Production of carboxylic acids from alcohols

Abstract: A process for the production of organic carboxylic acids by the catalytic reaction of alcohols and carbon monoxide in contact with an organic ester or a compound which under the reaction conditions is convertible to an organic ester, all in contact with a homogeneous catalyst system containing rhodium metal atom and lithium iodide.

Description: BACKGROUND OF THE INVENTION The production of organic compounds using synthesis gas, which is a mixture of carbon monoxide and hydrogen, or from carbon monoxide as one of the reactants has been known for a significant period of time. It is well known that one can produce methanol directly from synthesis gas and that methanol can be further reacted by hydroformylation, homologation and carbonylation reactions to produce acetaldehyde, ethanol and acetic acid or its methyl ester, respectively. It is also known that alcohols, esters, ethers, and other organic compounds can be reacted with synthesis gas or carbon monoxide to produce oxygenated organic compounds. The difficulties, however, have resided in the ability to carry out any one of these chosen reactions to produce the desired compound at acceptable efficiency, conversion rate and selectivity. In almost all instances the reaction is generally catalyzed using a Group VIII transition metal compound as catalyst and a halogen as the promoter. It is knwon that many other metal compounds and promoters can be used. In addition, the prior art has disclosed the use of secondary activators or ligands in conjunction with the metal catalysts and promoters. These secondary activators can be other metallic salts or compounds, amines, phosphorus compounds, as well as a multitude of other compounds that have been disclosed in the published literature. Thus, a typical catalyst system contains the metal atom catalyst, promoter and, optionally, ligands, solvents and secondary activators. Though a significant amount of literature does exist describing the production of acetic acid, to our knowledge it does not disclose or suggest our invention. Several of the pertinent patents in this area are discussed below. FR-A-2,317,269 discloses the production of aliphatic carboxylic acids by the reaction of an alcohol with carbon monoxide in the presence of a catalyst containing at least three essential components, iridium atom, copper atom and halogen. In EP-A1-0018927 there is described a process for the production of monocarboxylic acids by the carbonylation of an alcohol using a nickel catalyst, a halide and a solvent; in this reference synthesis gas is used. EP-A1-0045637 there is disclosed the direct conversion of formic acid esters to their corresponding carboxylic acids without the presence of carbon monoxide using as catalyst a soluble iridium salt and an iodine promoter. Another known procedure for producing acetic acid is the catalytic isomerization of methyl formate as shown by the reaction: CH₃OOCH → CH₃COOH This procedure is shown in U.S.-A-1,697,109. The process described is a vapor phase isomerization reaction carried out at 200°C to 450°C at a pressure up to 200 atmospheres using a metal oxide or acetate catalyst. It does not disclose the use of alcohols as starting materials. U.S.-A-2,508,513 claims an iron metal atom based catalyst, e.g. nickel, promoted with methyl iodide for the isomerization of methyl formate to acetic acid, carried out at 300°C to 400°C and a pressure up to 400 atmospheres. Carbon monoxide may be present. U.S.-A-3,060,233 discloses the carbonylation of methanol to acetic acid using a metal of the iron group of the Periodic Table and a halide. It does not disclose use of rhodium. U.S.-A-3,769,329 discloses the production of carboxylic acids from alcohols, or the ester, ether and halide derivatives thereof, and carbon monoxide using a rhodium catalyst and an acidic halogen component. It does not mention lithium iodide. The process disclosed in this reference requires the use of acidic halogen compounds which are corrosive and difficult to handle. High levels of methyl iodide are used and recycled in order to maintain activity. Further, the preferred mode of operation of this process uses a large excess of water to ensure selectivity to acetic acid. U.S.-A-3,798,267 relates to the conversion of methyl formate to acetic acid in the presence of a catalyst system consisting essentially of activated carbon and a halogen promoter. U.S.-A-4,194,056 discloses the production of carboxylic acid from methyl formate using a soluble rhodium catalyst, halogen promoter and carbon monoxide. U.S.-A-4,212,989 describes a process for producing carboxylic acids or their esters by reacting an alcohol or an ether with carbon monoxide using a Group VIII metal catalyst and an iodine promoter. GB-A-1,286,224 relates to the reaction of methyl formate with carbon monoxide in contact with a rhodium catalyst and a halogen promoter to produce acetic acid. It contains no recognition of the distinct advantages achieved with the use of lithium iodide, in fact it does not mention this specific compound. GB-A-1,293,193 relates to the direct conversion of formic acid esters to the corresponding carboxylic acids, in the presence of carbon monoxide, a catalyst that is a Group IIb or VIII metal and an organic polar solvent. JP-A1-50-16773 discloses the production of an organic acid from the corresponding formic acid ester in the presence of carbon monoxide using a catalyst system containing cobalt, iron or mercury and a halogen plus an alkali metal salt of a lower aliphatic carboxylic acid, triamine or cyclic amine. JP-A1-51-65703 discloses the reaction of methyl formate in the presence of carbon monoxide using a system containing a rhenium catalyst and halogen compound to produce acetic acid. JP-A1-56-22745 discloses the isomerization of a formic acid ester to the corresponding acid in the presence of carbon monoxide, palladium atom, halogen and base. JP-A1-56-73040 relates to a process for producing acetic acid by isomerizing methyl formate in the presence of carbon monoxide using a nickel catalyst, an iodine compound and an organic nitrogen compound. JP-A1-56-83439 discloses a method for producing acetic acid by heating methyl formate and carbon monoxide in contact with a catalyst containing palladium, ruthenium and/or irridium metal atom and a halide promoter: None of the 5 Japanese Patent Applications disclose a process for producing a carboxylic acid from an alcohol using a catalyst mixture consisting essentially of rhodium metal atom an lithium iodide. The subject matter of BE-A-794 803 is the production of acetic acid from methanol and CO in the vapor phase at a supported catalyst, while the catalytically effective substance is a rhodium compound and i.a. lithium chloride. Thus a reaction system with a heterogenous catalyst is concerned. The conversion rates of methanol to acetic acid are far too low for large scale production. US-A-38 45 112 is concerned with the processing of the reaction products of the carboxylation resulting in liquid phase by reacting an alcohol with CO in the presence of a catalyst system of a rhodium compound and a iodine compound. As iodine compounds firstly rhodium iodide and organo iodides come into question; inter alia sodium and potassium iodide are mentioned, but not lithium iodide. It can be seen that the prior art contains many disclosures dealing with the catalytic production of acetic acid, including its production from methanol. The art also discloses the production of other organic carboxylic acids from other alcohols. One of the disadvantages in many of these references is the presence of water with the eventual need to remove it from the desired organic acid product. This removal is both complicated and costly. Other disadvantages often include the simultaneous occurrence of other reactions leading to the formation of by-products, such as, dimethyl acetal, methyl acetate, ethanol, etc. These reactions compete with the organic acid production resulting in low conversion rate an selectivity to organic acid. Many processes employed for the production of organic acids use a catalyst system containing a source of metal atom and a source of halide atom. The alkali metal halides are often mentioned as suitable halide sources, but no distinction is made between any specific one of the alkali metal halides or between any other halogen compound. SUMMARY OF THE INVENTION A process for the production of acetic acid at high efficiency, selectively and conversion rate by the reaction of methanol with carbon monoxide or synthesis gas in contact with a catalyst system consisting of rhodium metal or a rhodium compound and lithium iodide has been found. The new process is characterized therein that the catalyst system is a homogeneous system and methyl acetate but no water is added to the reaction mixture. The catalyst system charged to the reactor in our process contains rhodium atoms, lithium iodide and optionally an organic ligand. The use of lithium iodide in this system within the ranges defined results in unexpectedly high efficiency, high conversion rate or activity and high selectivity not heretofore achieved. DESCRIPTION OF THE INVENTION In the catalytic reactions of synthesis gas or carbon monoxide in processes to produce oxygenated organic compounds there are several criteria required of the catalyst. The catalyst must be as stable as possible, it should have a high activity or conversion rate, and it should have as high a selectivity for the desired product as possible. Stability of the catalyst relates to how long the catalyst remains functional before either breaking down or losing its catalytic effect. Activity or conversion rate relates to the amounts of reactants the catalyst converts to product per unit of time, generally expressed in g. mole per liter per hour (g mole/ℓ·h). Selectivity relates to the quantity of desired product produced, generally expressed in mole percent, based on the total amount of both desired products and undesired products produced. The goal to be achieved is high values for all three criteria and continued efforts are being made to find new catalyst compositions to reach this goal without having a significant detrimental effect on the overall process. Toward this goal the prior art has developed catalyst systems containing a wide variety of metal atoms, promoters and activators, in many cases with diverse other components added. Though these catalyst systems are effective, improvement is always desirable. The present invention is based on the unexpected and unpredictable discovery that the rhodium-lithium iodide system in conjunction with methyl acetate is an unexpectedly superior catalytic system for the production or acetic acid from methanol and carbon monoxide at unexpected high efficiency, selectivity and conversion rate. It was also found that a ligand, ER '' / 3 can also be present as an optional component of the system. This unexpected improvement in efficiency, selectivity and conversion rate is achieved when the system's components are maintained within a defined range and when lithium iodide is present as the source of the halogen component in the system. Optionally a solvent and/or diluent can also be present. The improved catalyst system of this invention can be portrayed as containing the components Rh - Li I - ER '' / 3 , wherein Rh is the rhodium containing compound and ER '' / 3 is optionally present. Also present in the system is an ester. In the process of our invention methanol is reacted with carbon monoxide in the presence of added methyl acetate but no added water, using a particular catalyst system containing rhodium atoms and lithium iodide. This system produces acetic acid at unexpected high efficiency, conversion rate and selectivity, with a minimum of by-products and without the presence of water. The overall reaction that occurs is theoretically: CH₃OH + CO → CH₃COOH The rhodium component of the catalyst system can be supplied from any number of sources, many of these are known to those of ordinary skill in the art. Thus, it is not necessary for an understanding thereof to specifically enumerate every suitable type and every specific compound since any of the known rhodium compounds can be used. The essential rhodium component of the catalyst system of the present invention may be provided by introducing into the reaction zone a compound of rhodium or may be provided by introducing into the reaction zone rhodium. Among the materials which may be charged to the reaction zone to provide the rhodium component of the catalyst system of the present invention are rhodium metal, rhodium salts and oxides, organo rhodium compounds, coordination compounds of rhodium, and the like. Specific examples of materials capable of providing the rhodium constituent of the catalyst system of the present invention may be taken from the following list of suitable materials. RhCl₂ RhBr₃ Rhl₂ RhCl₃ 3H₂O RhBr₃ 3H₂O Rh₂(CO)₄Cl₂ Rh₂(CO)₄Br₂ Rh₂(CO)₄l₂ Rh₂(CO)₈ Rh[(C₅H₅)₃P]₂(CO)l Rh[(C₆H₅)₃P]₂(CO)Cl Rh metal Rh(NO₃)₃ RhCl[(C₆H₅)₃P]₂(CH₃l)₂ Rh(SnCl₃)[(C₆H₅)₃P]₂ RhCl(CO)[C₆H₅)₃AS]₂ Rhl(CO)[(C₆H₅)₃Sb]₂ [(n-C₄H₉)₄N][Rh(CO)₂X₂] where X = Cl-, Br-, l- [(n-C₄H₉)₄AS]₂(Rh(CO)₂Y₄] where X = Br-, l- [(n-C₄H₉)₄P)(Rh(CO)l₄] Rh[(C₆H₅)₃P]₂(CO)Br Rh[(n-C₄H₉)₃P]₂(CO)Br Rh[(n-C₄H₉)₃P]₂(CO)l RhBr[(C₆H₅)₃P]₃ Rhl[(C₆H₅)₃P]₃ RhCl[C₆H₅)₃P]₂ RhCl[(C₆H₅)₃P]₃H₂ [(C₆H₅)₃P]₃Rh(CO)H Rh₂O₃ [Rh(C₃H₄)₂Cl]₂ K₄Rh₂Cl₂(SnCl₂)₄ K₄Rh₂Br₂(SnBr₃)₄ K₄Rh₂l₂(Snl₂)₄ The rhodium metal atom concentration can vary over a wide range. Enough metal atom must be present to achieve reasonable reaction rates; however, an excess may on occasion result in undesired by-products formation. The mole ratio of rhodium atom to alcohol can very from 1:25 to 1:20.000, the preferred range is from 1:40 to 1:1000, with the most preferred range being from 1:100 to 1:500. The amount used is not a critical feature in this invention and higher rhodium concentrations are acceptable but are influenced by economic considerations. The second component of the catalyst system is lithium iodide. It can be charged directly, or it can be formed in situ by any combination of lithium compound and iodine component that will result in the formation of lithium iodide during the reaction. The presence of lithium iodide is a critical feature of this invention. Direct charge of lithium iodide is the preferred form. However, any convenient combination of compounds for in situ formation of lithium iodide can be used. This includes the use of lithium carboxylates, carbonates and the like with iodine or an alkyl iodine. A suitable combination for in situ formation is lithium carboxylate and and an alkyl iodide. Sufficient lithium iodide must be present to exert a promoting effect on the reaction and to result in high efficiency, conversion rate and selectivity to the corresponding organic acid. The mole ratio of Rh:Lil can vary over a wide range. A Rh:Lil mole ratio of from 1:1 to 1:1000 can be employed, the preferred range is from 1:2 to 1:450 and most preferably it is from 1:8 to 1:150. As indicated, an organic ligand of the general formula ER '' / 3 can optionally be present in the reaction system. The use of such ligands is known, as are their identities, to those skilled in this art. In this formula E represents a Group VA element, e.g., N, P, As, Sb and Bi, and R'' represents an organic moiety. The ligand can serve as a catalyst stabilizer and/or to further enhance efficiency, conversion rate and selectivity, especially when the reaction is carried out at higher temperatures, for example at about 200°C or above. The ligand also serves to inhibit equipment corrosion in some instances. However, the use of a ligand is not mandatory and the reaction can be carried out without it. A large number of organic ligands is known and any of these can be used provided they do not have an adverse effect on the reaction. Among those of paricular utility are the tertiary amines and the tri- and pentavalent phosphorus compounds. Though those skilled in the art know these compounds, illustrative of suitable compounds one can mention triethylphosphine, tributylphosphine, tri-2-ethylhexylphosphine, triphenylphosphine, tri(4-methoxyphenyl)phosphine, tri-p-tolylphosphine, tri(3-chlorophenyl)phosphine, diphenyl hexylphosphine, dimethyl (3-methoxyphenyl)phosphine, dibutyl stearylphosphine, tribenzylphosphine, dipropyl phenylphosphine, ethyl dipropylphosphine, tricyclohexylphosphine, cyclohexyl dibutylphosphine, propyl diphenylphosphine, dipropyl phenylphosphine, phenyl diethylphosphine, tridecylphosphine, trioctadecylphosphine, tribenzylphosphine, methyl diethylphosphine, ethyl diphenylphosphine, tolyl diethylphosphine, cyclohexyl diethylphosphine, diethyl cyclohexylphosphine, bis-(diphenylphosphino)-ethane, bis-(diethylphosphino)-propane, bis-(diphenylphosphino)-butane, bis-(diethylphosphino)-octane, trimethylamine, triethylamine, tri-n-butylamine, tri-t-butylamine, tri-2-ethylhexylamine, methyl dibutylamine, tridodecylamine, tristearylamine, ethyl dibutylamine, tricyclohexylamine, triphenylamine, tri(4-methoxyphenyl)amine, tri(p-chlorophenyl)-amine, dibutyl phenylamine. dipentyl cyclopentylamine, ethyl diphenylamine, trinaphthylamine, tri-p-tolylamine, tri-benzylamine, tri(3-methylcyclohexyl)amine, and the arsines, stibines and bismuthines corresponding to the above-identified phosphines and amines. They can be used singly or, if one desires, mixtures containing two or more ligands can be used. One can also employ a phosphine oxide or phosphite corresponding to the above phosphines as the ligand; these are also well known. The concentration of ligand charged can vary from a molar ratio of ligand to rhodium of from 50:1 to 1:50, preferably from 10:1 to 1:10, most preferably 3:1 to 1:1. The present invention does not require the use of acidic halogen promoters, it employs the alkali metal halide lithium iodide. Nor does it require the presence of water or use of large quantities of methyl iodide to give high selectivity to acetic acid, as are taught in U.S.-A-3,769,329. It was surprising, unexpected and unpredictable that a basic iodide, lithium iodide, would convert methanol to acetic acid because Example 15 of U.S.-A-3,769,329 taught that use of rhodium, water, acetic acid, methanol and the basic iodide potassium iodide showed little, if any, reaction at carbon monoxide pressure of 55.2 bar (800 psig) and a reaction temperature of 175°C. In this reference, reaction was not observed until the reaction mixture was acidified with a mineral acid, e.g. phosphoric acid. In our invention addition of acid is not required and the basic iodide lithium iodide is used. Under essentially the same conditions of pressure and temperature, a reaction mixture of methanol, methyl acetate, rhodium and lithium iodide produced acetic acid at excellent rates and selectivities; contra to the teachings of U.S.-A-3,769,329. Also essential to this invention is the presence in the reaction mixture of methyl acetate. The presence of said compound is critically important. Thus, it was observed in the reaction to produce acetic acid from methanol that pure methanol in the absence of methyl acetate did not react with carbon monoxide in the presence of rhodium atom and lithium iodide at 55.2 bar (800 psig) and about 180°C. Nor did reaction occur when 1,4-dioxane was used as the solvent. However, the addition of methyl acetate to the reaction mixture resulted in good conversion rates and high selectivity to acetic acid as shown in our examples. The reaction is carried out at a temperature of from 50°C to 350°C, preferably from 120°C to 220°C and most preferably from 150°C to 200°C. When the reaction is carried out at temperatures above 200°C in the presence of an ER '' / 3 ligand, the preferred ligands are the phosphines, especially triphenyl phosphine. The pressure of the reaction can be from 10.35 to 690 bar (150 psig to 10.000 psig), preferably from 13.8 to 138 bar (200 psig to 2.000 psig), most preferably from 34.5 bar to 69 bar (500 psig to 1.000 psig). The reaction time varies depending upon the reaction parameters, reactor size and charge, and the individual components employed at the specific process conditions. The reaction can be a batch or continuous reaction. The experiments and examples detailed below were carried out in a Hasteloy® steel autoclave reactor having a volume of 300 ml, which was equipped with temperature and pressure sensing means, heating and cooling means, agitator and inlet and outlet means for introducing and removing components from the reactor. The autoclaves used in synthesis gas reactions are well known in the art and can be used in this process. Prior to charging the reactants the autoclave was washed with methanol at 100°C under a nitrogen gas pressure of 34.5 to 69 bar (500 to 1.000 psig) by agitating for 30 minutes, the autoclave was drained, rinsed with dry acetone, and dried with nitrogen. The liquid components were charged to the cleaned autoclave first and then the solid components were added and stirred. The autoclave was closed, purged with carbon monoxide and then pressurized to the desired pressure with carbon monoxide. The autoclave contents were heated to the selected temperature, with agitation (usually 750 rpm), in about 45 minutes. After the desired temperature was reached, the reaction was allowed to consume carbon monoxide for the time period indicated. During this time the pressure was maintained by addition of carbon monoxide as needed. At the end of the reactor run, the contents were cooled, generally to about 10°C. A vapor phase sample was taken for gas chromatography analysis; the gas phase was vented through 2 dry-ice acetone traps and then through a 10 liter saturated solution of calcium hypochlorite to remove metal carbonyls, if formed. The reactor was pressurized three times with nitrogen 6.2 bar (90 psig), and vented through the same system. The residual reactor contents were dumped into a chilled pressure bottle and sealed. Subsequent analysis was performed using a Hewlett-Packard Model 5880 gas chromatograph equipped with a 3.2 mm (one-eight inch) diameter by 3m (ten feet) long column packed with Cromosorb 101. The following examples serve to further illustrate this invention. Example 1 The autoclave was charged with 8 mmoles of rhodium dicarbonyl acetylacetonate, 64 mmoles of lithium iodide, 50 ml of methanol and 100 ml of methyl acetate. The reactor was pressurized with carbon monoxide to a total pressure of 69 bar (1.000 psig) at 180°C and maintained at those conditions for 3.2 hours. Analysis of the products at the conclusion established that 65% of the methanol charged had been converted to acetic acid at a selectivity greater than 95%. For comparative purposes, the reaction was repeated but in this instance the methyl acetate was replaced by 100 ml of 1,4-dioxane. Under the same conditions little, if any, reaction had occurred after 3 hours. Essentially all of the methanol was recovered unreacted. Example 2 The autoclave was charged with a 8 mmoles of rhodium dicarbonyl acetylacetonate, 128 mmoles of lithium iodide, 50 ml of methanol and 100 ml of methyl acetate. The reactor was pressurized to a total pressure 69 bar (1.000 psig) at 180°C and maintained at those conditions for 1.16 hours. Analysis of the products at the conclusion established that 65% of the methanol charged had been converted to acetic acid at a selectivity greater than 95%. In a similar manner, but with the presence of triphenylphosphine, similar conversions and selectivities are obtained. Examples 3 to 6 In a manner similar to Example 2, essentially similar conversions of from 60 to 70% and selectivities of about 95% are obtained by the use of the following rhodium compounds - rhodium iodide, rhodium metal, rhodium tetracarbonyl diiodide, and Rhl(C₆H₅)₃P]₃.

Claims: A process for the production of acetic acid by the catalytic reaction of methanol and carbon monoxide or synthesis gas in contact with a catalyst system consisting of rhodium metal or rhodium compound and lithium iodide, characterized in that the catalyst system is a homogeneous catalyst system and methyl acetate but no water is added to the reaction mixture. The process as claimed in claim 1 wherein the temperature is from 50°C to 350°C and the pressure is from 10.35 to 690 bar. The process as claimed in claim 1 wherein the mole ratio of Rh:Lil is from 1:1 to 1:1,000 or from 1:8 to 1:150. The process as claimed in claims 1 to 3, wherein an organic ligand of the formula ER '' / 3 is present, wherein E is nitrogen, phosphorus, arsenic, antimony and bismuth and R'' is an organic moiety. The process as claims in claim 4 wherein the ligand is a phosphine.

Inventors: SCHRECK DAVID JAMES, SCHRECK, DAVID JAMES
Applicants: UNION CARBIDE CORP, UNION CARBIDE CORPORATION
Application year: 1984
Main classification: C07C51
IPC codes: C07C67, C07C51, C07C53, C07B61, B01J27