preferably from 150 to 225°C. (ii) the production of ethers by reacting one or more epoxides in the presence of a hydrogen ion-exchanged layered clay as catalyst. Thus for example reaction of ethylene oxide yields 1,4-dioxan and 2 methyl-1, 3-dioxan. Other epoxides produce cyclic ethers but alpha, beta-unsaturated aldehydes may also be formed. The proportion of the unsaturated aldehyde generally tends to increase with the carbon number of the epoxide. (iii) the formation of esters by reacting one or more epoxides with one or more carboxylic acids in the presence of a hydrogen ion-exchanged layered clay as catalyst. Thus for example ethylene glycol diacetate and 2-hydroxyethyl acetate can be obtained by reaction of ethylene oxide and acetic acid. (iv) the formation of ethers by reacting one or more epoxides with one or more alcohols, polyols or polysaccharides in the presence of a hydrogen ion-exchanged layered clay. Thus for example 2 ethoxy ethanol, diethylene glycol monoethyl ether, ethylene glycol diethyl ether and diethylene glycol diethyl ether can be obtained by reaction of ethylene oxide and ethanol. (ix) the production of alkyl aromatic compounds by reacting one or more aromatic compounds with one or more olefins, e.g. the production of ethylbenzene by reacting benzene with ethylene, and isopropylbenzene by reacting benzene with propylene, at elevated temperatures suitably up to 250°C, preferably in the range 175 to 250°C and elevated pressures. (x) the production of alcohols by the hydration of olefins at elevated temperature and pressure. (ix) the production of esters by reaction of an alcohol with a carboxylic acid at elevated temperature and atmospheric or elevated pressure. The invention will now be illustrated by reference to the following Examples. All analytical results were determined using gas chromatography and the identity of the products were confirmed by comparison with authentic materials, mass spectroscopy or nuclear magnetic resonance spectroscopy. PREPARATION OF HYDROGEN ION-EXCHANGED LAYERED CLAY Example 1 Sodium bentonite (a Wyoming Bentonite supplied as a fine powder for use in drilling muds) was added to a solution of concentrated sulphuric acid (400 ml) in water (1100 ml) and left for 2 days with occasional stirring. The clay was separated from the solution and washed with water by repeated centrifuging and resuspending in water until the pH of the supernatant solution was the same as the distilled water used in the washing. The clay was dried at 80°C in air and ground to give a fine powder of hydrogen bentonite. PRODUCTION OF ESTERS BY REACTING AN OLEFIN WITH A CARBOXYLIC ACID (A) IN THE VAPOUR PHASE Example 2 1/8 inch cylindrical pellets of the hydrogen bentonite prepared in the manner described were packed in the lower portion of a glass reactor tube. A 2:1 molar ratio mixture of ethylene and acetic acid was passed over the catalyst which was maintained at 170 to 180°C and ambient pressure, the residence time being 30 seconds. The effluent vapours were condensed to give a liquid product containing 22.4% w/w ethyl acetate which had been produced from acetic acid with greater than 99% selectivity. (B) IN THE LIQUID PHASE Example 3 10 g of the dry hydrogen bentonite prepared in the manner described in Example 1 and acetic acid (80 g) were added to a Baskerville 100 ml stainless steel autoclave fitted with a stirrer. The autoclave was pressurised with ethylene (approximately 2:1 molar ratio of ethylene to acetic acid) so that the required pressure (55 bar) was reached at the reaction temperature (200°C). The autoclave was kept at 200°C for 2.5 hours and then cooled. The liquid products were shown by gas chromatographic analysis to contain 39.8% ethyl acetate formed from acetic acid with greater than 99% selectivity. Example 4 Hydrogen ion-exchanged bentonite (0.5 g) (prepared from sodium bentonite in a similar manner to that described in Example 1) which had previously been equilibrated in a desiccotor over granular anhydrous calcium chloride, hex-1-ene (5 ml) and acetic acid (1.5 ml) were placed in a standard steel reactor of capacity 20 ml. The reactor was closed by a screw cap provided with an O-ring seal and immersed up to the screw cap in a silicone oil bath which was maintained at 200°C. After 4 hours the reactor was removed from the bath, cooled and its contents analysed. The results in terms of weight percentage of the individual products (rounded to the nearest whole number) are given in Table 1. Example 5 Example 4 was repeated except that acetic acid was replaced by propionic acid. Example 6 Example 4 was repeated except that acetic acid was replaced by isobutyric acid. Example 7 Example 4 was repeated except that hex-1-ene was replaced by hept-1-ene. Example 8 Example 4 was repeated except that hex-1-ene was replaced by oct-1-ene. Example 9 Example 4 was repeated except that hex-1-ene was replaced by 4-methylpent-1-ene. Example 10 Example 4 was repeated except that hex-1-ene was replaced by hex-2-ene. The results of Example 5 to 10 are given in Table 1. Example 11 Example 4 was repeated except that hex-1-ene was replaced by 1,5-hexadiene. The product contained 5% ester and 7% alkene dimers. Example 12 Example 4 was repeated except that hex-1-ene was replaced by cyclohexene. 15% of products were obtained, 10% being ester. PRODUCTION OF ETHERS BY REACTING AN ALKANOL WITH A LINEAR OLEFIN Example 13 The procedure described in Example 4 was followed except that the hex-1-ene and acetic acid were replaced by a 50:50 v/v mixture (5 ml) of hexan-1-ol and hex-1-ene. The analysis of the product mixture gave: Example 14 5 g of the dry hydrogen ion-exchanged bentonite prepared in the manner described in Example 1, hex-1-ene (25 g) and methanol (19 g) were sealed in a Baskerville 100 ml stainless steel autoclave fitted with a stirrer. The autoclave was heated at 150°C for 2.5 hours, then cooled. The liquid products (37.5 g, 85% weight recovered) were recovered and shown to contain 2-methoxyhexane (19%) and dimethyl ether (7%) as the two major new products. The product percentages are based on peak areas shown in a flame ionisation gas chromatograph. The gaseous products were not examined. Example 15 As Example 14 but using ethanol (19 g) instead of methanol. The sealed autoclave was pressurised with nitrogen to give a reaction pressure of 50 bar at 180°C. The autoclave was heated at 180°C for 2.5 hours, and then cooled. The liquid products (35.1 g, 80% weight recovered) were recovered and shown to contain 2-ethoxyhexane (23.5%) and diethyl ether (8.8%) as the two major new products. The product percentages are based on peak areas shown on a flame ionisation gas chromatograph. The gaseous products were not examined. Example 16 5 g of the dry hydrogen ion-exchanged bentonite prepared as in the manner described in Example 1 and methanol (19 g) were cooled to -20°C in the detached bottom-half of a Baskerville 100 ml stainless steel autoclave. But-1-ene (ca 30 ml of condensed liquid in a cardice cold trap) was added and the autoclave sealed. The autoclave was flushed with nitrogen and stirred at 200°C for 2.5 hours, and allowed to cool. The liquid products (7 g, 18% weight recovered) were recovered and shown to contain 2-methoxybutane (40%) and dimethyl ether (55%) and a little C₄ dimers as the major products. The product percentages are based on peak areas shown on a flame ionisation gas chromatograph. The gaseous products were not examined. PRODUCTION OF ETHERS BY REACTING A PRIMARY OR SECONDARY ALIPHATIC ALCOHOL OR A POLYOL IN THE PRESENCE OF A HYDROGEN ION-EXCHANGED LAYERED CLAY Example 17 Hydrogen ion-exchanged bentonite (0.5 g) (prepared in a similar manner to that described in Example 1) which had previously been equilibrated in a desiccator over calcium chloride and propan-2-ol (5 ml) were placed in a standard steel reactor of capacity 20 ml. The reactor was closed by a screw cap provided with an O-ring seal and immersed up to the screw cap in a silicone oil bath which was maintained at 200°C. After 4 hours the reactor was removed from the bath, cooled and its contents analysed. The results in terms of wt. % of individual products in the product mixture are in the following Table 2. Example 18 Example 17 was repeated except that butan-2-ol was used in place of propan-2-ol. Example 19 Example 17 was repeated except that pentan-2-ol was used in place of propan-2-ol. Example 20 Example 17 was repeated except that hexan-2-ol was used in place of propan-1-ol. Example 21 Example 17 was repeated except that butan-1-ol was used in place of propan-2-ol. Example 22 Example 17 was repeated except that pentan-1-ol was used in place of propan-2-ol. Example 23 Example 17 was repeated except that hexan-1-ol was used in place of propan-2-ol. Example 24 Example 17 was repeated except that heptan-1-ol was used in place of propan-2-ol. Example 25 Example 17 was repeated except that octan-1-ol was used in place of propan-2-ol. Example 26 Example 17 was repeated except that 3-methylbutan-1-ol was used in place of propan-2-ol. Example 27 Example 17 was repeated except that 3-methylpentan-1-ol was used in place of propan-2-ol. The results of Examples 14 to 24 are given in Table 2. Example 28 Example 17 was repeated except that diethylene glycol was used in place of propan-2-ol. Analysis of the product showed:-

Claims: A process for carrying out a proton-catalysed organic reaction selected from the group consisting of (a) producing an ester by reacting either an olefin or an epoxide with a carboxylic acid under reaction conditions which result in the formation of an ester, (b) producing an ether by reacting an alcohol with either an olefin or an epoxide under reaction conditions which result in the formation of an ether, (c) producing an ether by reacting at elevated temperature and a pressure such that the reactants are maintained in the liquid phase a primary or secondary aliphatic alcohol or a polyol, (d) producing an ether by reacting an epoxide at elevated temperature, (e) producing an alkyl aromatic compound by reacting at elevated temperature an aromatic compound with an olefin, (f) producing an alcohol by the hydration of an olefin at elevated temperature, employing as catalyst a source of protons characterised in that as the source of protons there is used a hydrogen ion-exchanged layered clay in which the layered structure is essentially intact and which is free from residual mineral acid. A process according to claim 1 wherein the hydrogen ion-exchanged layered clay is obtained by exchange of a cation-exchanged layered clay at ambient temperature with excess hydrogen ions in solution. A process according to claim 2 wherein the cation-exchangeable layered clay is a bentonite A process according to any one of the preceding claims wherein the proton-catalysed organic reaction is the production of an ester by reacting an olefin with a carboxylic acid under reaction conditions which result in the formation of an ester. A process according to claim 4 wherein the olefin is ethylene, propylene, a butene, a pentene, a hexene or cyclohexene. A process according to either one of claims 4 or 5 wherein the carboxylic acid is formic acid, acetic acid, propionic acid, butyric acid or a phthalic acid. A process according to any one of claims 4 to 6 wherein the olefin is ethylene, the carboxylic acid is acetic acid and the ester is ethyl acetate. A process according to any one of claims 4 to 7 wherein the olefin is contacted with the carboxylic acid in the liquid phase. A process according to any one of claims 4 to 8 wherein the temperature is in the range from 100 to 300°C and the pressure is that pressure which maintains a liquid phase at the reaction temperature. A process according to any one of claims 4 to 7 wherein the olefin is contacted with the carboxylic acid in the vapour phase. A process according to any one of claim 4 to 7 and 10 wherein the temperature is in the range from 120 to 180°C and the residence time is in the range from 10 to 60 seconds. A process according to any one of claims 1 to 3 wherein the proton-catalysed organic reaction is the production of ethers by reacting one or more alcohols with one or more olefins under reaction conditions which result in the formation of ethers. A process according to claim 12 wherein the alcohol is methanol, ethanol, propanol, a butanol, a pentanol, or a hexanol. A process according to either claim 12 or 13 wherein the olefin is ethylene, propylene, a butene, a pentene or a hexene. A process according to any one of claims 12 to 14 wherein the alcohol is contacted with the olefin in the liquid phase. A process according to any one of the preceding claims wherein the hydrogen ion-exchanged clay is activated before use by heating in air at a temperature up to 220°C. A process according to any one of claims 1 to 3 wherein the proton-catalysed reaction is the production of an alkylaromatic compound by reacting an aromatic compound with an olefin. A process according to claim 17 wherein the aromatic compound is benzene, the olefin is ethylene and the alkylaromatic compound is ethyl benzene. A process according to claim 17 wherein the aromatic compound is benzene, the olefin is propylene and the alkylaromatic compound is isopropylbenzene.

Inventors: BALLANTINE, JAMES ARCHIBALD, GREGORY, REGINALD THE BRITISH PETROLEUM COMP. LTD., PURNELL, JOHN HOWARD, THOMAS, JOHN MEURIG, WESTLAKE, DAVID JACK
Applicants: THE BRITISH PETROLEUM COMPANY P.L.C.
Application year: 1980
Main classification: C07C67
IPC codes: C07D319, C07C45, C07B61, C07D295, B01J21, C07C211, C07C43, C07C313, C07C209, B01J39, C07C319, C07C41, C07C67, C07D317, C07C321