PROCESS FOR THE PRODUCTION OF DIHYDROCARBYL CARBONATES, THEIR USE AS FUELS ADDITIVES

Abstract: Dihydrocarbyl carbonates are produced by reacting in the liquid phase under substantially anhydrous conditions a dihydrocarbyl peroxide, a primary or secondary alcohol and carbon monoxide in the presence as catalyst of copper in elemental or compound form, optionally in the presence as promoter of a heterocyclic aromatic nitrogen compound. The products are useful as additives to internal combustion engine fuels.

Description: PROCESS FOR THE PRODUCTION OF DIHYDROCARBYL CARBONATES THEIR USE AS FUELS ADDITIVES AND FUEL COMPOSITIONS CONTAINING THEM The present invention relates to a process for the production of dihydrocarbyl carbonates, their use as additives in internal combustion engine fuels and fuel compositions containing them. Dihydrocarbyl carbonates have a number of actual and potential uses, for example dialkyl carbonates as solvents and diphenyl carbonate as an intermediate in the production of aromatic polycarbonates (high performance thermoplastic resins), monoisocyanates (pharmaceuticals and pesticides intermediates), diisocyanates (monomers for polyurethane elastomers) and carbamates (pesticides). Their use as additives to liquid hydrocarbon fuel mixtures has also been proposed. Conventionally, they are produced by reacting phosgene with alcohols or phenols. Alkyl carbonates can also be produced by reacting saturated aliphatic alcohols with carbon monoxide in the presence as catalyst of palladium or platinum salts (USP 3114762) or an organic copper complex (USP 3846468). Even more recently the production of dimethyl carbonate by the copper catalysed oxidative carbonylation of methanol by oxygen has been proposed. Furthermore, carbonic diesters are produced as by-products in the production of dialkyl oxalates by reaction of an aliphatic alcohol with carbon monoxide and oxygen under pressure in the presence of a catalyst composed of a mixture of a salt of a platinum group metal and a salt of copper or iron. Of necessity water is formed when an alcohol is reacted with carbon monoxide and molecular oxygen, whether the product be a dialkyl oxalate or a dihydrocarbyl carbonate, or a mixture thereof. It is recognised that the formation of water is undesirable, because it can deactivate the catalyst (see for example USP 4360477), it can complicate product separation and it can depress the yield. For this reason steps have been taken either to remove the water as it is formed in the production of dialkyl oxalates by the addition of a dehydrating agent, for example alkyl orthoformic esters, or to use catalysts which are purportedly not moisture sensitive, for example cupric halides. Moreover, the use of molecular oxygen can raise the problem of explosive mixture formation. Canadian Patent No. 743559 describes a method of producing a tertiary ester of a carboxylic acid comprising contacting with agitation carbon monoxide and di-t-hydrocarbyl peroxide of the formula (RR1R11) C-OO-C(RR1R11) wherein R, R1 and R11 are hydrocarbyl radicals selected from the group consisting of alkyl, aryl, alkaryl and aralkyl having up to nine carbon atoms, said contacting being conducted at an elevated temperature and carbon monoxide pressure and in the presence of inert organic liquid diluent. The use of transition metal salts as catalysts is said to be desirable for optimum yields of ester. Specific examples of transition metal salts contemplated are said to be halides, carboxylates and nitrates of copper, cobalt, manganese, iron and vanadium. We have now found that the aforesaid problems associated with the production of dihydrocarbyl carbonates can be substantially overcome by using as the oxidant a dihydrocarbyl peroxide in place of molecular oxygen because the formation of water is thereby avoided and the risk of forming explosive mixtures is diminished. From an economic standpoint the use of a dihydrocarbyl peroxide can be more attractive because desirable alcohols can be formed from the peroxide as the principal by-product of the reaction. Thus, using di-tertiary-butyl peroxide the principal co-product is t-butanol, which is assuming significant importance as a fuels additive. Accordingly, the present invention provides a process for the production of a dihydrocarbyl carbonate which comprises reacting in the liquid phase under substantially anhydrous conditions a dihydrocarbyl peroxide, a primary or secondary alcohol and carbon monoxide in the presence as catalyst of copper in elemental or compound form. The term 'hydrocarbyl' is used in the commonly accepted sense as denoting the moiety formed by the removal of a hydrogen atom from a hydrocarbon. Carbon monoxide is available commercially on a large scale. It may be substantially pure or may contain for example such impurities as hydrogen and/or nitrogen. Suitably a substantial excess of carbon monoxide may be employed. Maintenance of an excess may suitably be accomplished by keeping the reaction system under a carbon monoxide pressure, suitably in the range from 15 to 150 bars, though lower and higher pressures may be employed if desired. With regard to the dihydrocarbyl peroxide, the dihydrocarbyl radical may suitably be an alkyl, aryl, alkaryl or aralkyl group having up to 9 carbon atoms, and may be the same or different. As the dihydrocarbyl peroxide, there may be used any suitable peroxide, such as for example di-cumyl peroxide, and di-tertiary-butyl peroxide (DTBP), of which DTBP is preferred. As hereinbefore mentioned, by using a peroxide in place of oxygen, the risk of forming explosive mixtures is substantially reduced and the use of dehydrating agents can be avoided because no water is formed in the reaction. DTBP may readily be obtained, for example, by reacting tertiary-butyl alcohol with tertiary-butyl hydroperoside, which in turn may readily be obtained by oxidation of isobutane. A suitable process for producing DTBP is described in US Patent No 2862973. As the catalyst there is used copper in elemental or compound form. Although the copper may be added as the elemental metal, suitably in finely divided form, it is preferred to add it in the form of a compound of the metal, suitably as a salt, such as a halide or alkoxide, or a complex. It is preferred to add the copper in compound form and even more preferably as a copper (I) compound. Of the copper (I) compounds the halides, for example copper (I) chloride or copper (I) bromide, are preferred. The primary or secondary alcohol reactant may be a simple alkanol, eg methanol, ethanol and propanol; a glycol, eg ethylene glycol; a polyalkylene glycol, eg polyethylene glycol or an aryl alcohol, eg benzyl alcohol. Furthermore, mixtures may be employed if so desired. Preferably an alkanol is employed and most preferably the alkanol is methanol, ethanol or isopropanol, which are commercially available on a large scale. Although trace amounts of impurities, for example at the levels obtaining in commercially available materials, may be tolerated, substantial amounts of water should be avoided. It is preferred to employ a catalyst promoter. Suitable promoters include heterocyclic aromatic nitrogen compounds, such as pyridine or a derivative thereof. Examples of suitable promoters which may be used in the process of the invention include pyridine, 2,6-dimethyl pyridine and 2-methyl-S-ethyl pyridine. The heterocyclic aromatic nitrogen compound may be added independently or combined with the catalyst in the form of a complex therewith. Thus pyridine may suitably be added in the form of pyridine copper methoxy chloride. A diluent may also be employed if so desired. Suitably the diluent may be an aromatic hydrocarbon solvent, such as toluene. Alternatively, the heterocyclic aromatic nitrogen compound, when used as a promoter, may also serve as a diluent. As regards the reaction conditions, the carbon monoxide partial pressure has been mentioned hereinbefore. The temperature may suitably be above ambient temperature. The actual temperature employed will depend, amongst other factors, upon the amount of catalyst and promoter, if any, used. Generally, the rate of the reaction will increase with increasing catalyst and promoter concentration. Within any constraint imposed by controlling the reaction temperature, for the reaction is highly exothermic, the copper catalyst may be employed in an amount up to and beyond stoichiometric and there is no restriction on the amount of promoter which may be used. However, it will usually be found convenient to add copper in an amount in the range from 1 to 10 mole Z (calculated as copper (I) chloride) based on the number of moles of peroxide present, at which concentration the reaction temperature may suitably be greater than 50"C, for example in the range from 80 to 1500C. The reaction in its simplest form is thought to be represented by the following equation: EMI5.1 wherein R1 and R11 are independently alkyl, aryl, alkaryl or aralkyl groups having up to 9 carbon atoms and Rl11 is the hydrocarbyl group of a primary or secondary alcohol as hereinbefore described. It will be appreciated by those skilled in the art that the dihydrocarbyl peroxide may react directly with carbon monoxide according to the equation: EMI5.2 The extent to which this reaction also occurs will depend to some extent on the type of reactant and the reaction conditions employed. The process may be operated batchwise or continuously, preferably continuously. The products may be separated in conventional manner. In this respect the absence of water can considerably simplify the separation. In a particular embodiment the present invention provides a process for the production of a mixture comprising t-butanol and a dialkyl carbonate wherein the alkyl groups are independently either methyl, ethyl or isopropyl which process comprises reacting in the liquid phase under substantially anhydrous conditions at elevated temperature di-tertiary-butyl peroxide, one or more of methanol, ethanol or isopropanol and carbon monoxide in the presence as catalyst of a copper compound and a promoter which is pyridine or a derivative thereof. Preferably methanol, carbon monoxide and di-tertiary-butyl peroxide are reacted to form a mixture comprising t-butanol and dimethyl carbonate. The mixture comprising t-butanol and dialkyl carbonate may be recovered and separated into individual components by conventional methods, for example by distillation. The t-butanol may thereafter be dehydrated in known manner to form isobutene and the isobutene hydrogenated in known manner to form isobutane, which may then be recycled as feed to the reaction producing DTBP. Alternatively, the t-butanol may be used as a fuels supplement, as may also the dialkyl carbonate. In another aspect the present invention provides an additive composition for use in internal combustion engine fuels which composition comprises t-butanol and one or more dialkyl carbonates wherein the alkyl groups are independently either methyl, ethyl or isopropyl. Suitable dialkyl carbonates for use in the composition include dimethyl carbonate, diethyl carbonate, diisopropyl carbonate and methyl ethyl carbonate. Preferably the dialkyl carbonate is dimethyl carbonate. The additive composition may also contain one or more of methanol, ethanol and isopropanol. A particularly suitable additive composition is the product comprising t-butanol, dialkyl carbonate wherein the alkyl groups are independently either methyl, ethyl or isopropyl, optionally together with all or part of any unreacted methanol, ethanol or isopropanol as obtained by the process hereinbefore described. If desired the proportions of the components may be varied by appropriate blending. In another aspect there is provided an internal combustion engine fuel composition comprising a hydrocarbon fuel and the additive composition as hereinbefore described. The hydrocarbon fuel is preferably gasoline, in which case the fuel composition is particularly suitable for use in spark ignition engines. It may suitably have an octane number suitable for existing engines, e.g. a Research Octane Number (RON) of 85 to 105, and may contain olefins as well as aromatics and saturated hydrocarbons. The proportion of the aforesaid additive composition in the fuel composition may suitably be from 0.1 to 50t, preferably from 5 to 255 by volume of the composition. Internal combustion engine fuel compositions generally contain other additive components. Thus, a spark ignition engine fuel composition may contain, for example, an anti-knock agent, a scavenger, other oxygenated compounds, anti-icing and other conventional agents. The invention will now be illustrated by reference to the following Examples. In certain of the Examples reference will be made to the RON and MON. These values were determined by the CFR test method according to ASTM D 2699 and D 2700 on a blend of the additive and a gasoline base stock (10:90 volume). The Blending Octane Values were calculated from the measured RONs and MONs. Example 1 An autoclave was charged with methanol (8.9 gm), di-tertiary-butyl peroxide (20.4 gm), cuprous chloride (0.28 gm) and pyridine (2.2 gm). Carbon monoxide gas was introduced to a pressure of 46 bar at ambient temperature. The mixture was heated, with stirring to 920C and maintained at this temperature for 18 h, During this time further carbon monoxide gas was introduced as necessary to maintain a pressure between 47 and 51 bar. After cooling to ambient temperature the mixture was analysed by gas chromatography and 1H n.m.r. The major component was tertiary butanol and no residual di-tertiary butyl peroxide was detected. The mixture also contained dimethyl carbonate (11.1 gm), methanol and pyridine as well as small amounts of other compounds among which were identified acetone and methyl acetate. Example 2 An autoclave was charged with methanol (32 ml), di-tertiary-butyl peroxide (14.5 ml) and pyridine copper methoxy chloride (0.85 gm). Carbon monoxide gas was introduced to a pressure of 75 bar at 220C. The mixture was heated to 1200C with stirring, pver a period of 9 minutes. An exothermic reaction took place, the temperature of the mixture reaching a maximum value of 188"C after a further 90 seconds while the recorded pressure decreased. The reaction mixture returned to 1200C during 20 minutes and no further gas uptake occurred. After cooling to room temperature the 1E n.m.r. of the product mixture showed a molar ratio of methanol:tertiary butanol:dimethyl carbonate of 4.4:1:0.41, as well as traces of acetone and methyl acetate. Example 3 An autoclave was charged with methanol (32 ml), di-tertiary butyl peroxide (14.5 ml), pyridine (1 ml) and cuprous chloride (0.4 gm). Carbon monoxide gas was introduced to a pressure of 37.5 bar, then hydrogen gas to give a total pressure of 67 bar at 240C. The mixture was heated to 1200C, with stirring, over a period of 8 minutes. An exothermic reaction took place, the temperature of the mixture reaching a maximum value of 1600C after a further 90 seconds. The reaction mixture returned to 1200C during 25 minutes and no further uptake of gas occurred. After cooling to room temperature the 1H n.m.r. of the product mixture showed a molar ratio of methanol:tertiary butanol:dimethyl carbonate of 3.9:1:0.37 as well as traces of acetone and methyl acetate. Example 4 An autoclave was charged with methanol (9.0 gm), di-tertiary butyl peroxide (20.4 gm), cuprous chloride (0.28 gm) and 2,6--dimethyl pyridine (3.1 gm). Carbon monoxide gas was introduced to a pressure of 46 bar at ambient temperature. The mixture was heated, with stirring to 970C and maintained at this temperature for 19 h. During this time further carbon monoxide gas was introduced as necessary to maintain the pressure between 46 and 52 bar. After cooling to ambient temperature the mixture was analysed by gas chromatography and 1H n.m.r. The major component was tertiary butanol and no residual di-tertiary-butyl peroxide was detected The mixture also contained dimethyl carbonate (11.2 gm), methanol and 2,6dimethyl pyridine as well as small amounts of other compounds among which were identified acetone and methyl acetate. Example 5 An autoclave was charged with methanol (9.0 gm), di-tertiary butyl peroxide (20.5 gm) cuprous chloride (0.29 gm) and pyridine.(2,2 gm). Hydrogen gas-was introduced to a pressure of 22 bar at ambient temperature. Carbon monoxide was then introduced to a total pressure of 46 bar at ambient temperature. The mixture was heated with stirring to 920C and maintained at this temperature for 15h. Further carbon monoxide gas was introduced as necessary to maintain a pressure between 41 and 50 bar. After cooling to ambient temperature the mixture was analysed by gas chromatography and 1H n.m.r. The major component was tertiary butanol and no residual di-tertiary-butyl peroxide was detected. The mixture also contained dimethyl carbonate (10.7 gm), methanol and pyridine as well as small amounts of other compounds among which were identified acetone and methyl acetate. Example 6 An autoclave was charged with methanol (9.0 gm), di-tertiarybutyl peroxide (20.5 gm) and pyridine copper methoxy chloride (0.59 gm). Carbon monoxide gas was introduced to a pressure of 45 bar at ambient temperature. The mixture was heated, with stirring to 92"C and maintained at this temperature for 12 h. During this time further carbon monoxide gas was introduced as necessary to maintain a pressure between 40 and 51 bar. After cooling to ambient temperature the mixture was analysed by gas chromatography and 1H n.m.r. The major component was tertiary-butanol and no residual di-tertiary-butyl peroxide was detected. The mixture also contained dimethyl carbonate (8.6 gm) and methanol as well as small amounts of other compounds among which were identified acetone and methyl acetate. Example 7 An autoclave was charged with ethanol (16.6 gm), di-tertiarybutyl peroxide (17.5 gm) cuprous chloride (0.24 gm) and pyridine (0.6 gm). Carbon monoxide gas was introduced to a pressure of 72 bar at ambient temperature. The mixture was heated with stirring to 1000C and maintained at this temperature for 18 h. During this time further carbon monoxide gas was introduced as necessary to maintain a pressure between 88 and 99 bar. After cooling to ambient temperature the mixture was analysed by gas chromatography and 1H n.m.r. The major component was tertiary-butanol. The mixture also contained diethyl carbonate (8.2 gm), ethanol and pyridine as well as small amounts of other unidentified components. Example 8 A fuel additive mixture containing methanol (52 wt %), t-butanol (30 wt %), and dimethyl carbonate (18 wt Z) was prepared by blending the components together. The RONs and MONs of the 10:90 volume % blend of this mixture with gasoline, and the unblended gasoline were determined. The values obtained are given in the following Table. TABLE EMI10.1 <tb> Blend <SEP> Composition <SEP> % <SEP> vol <tb> <SEP> Gasoline <SEP> 100 <SEP> 1 <SEP> 90 <tb> <SEP> Additive <SEP> mixture <SEP> i <SEP> 10 <tb> CFR <SEP> Ratings <tb> <SEP> RON <SEP> 89.2 <SEP> 92.2 <tb> <SEP> MON <SEP> 80.8 <SEP> 82.8 <tb> Blending <SEP> Octane <SEP> Values <tb> RON <SEP> - <SEP> <SEP> 119 <tb> <SEP> NON <SEP> - <SEP> <SEP> 100.8 <tb> The Figures in the Table show that the addition to the gasoline of 10% vol of the additive mixture gives a significant increase in both the RON and the MON. Example 9 An autoclave was charged with methanol (32 ml), di-tertiary butyl peroxide (14.5 ml) and methoxy copper pyridine chloride (0.845 gm) and pressurised to 75 bar at 220C. The reaction mixture was heated, with stirring, to 1200C over a period of nine minutes. An exothermic reaction took place, the temperature of the reaction mixture -reaching a maximum value of 188"C after a further lj minutes and a decrease in pressure was observed. The reaction mixture returned to 1200C during 8 minutes and was maintained at this temperature for 70 minutes. After cooling, the volatile products were separated from the catalyst by distillation under reduced pressure at ambient temperature. The reaction was carried out twice more under similar conditions using the recovered catalyst each time. During the second and third cycles the exothermic reaction was less pronounced and the reaction time at 120 C was extended to 90 minutes and 115 minutes respectively. Approximately equal portions of the liquid products from each cycle were combined. GC-analysis showed this mixture to contain methanol (53 wt Z), tertiary-butanol (31 wt %) and dimethyl carbonate (12.5 wt %), as well as small amounts of acetone, methyl acetate and methyl formate. The blending RON and MON of the additive mixture were 110.8 and 94.0 respectively.

Claims: Claims: 1. A process for the production of a dihydrocarbyl carbonate which comprises reacting in the liquid phase under substantially anhydrous conditions a dihydrocarbyl peroxide, a primary or secondary alcohol and carbon monoxide in the presence as catalyst of copper in elemental or compound form. 2. A process according to claim 1 wherein the hydrocarbyl groups of the dihydrocarbyl peroxide are independently either alkyl, aryl, alkaryl or aralkyl groups having up to nine carbon atoms. 3. A process according to claim 2 wherein the dihydrocarbyl peroxide is di-tertiary-butyl peroxide. 4. A process according to any one of the preceding claims wherein copper is added in the form of a copper (I) compound. 5. A process according to claim 4 wherein the copper (I) compound is a halide. 6. A process according to any one of the preceding claims wherein the alcohol is an alkanol which is either methanol, ethanol or isopropanol. 7. A process according to any one of the preceding claims wherein there is added an heterocyclic aromatic nitrogen compound. 8. A process according to claim 7 wherein the heterocyclic aromatic nitrogen compound is either pyridine or a derivative thereof. 9. A process according to claim 8 wherein di-tertiary-butyl peroxide, carbon monoxide and one or more of methanol, ethanol-or isopropanol are reacted in the presence as catalyst of a copper compound to produce a mixture comprising t-butanol and a dialkyl carbonate wherein the alkyl groups are independently either methyl, ethyl or isopropyl. 10. A process according to claim 9 wherein di-tertiary-butyl peroxide, carbon monoxide and methanol are reacted to produce a mixture comprising t-bitanol and dimethyl carbonate. 11. A process according to either claim 9 or claim 10 wherein a mixture comprising t-butanol, a dialkyl carbonate wherein the alkyl groups are independently either methyl, ethyl or isopropyl, and all or part of the unreacted methanol, ethanol or isopropanol is recovered. 12. An additive composition for use in internal combustion engine fuels comprising t-butanol and one or more dialkyl carbonates wherein the alkyl groups are independently either methyl, ethyl or isopropyl. 13. An additive composition according to claim 12 comprising the mixture obtained by the process of any one of claims 8 to 10. 14. An internal combustion engine fuel composition comprising a hydrocarbon fuel and the additive composition of either claim 12 or claim 13.

Inventors: MORRIS, GEORGE ERNEST
Applicants: THE BRITISH PETROLEUM COMPANY P.L.C.
Application year: 1983
Main classification: C07C68
IPC codes: C07C68, C10L1