Production of alkylated hydroxy aromatic compounds

Abstract: A process for producing a hydroxy-containing alkylated aromatic compound comprising reacting aromatic compound having at least one hydroxyl group with alkylating agent characterised in that the reaction is conducted in the liquid phase in the presence of heteropoly acid. The heteropolyacid (e.g. silicotungstic acid) catalyst gives good selectivity, conversion and yields, is substantially non-corrosive, and is readily recovered for re-use. A regulated amount of water is preferably maintained in the reaction system for best efficiency.

Description: The present invention relates to a novel method for producing a hydroxy-containing alkylated aromatic compound by reacting an aromatic compound having at least one hydroxyl group with an alkylating agent in the liquid phase. Hydroxy-containing alkylated aromatic compounds, particularly alkylphenolic compounds obtained by the reaction of phenolic compound with alkylating agent (particularly isobutene or an isobutene-containing gas) are finding wide applications, for example as anti-oxidants, stabilizers, intermediates for agricultural chemicals and dyestuffs, materials for resins and industrial chemicals. Particularly, 2,6-di-tert-butyl-4-methylphenol obtained by reacting p-cresol or a cresol mixture containing p-cresol with isobutene or an isobutene-containing gas in the presence of a heteropoly acid is typical of alkylphenolic compounds with which the present invention is concerned. The common method of producing alkylphenolic compounds, particularly tert-alkylphenolic compounds, by the alkylation of phenolic compound with branched olefin, is one in which the reaction is carried out in the presence of an acid catalyst - e.g. sulfuric acid [Industrial and Engineering Chemistry, Vol. 35, pp. 264-272 (1943)], aluminum chloride [Journal of American Chemical Society, Vol. 67, pp. 303-307 (1945)], metalloaryl oxide (U.S. Patent No. 2831898), toluenesulfonic acid and toluenesulfonic acid type cation-exchange resin (Japanese Patent Publication No. 18182/1962), cresolsulfonic acid (U.S. Patent No. 2733274), etc. In practice, however, the phenolic compound is reacted not with isobutene, but with gas containing isobutene, butene-1, butene-2, etc. which is cheaply and easily available in industry, and this yields secalkylphenolic compounds, etc. as by-products in large amounts. Use of high-purity hydrocarbon, however, is industrially disadvantageous because the isobutene has to be separated from the isobutene-containing mixture and purified, for example, like more volatile components produced by cracking of petroleum products. The method of reacting phenolic compound with an isobutene-containing mixture has been thought to be industrially and economically advantageous and has been extensively studied. It is however very difficult to selectively react isobutene in the mixture, so that much research for high-selectivity catalysts has been made and various kinds of catalyst have been proposed. All of these conventional methods have the defect that increasing the selectivity causes reduction in the conversion and in the rate of absorption of isobutene. When increasing conversion is tried, the consumption of isobutene increases, but sec-alkylphenolic compounds, isobutene polymers and polymers of other olefin gases increase. As a result, washing and purification operations for obtaining the desired product become complicated, and special treatment of the formed waste liquor becomes necessary. Also, the exhaust gas cannot be used directly as fuel because it contains the foregoing polymers in large amounts, so that purification and separation operations are necessary. When conventional catalysts such as sulfuric acid, toluenesulfonic acid, etc. are used, sulfonated products and neutral esters (butyl sulfate, etc.) are formed. As is well known, these esters, etc. remain in the reaction product even after neutralization and washing, and act as dealkylation catalysts when heated to a high temperature on distillation,preventing production of high-quality alkylphenolic compounds in high yields. For this reason, a method has been employed in which the reaction product is neutralized with an aqueous alkali solution at high temperature and high pressure to decompose the esters [Industrial and Engineering Chemistry, Vol. 35, pp. 265-272 (1943)]. There is also the problem that since these catalysts have a violent corrosive action, equipment of high-grade materials is necessary for use of the catalysts in industry. JP-A-59-155332 discloses the preparation of p-ethylphenol by reacting phenol with ethylene in the presence of supported heteropolyacid catalyst and water; it contains no disclosure or suggestion of operation in the liquid phase. DE-PS-645242 discloses alkylation of phenol using alkanol and heteropolyacid; there is no disclosure or suggestion of using unsaturated hydrocarbon alkylating agents in a liquid phase operation. The present invention provides a process for producing a hydroxy-containing alkylated aromatic compound which comprises reacting aromatic compound having at least one hydroxyl group and selected from monohydric phenols, polyhydric phenols and naphthols with alkylating agent selected from unsaturated hydrocarbons containing at least one double bond, the reaction being carried out in the liquid phase and at a temperature of 30°C to 150°C, in the presence of heteropoly acid catalyst and an amount of water which is 0.001 to 0.05 times the weight of the aromatic compound, and the molar ratio of alkylating agent to aromatic compound being (1-20):1. The process of the invention permits production of the desired product with good selectivity and yield by economical and simple operations. Particularly, in the reaction of phenolic compound with gas containing isobutene, butene-1, butene-2, etc., the process of the invention can inhibit the side reactions of butene-1, butene-2, etc., and prevent the polymerization of isobutene, etc.; the desired alkylphenolic compounds can thus be produced in high purity and high yield with ease. Further the heteropoly acid is easily recovered after reaction, and can be re-used in the subsequent reaction; and it has very little corrosive action on equipment. Examples of hydroxy aromatic reactants for use in the present invention include: monohydric phenols such as phenol, o-, m- or p-cresol and mixtures thereof, o-, m- or p-ethylphenol, o-, m- or p-isopropylphenol, o-, m- or p-tert-butylphenol, o-, m- or p-sec-butylphenol, 4-tert-butyl-6-methylphenol, 2,4-dimethylphenol, 2-methyl-4-ethylphenol, 2,4-diisopropylphenol, 4-methyl-6-isopropylphenol, 2,6-di-tert-butylphenol, 2-tert-butyl-4-methylphenol, 3-methyl-6-tert-butylphenol, 2-chloro-4-methylphenol, p-chlorophenol, p-bromophenol, 2,4-dichlorophenol, 2,4-dibromophenol, 2-methyl-4-chlorophenol, 2-methyl-4-bromophenol, 2,4-dichloro-3-methylphenol, 3-methyl-6-cyclohexylphenol, 3-methyl-4-cyclohexylphenol, etc.; polyhydric phenols such as resorcinol, hydroquinone, catechol, 2-methylresorcinol, 2-chlororesorcinol, 2-carboxy-resorcinol, 2-chlorohydroquinone, 4-tert-butylresorcinol, phloroglucinol, etc.; and naphthols such as 1-naphthol, 2-naphthol, 2-hydroxy-3-carboxynaphthalene, 1-hydroxy-5-methylnaphthalene, 2-hydroxy-5-methylnaphthalene, 2-hydroxy-8-isopropylnaphthalene, 2-hydroxy-5-isopropylnaphthalene, etc. Of these compounds, cresols (including mixed cresols), resorcinol, etc. are preferably used. Alkylating agents for the present invention are unsaturated hydrocarbons having at least one double bond. Preferred is isobutene or isobutene-containing gas; other suitable such unsaturated hydrocarbons include those represented by the general formula (I), R₁-CH = CH₂ (I) wherein R₁ represents a hydrogen atom or a straight or branched hydrocarbon residue having from 1 to 10 carbon atoms; those represented by the general formula (II), R₂-CH = CH-CH₃ (II) wherein R₂ represents a straight or branched hydrocarbon residue having from 1 to 9 carbon atoms; and cyclic unsaturated hydrocarbons having up to 10 carbon atoms. Specific examples of these hydrocarbons include ethylene, propylene 1-butene, 2-butene, isobutene, 1-pentene, 2-pentene, isopentene, 1-hexene, 2-hexene, 1-heptene, 2-heptene, 1-octene, 2-octene, 1-nonene, 2-nonene, 1-decene, 2-decene, 1-dodecene, 2-dodecene, cyclopropene, cyclobutene, cyclopentene, cyclohexene, cyclooctene, etc. These alkylating agents may also be used in admixture. As an example of a mixture, an isobutene-containing gas containing 1-butene, 2-butene, etc. in addition to isobutene (hereinafter referred to as LBB gas) is preferably used. In carrying out the present invention, the alkylating agent is used in a proportion from 1 to 20 times by mole, more preferably from 1 to 5 times by mole, based on the aromatic compound having at least one hydroxyl group. In polyalkylation wherein two or more alkyl groups are introduced into an aromatic ring, the amount of the alkylating agent is generally from 2 to 20 times by mole, more preferably from 2 to 5 times by mole. In the process of the present invention, it is essential to employ a heteropoly acid as a catalyst. The heteropoly acids herein are polyacids formed by two or more metals/metalloids; they may comprise one metal/metalloid (hetero-atom) located at the center and another (polyatom) coordinated to the former through oxygen, etc. The hetero-atoms include boron, aluminum, silicon, phosphorus, titanium, germanium, arsenic, zirconium, tin, tellurium, etc., and the polyatoms include molybdenum, tungsten, vanadium, niobium, etc. Specific examples are phosphomolybdic acid, silicomolybdic acid, arsenomolybdic acid, telluromolybdic acid, aluminomolybdic acid, silicotungstic acid, phosphotungstic acid, borotungstic acid, titanotungstic acid stannotungstic acid, etc. of these compounds, phosphomolybdic acid, silicomolybdic acid, phosphotungstic acid, silicotungstic acid, etc. are particularly preferably used, and silicotungstic acid is most preferably used. These heteropoly acids are generally used in hydrate form. The amount of these catalysts used varies with reaction forms and other conditions, but it is for example from 0.00001 to 0.3 time by weight, preferably from 0.0001 to 0.1 time by weight, more preferably from 0.0002 to 0.03 time by weight, based on the aromatic compound. The amount of the heteropoly acid used in the method of the present invention need not always be limited to a low level, considering that the acid is recoverable after reaction, for example as an aqueous solution, and re-used. It is rather preferred to use the acid in relatively large amounts so that the reaction proceeds stably, and to obtain advantage by the recovery and re-use of the acid. In the present invention, the reaction temperature is from 30° to 150° C, preferably from 40° to 90° C. Too low temperatures retard the reaction rate, while too high temperatures show a tendency to increase the amount of by-products. In the present invention, the reaction time is not critical, a period of from about 0.5 to about 50 hours is usually appropriate. The method of introducing the alkylating agent into the reaction system is not critical, and when for example an LBB gas is used, the agent may be introduced into the reaction system in the form of a gas or Depending upon the reaction conditions, the heteropoly acid catalyst may be used undissolved, i.e. in a heterogeneous system. In this case, water, acetone, etc. may coexist in the system as a diluent or dissolving agent. The amount of such water, acetone, etc. is generally from 0.1 to 20 times by weight, preferably from 0.5 to 5 times by weight, based on the heteropoly acid. In carrying out the present invention, the selectivity and yield of the desired alkylphenolic compounds, particularly tert-alkylphenolic compounds, is increased by causing water to exist in the reaction system in amounts of from 0.001 to 0.05, more preferably from 0.002 to 0.03, part by weight based on the aromatic hydroxy starting material; in determining the amount of water to exist in the reaction system, the water of crystallization of the heteropoly acid used as a catalyst is also taken into account. Consequently, if the water content of the reaction system is regulated within the above range by increasing the amount of water when the amount of heteropoly acid used is large, and vice versa, the reaction proceeds more smoothly to favour high selectivity and yield. When the amount of water present in the system exceeds the above range, the reaction of phenolic compound with isobutene slows down, and unreacted phenolic compound and intermediate products are left behind; when it is below the above range, there is a tendency for reaction of phenolic compound with butene-1, butene-2, etc. in LBB gas to proceed as fast as or faster than that with isobutene, so that unpreferred by-product sec-alkylphenolic compounds are formed. This is completely beyond expectation from the common wisdom in the art that, in a system wherein reaction is carried out using a solid acid catalyst, coexistence of water causes a reduction in the acid strength accompanied by a reduction in the catalytic activity. When a large amount of the phenolic starting material is left unreacted, troublesome recovery operations are necessary; and when undesirable by-products arise in large amounts, troublesome and difficult purification operations are necessary. It is therefore advantageous to determine the reaction conditions so as to avoid such troublesome operations, and for this purpose, it becomes important to carry out the reaction within the range of water content preferred by the present invention. Any of pure water, industrial water, recovered water, steam, etc. may be used as water for the reaction system. Incorporation of water in the reaction system is e.g. by feeding the phenolic starting material and heteropoly acid to the system and then introducing a prescribed amount of water into the system. In another method, the water content of the phenolic starting material is previously controlled so that, when it and the heteropoly acid have been fed, the water content of the system is in the pre-determined range. Another method may be used in which the concentration of an aqueous heteropoly acid solution is previously controlled so that, when the solution and the phenolic starting material have been fed, the water content of the system is in the pre-determined range. It is an advantage of the present invention that, usually, high-boiling products such as butene dimers, etc. are hardly produced in the exhaust gas. In producing alkylphenolic compounds from isobutene or an LBB gas, using sulfuric acid etc. as catalyst increases the butene dimer content of the exhaust gas, which thus cannot be used directly as fuel, city gas etc; consequently, removing these high-boiling products from the exhaust gas becomes necessary, which is disadvantageous industrially. On the other hand, the process of the present invention produces few high-boiling products from butenes, so that high-quality liquefied petroleum gas can easily be recovered by merely compressing the exhaust gas. The form of reaction for the present invention is not limited to those described in the examples, but any of batchwise and continuous forms carried out at atmospheric pressure or under pressure may be used. The reaction may be carried out with or without a solvent. Solvents usable in the reaction include aromatics such as benzene, toluene, xylene, ethylbenzene, ethyltoluene, cumene, nitrobenzene, chlorobenzene, etc., and ethers such as isopropyl ether, etc. The amount of solvent used is not influential, and it is preferably from 0.5 to 50, more preferably from 1 to 20, times by weight based on the hydroxy aromatic starting material. As described above, when sulfuric acid or toluenesulfonic acid is used as catalyst, neutral esters (butyl sulfate, etc.) are formed, so that neutralization at high temperature and under pressure is essential. In carrying out the present invention, however, it was found that little or no such impurities are formed and neutralization is possible under very mild conditions; removal of impurities is possible by merely neutralizing or washing the reaction product with aqueous alkali solution or warm water. The temperature at which the neutralization or washing is carried out need not be high, unlike the conventional methods, and impurities can be removed adequately at a temperature of from 40°to 90°C. As to the amount of aqueous alkali solution or warm water, enough to make the aqueous layer neutral will suffice, and it is generally from 0.1 to 10, preferably from 0.2 to 5, times by weight based on the reaction product. When the aqueous alkali solution or warm water is used not all at once, but in several portions, the removal effect improves further. Contact between the aqueous alkali solution or warm water and the reaction product may be stirring-contact for from 5 minutes to 10 hours, preferably from 10 minutes to 5 hours. The aqueous alkali solution can be prepared, for example, with sodium hydroxide and water. In producing alkylphenolic compounds by the reaction of a phenolic compound with isobutene or an isobutene-containing gas, the amount of heteropoly acid which precipitates in the system may increase with progress of the reaction, so that when the reaction ends most of the heteropoly acid is precipitated. The heteropoly acid precipitate is separable from the reaction solution which may or may not be cooled. This separation can be effected by the usual separation techniques such as filtration, centrifugation, decantation, etc. In separating the heteropoly acid, complete solid-liquid separation is unnecessary, and even heteropoly acid containing reaction solution in large amounts can be re-used. Also, the oily layer may contain the heteropoly acid as a solid, if the amount of the heteropoly acid is such that there are no adverse effects such as dealkylation in the subsequent distillation step. Even if neutralization with an aqueous alkali solution is carried out before distillation,an extremely small amount of alkali will suffice. For separating the heteropoly acid from the reaction mixture after reaction, there is another method of treating the reaction mixture with water to dissolve the heteropoly acid in the aqueous layer and separating the oily layer by means such as liquid-liquid separation etc. In this case, any of pure water, industrial water, recovered water, steam, etc. may be used as water for treatment of the reaction mixture. For extraction-recovering the heteropoly acid catalyst by treatment of the reaction mixture with water, any of counter-flow and parallel-flow batch and continuous processes may be used. For recovering the heteropoly acid and re-using it in the next reaction, it is practically advantageous to adjust the heteropoly acid content of recovered aqueous acid to 20 wt.% or more, preferably 30 wt.% or more. Any amount of water may be added to recover the heteropoly acid by a batch process, but it is preferred to restrict the concentration of the aqueous heteropoly acid solution recovered by this process within the above range so that the solution can be re-used in the next reaction. When, however, the volume ratio of oily layer to aqueous layer, because of the heteropoly acid catalyst being small in amount, would be too large for separation of the aqueous layer, it is possible to extraction-recover the heteropoly acid catalyst with an increased amount of water and vaporize water to the foregoing desired concentration of the heteropoly acid. After completion of the reaction, when precipitated heteropoly acid is present in the system, it is preferred to add a small amount of water necessary to dissolve the heteropoly acid. Water to be added after completion of the reaction may be added all at once or in several portions. When the heteropoly acid is recovered by a continuous process wherein the reaction mixture is continuously supplied to a mixer-settler containing a prescribed amount of water, continuously mixed and separated into an aqueous and oily layers, it is possible to operate the process so that the heteropoly acid concentration of the aqueous layer is in the desired range described above, so that this continuous process is industrially advantageous. This process can be carried out either single-stage or multi-stage, and the percent recovery of the heteropoly acid can be 95% or more. It may be necessary to supply water to the settler so that the proportion of water does not decrease below that preferred. The mixer-settler is preferably a vertical-type mixer/settler assembly with the lower part as mixer and the upper part as settler. Even when the mixer and settler are used separately, the object can be attained by circulating the aqueous layer from the settler to the mixer. Further, various kinds of common extractor can be used for the purpose of the present invention, and as need arises, it is also possible to pack a net made of glass fibers, polymer fibers, etc., for example "Coalescer" (a trade name of Nihon Mesh K.K.), between the mixer and settler in order to improve the separation of the oily and aqueous layers. In this case,the temperature at which separation of the oily and aqueous layers is carried out should be above that at which the alkylphenolic compounds crystallize. Industrially, separation may be carried out at the temperature at which the reaction has come to an end,or somewhat lower. The heteropoly acid separated and recovered in this way can be used in the next reaction, and in this case it is preferred to cause a definite amount of water to exist in the reaction system, as described above. The reaction solution after removal of the heteropoly acid from the system can be washed or neutralized with a small amount of water or aqueous alkali, and in the case of reaction carried out with a solvent, the desired alkylphenolic compounds can be obtained by removal of the solvent by the usual methods. If necessary, the product can be purified by distillation, extraction, recrystallization, etc. In the case of alkylphenolic product obtained according to the invention by reaction of a cresol with isobutene or an isobutene, then after separating the heteropoly acid from the reaction mixture by the method described above, high-purity 2,6-di-tert-butyl-4-methylphenol can be obtained from the oily layer easily and in high yields (that is, without dealkylation) under very mild industrial distillation conditions. For example, after dehydration and removal of low-boiling components by heating the oily layer to a temperature of from 100° to 160°C at atmospheric pressure, the monobutyl derivative is removed by distillation at from 120° to 160°C under a reduced pressure of from 2.666 x 10³ to 1.333 x 10⁴Pa (20 to 100 Torr), 20 to 100 Torr and then desired 2,6-di-tert-butyl-4-methylphenol is obtained by distillation at from 140° to 200°C under a reduced pressure of from 1.333 x 10³ to 9.333 x 10³Pa (10 to 70 Torr). This distillation (rectification) can be carried out by any of continuous and batch processes, its conditions being not limited to those described above. 2,6-Di-tert-butyl-4-methylphenol contained in the oily layer is recovered almost quantitatively without being decomposed (for example by debutylation) and yet the monobutyl derivative, a low-boiling component, can be recovered almost quantitatively. These compounds are used in cycle for butylation. When a cresol mixture containing p-cresol is used, a high-boiling fraction left behind after removal of 2,6-di-tert-butyl-4-methylphenol by distillation contains 4,6-di-tert-butyl-3-methylphenol as a main component, and this component is also recovered almost quantitatively without being decomposed (for example by debutylation). The present invention is illustrated in more detail by the following Examples, but it is not limited thereto. Parts and percents (%) in the Examples are by weight. Example 1 100 Parts of a cresol mixture (p-cresol, 70%; m-cresol, 30%) and 0.04 part of phosphotungstic acid were added to a flask, and 288 parts of an LBB gas (isobutene content, 45%) was bubbled into the mixture over 8 hours with stirring while maintaining the temperature at from 60° to 65°C. The weight of the reaction mixture was 195.1 parts. On washing the reaction product with water and aqueous alkali, 186.5 parts of an oily product was obtained. The composition of this oily product was analyzed by gas chromatography to obtain the following results : Unreacted cresol 1.5% 2-Tert-butyl-4-methylphenol 19.5% 6-Tert-butyl-3-methylphenol 5.6% 2,6-Di-tert-butyl-4-methylphenol 44.2% 4,6-Di-tert-butyl-3-methylphenol 22.5% Others 6.7% Example 2 100 Parts of a cresol mixture (p-cresol, 70%; m-cresol, 30%) and 0.15 part of silicotungstic acid were added to a flask, and 288 parts of an LBB gas (isobutene content, 45%) was bubbled into the mixture over 10 hours with stirring while maintaining the temperature at from 45°to 55°C. The weight of the reaction mixture was 210.3 parts. On washing the reaction product with water and aqueous alkali, 192.5 parts of an oily product was obtained. The composition of this oily product was analyzed by gas chromatography to obtain the following result : Unreacted cresol 0.9% 2-Tert-butyl-4-methylphenol 19.1% 6-Tert-butyl-3-methylphenol 3.6% 2,6-Di-tert-butyl-4-methylphenol 42.8% 4,6-Di-tert-butyl-3-methylphenol 24.3% Others 9.3% Example 3 100 Parts of p-cresol and 0.9 part of phosphomolybdic acid were added to a flask, and 110 parts of an isobutene gas was bubbled into the mixture over 5 hours with stirring while maintaining the temperature at from 55°to 65°C. The weight of the reaction mixture was 206.7 parts. On washing the reaction product with water and aqueous alkali, 198.3 parts of an oily product was obtained. The composition of this oily product was analyzed by gas chromatography to obtain the following result : Unreacted p-cresol 1.0% 2-Tert-butyl-4-methylphenol 7.1% 2,6-Di-tert-butyl-4-methylphenol 85.4% Others 6.5% The content of isobutene dimer and isobutene trimer of the unreacted gas was 1.2%. Example 4 100 Parts of a cresol mixture (p-cresol, 70%; m-cresol, 30%) and 0.02 part of silicotungstic acid were added to a flask, and 110 parts of an isobutene gas was bubbled into the mixture over 6 hours with stirring while maintaining the temperature at from 70°to 75°C. On washing the reaction product with water and aqueous alkali, 193.5 parts of an oily product was obtained. The composition of this oily product was analyzed by gas chromatography to obtain the following result : Unreacted cresol 0.9% 2-Tert-butyl-4-methylphenol 6.0% 6-Tert-butyl-3-methylphenol 1.5% 2,6-Di-tert-butyl-4-methylphenol 60.1% 4,6-Di-tert-butyl-3-methylphenol 26.4% Others 5.1% Example 5 To 94.1 parts of phenol was added 0.06 part of silicotungstic acid, and 118 parts of an isobutene gas was bubbled into the mixture over 4 hours with stirring while maintaining the temperature at from 50°to 60°C. The weight of the reaction mixture was 200.7 parts. On washing the reaction product with water and aqueous alkali, 190.1 parts of an oily product was obtained. The composition of this oily product was analyzed by gas chromatography to obtain the following result : Unreacted phenol 1.5% 2-Tert-butylphenol 15.4% 4-Tert-butylphenol 9.6% 2,6-Di-tert-butylphenol 15.5% 2,4-Di-tert-butylphenol 37.5% 2,4,6-Tri-tert-butylphenol 14.7% Others 5.8% Example 6 To 54.8 parts of o-cresol was added 1.0 part of phosphotungstic acid, and 71 parts of an isobutene gas was bubbled into the mixture over 5 hours with stirring while maintaining the temperature at from 50°to 55°C. The weight of the reaction mixture was 104.5 parts. By gas-chromatographic analysis, the following result was obtained : Unreacted o-cresol 1.5% 6-Tert-butyl-2-methylphenol 6.5% 4-Tert-butyl-2-methylphenol 10.1% 4,6-Di-tert-butyl-2-methylphenol 76.7% Others 5.2% The content of isobutene dimer and isobutene trimer of the unreacted gas was 1.0%. Example 7 40 Parts of resorcinol, 200 ml of toluene (solvent) and 1.2 parts of silicotungstic acid were added to a flask, and an isobutene gas was bubbled into the mixture with stirring while maintaining the temperature at from 50°to 60°C. After reaction, the precipitated catalyst was filtered off and washed with 40 ml of water. The washing was concentrated to 200 ml under reduced pressure and after adding 20 ml of water, cooled with ice. The precipitated crystals were recovered by filtration and dried under reduced pressure to obtain 79.5 parts of a solid. By gas-chromatographic analysis, it was found that 98.5%-purity 4,6-di-tert-butylresorcinol was obtained. Example 8 To 54.1 parts of m-cresol was added 1.2 parts of phosphomolybdic acid, and 45.2 parts of cyclohexene was added dropwise to the mixture over 3 hours with stirring while maintaining the temperature at from 90° to 95°C. The weight of the reaction mixture was 98 parts. By gas-chromatographic analysis, the following result was obtained : 6-Cyclohexyl-3-methylphenol 10.2% 4-Cyclohexyl-3-methylphenol 20.5% 4,6-Dicyclohexy1-3-methylphenol 1.2% Examples 9 to 14 Using the same reactor and procedure as in Example 1, reaction was carried out in completely the same manner as in Example 1 except that the kinds of the aromatic compound and alkylating agent and other reaction conditions were varied. The results obtained are shown in Table 1. Example 15 100 Parts of a cresol mixture (p-cresol, 70%; m-cresol, 30%) and 1 part of silicotungstic acid were added to a flask, and water was added so that the water content of the mass in the flask was 0.026 time by weight based on the cresol mixture. Thereafter, 288 parts of an LBB gas (isobutene content, 45%) was bubbled into the mass over 5 hours with stirring while maintaining the temperature at from 45° to 55°C. The weight of the reaction mixture was 206.3 parts. On washing the reaction product with water and aqueous alkali, 191.5 parts of an oily product was obtained. The composition of this oily product was analyzed by gas chromatography to obtain the following result : Unreacted cresol 0.7% 2-Tert-butyl-4-methylphenol 17.8% 6-Tert-butyl-3-methylphenol 2.4% 2,6-Di-tert-butyl-4-methylphenol 48.1% 4,6-Di-tert-butyl-3-methylphenol 26.4% Others 4.6% Example 16 100 Parts of a cresol mixture (p-cresol, 70%; m-cresol, 30%) and 1 part of phosphotungstic acid were added to a flask, and water was added so that the water content of the mass in the flask was 0.002 time by weight based on the cresol mixture. Thereafter, 288 parts of an LBB gas (isobutene content, 45%) was bubbled into the mass over 7 hours with stirring while maintaining the temperature at from 55° to 60°C. The weight of the reaction mixture was 204.1 parts. On washing the reaction product with water and aqueous alkali, 194.1 parts of an oily product was obtained. The composition of this oily product was analyzed by gas chromatography to obtain the following result : Unreacted cresol 0.6% 2-Tert-butyl-4-methylphenol 16.9% 6-Tert-butyl-3-methylphenol 3.2% 2,6-Di-tert-butyl-4-methylphenol 48.5% 4,6-Di-tert-butyl-3-methylphenol 25.6% Others 5.2% Example 17 To 100 parts of p-cresol was added 0.8 part of a 50% aqueous silicotungstic acid solution, and 242 parts of an LBB gas (isobutene content, 45%) was bubbled into the mixture over 10 hours with stirring while maintaining the temperature at from 50° to 60°C. The weight of the reaction mixture was 202.0 parts. The precipitated silicotungstic acid was filtered off by means of a glass filter, and the filtrate was washed with a small amount of water to obtain 200.2 parts of an oily product. The composition of this oily product was analyzed by gas chromatography to obtain the following result : Unreacted p-cresol 0.7% 2-Tert-butyl-4-methylphenol 7.3% 2,6-Di-tert-butyl-4-methylphenol 88.8% Others 3.2% The content of isobutene dimer and isobutene trimer of the unreacted gas was 0.2%. Example 18 To 100 parts of m-cresol was added 1.0 part of a 40% aqueous phosphotungstic acid solution, and 242 parts of an LBB gas (isobutene content, 45%) was bubbled into the mixture over 6 hours with stirring while maintaining the temperature at from 60° to 65°C. The weight of the reaction mixture was 202.5 parts. Five parts of water was added to the reaction mixture to dissolve phosphotungstic acid in the aqueous layer, and the oily layer was separated from the aqueous layer. By washing with a small amount of aqueous alkali, 201.8 parts of an oily product was obtained. The composition of this oily product was analyzed by gas chromatography to obtain the following result : Unreacted m-cresol 0.9% 6-Tert-butyl-3-methylphenol 7.0% 4,6-Di-tert-butyl-3-methylphenol 88.6% Others 3.5% Example 19 94.1 Parts of phenol and 0.12 part of phosphomolybdic acid were added to a flask, and water was added so that the water content of the mass in the flask was 0.01 time by weight based on phenol. Thereafter, 250 parts of an LBB gas (isobutene content, 45%) was bubbled into the mass over 3 hours with stirring while maintaining the temperature at from 45° to 55°C. The weight of the reaction mixture was 201.5 parts. On washing the reaction product with water and aqueous alkali, 196.1 parts of an oily product was obtained. The composition of this oily product was analyzed by gas chromatography to obtain the following result : Unreacted phenol 0.9% 2-Tert-butylphenol 13.1% 4-Tert-butylphenol 9.6% 2,6-Di-tert-butylphenol 22.7% 2,4-Di-tert-butylphenol 34.9% 2,4,6-Tri-tert-butylphenol 15.8% Others 3.0% Examples 20 to 25 Reaction was carried out using the same reactor and procedure as in Example 15 except that the kind of phenolic compound, amount of heteropoly acid, water content of the system and temperature were varied. The results obtained are shown in Table 2. Symbols in the table mean the following compounds : 4M2B : 2-Tert-butyl-4-methylphenol 3M6B : 6-Tert-butyl-3-methylphenol 4M26B : 2,6-Di-tert-butyl-4-methylphenol 3M46B : 4,6-Di-tert-butyl-3-methylphenol Example 26 100 Parts of a cresol mixture (p-cresol, 70%; m-cresol, 30%) and 1 part of silicotungstic acid were added to a flask, and 288 parts of an LBB gas (isobutene content, 45%) was bubbled into the mixture over 5 hours with stirring while maintaining the temperature at from 45° to 55°C. After completion of the reaction, the precipitated silicotungstic acid was filtered off at a temperature of 45°C by means of a glass filter (G4). The weight of the recovered silicotungstic acid was 0.99 part, and the water content of the acid was 5.0%. The content of dissolved silicotungstic acid of the filtrate was 0.002 wt.%. The filtrate was washed with water and aqueous alkali to obtain 190.8 parts of an oily product. The composition of this oily product was analyzed by gas chromatography to obtain the following result : Unreacted cresol 1.0% 2-Tert-butyl-4-methylphenol 17.3% 6-Tert-butyl-3-methylphenol 2.6% 2,6-Di-tert-butyl-4-methylphenol 46.0% 4,6-Di-tert-butyl-3-methylphenol 25.7% Others 7.4% Example 27 0.4 Part of silicotungstic acid (water content, 5%) recovered in Example 26 and 100 parts of p-cresol were added to a flask, and water was added so that the water content of the mass in the flask was 0.004 time by weight based on p-cresol. Thereafter, 242 parts of an LBB gas (isobutene content, 45%) was bubbled into the mass over 7 hours with stirring while maintaining the temperature at from 50° to 55°C. After completion of the reaction, the precipitated silicotungstic acid was filtered off at a temperature of 50°C by means of a glass filter (G4). The weight of the recovered silicotungstic acid was 0.38 part. The filtrate was washed with a small amount each of water and aqueous alkali to obtain 195.2 parts of an oily product. The composition of this oily product was analyzed by gas chromatography to obtain the following result : Unreacted p-cresol 0.9% 2-Tert-butyl-4-methylphenol 10.5% 2,6-Di-tert-butyl-4-methylphenol 84.5% Others 4.1% The content of isobutene dimer and isobutene trimer of the unreacted gas was 0.5%. Example 28 100 Parts of a cresol mixture (p-cresol, 70%; m-cresol, 30%) and 0.8 part of silicotungstic acid were added to a flask, and reaction was carried out in the same manner as in Example 26. After completion of the reaction, the reaction solution was centrifuged on a centrifuge (centrifugal effect, 2000G) to separate the mixture into an oily layer which is a supernatant and the layer of precipitated silicotungstic acid. The content of silicotungstic acid of the oily layer, a supernatant, was 0.01 wt.%. The weight of the precipitated silicotungstic acid layer was 3 parts. This layer and 100 parts of a cresol mixture (p-cresol, 70%; m-cresol, 30%) were added to a flask, and water was added so that the water content of the mass in the flask was 0.02 time by weight based on the cresol mixture. Thereafter, 288 parts of an LBB gas (isobutene content, 45%) was bubbled into the mass over 5 hours with stirring while maintaining the temperature at from 50° to 55°C. The weight of the reaction mixture was 204.1 part. After removing the precipitated silicotungstic acid from the reaction mixture, washing with water and aqueous alkali was carried out to obtain 190.1 parts of an oily product. The composition of this oily product was analyzed by gas chromatography to obtain the following result : Unreacted cresol 0.5% 2-Tert-butyl-4-methylphenol 18.0% 6-Tert-butyl-3-methylphenol 3.3% 2,6-Di-tert-butyl-4-methylphenol 48.0% 4,6-Di-tert-butyl-3-methylphenol 26.2% Others 4.0% The content of isobutene dimer and isobutene trimer of the unreacted gas was 0.4%. Example 29 100 Parts of a cresol mixture (p-cresol, 70%; m-cresol, 30%) and 1 part of silicotungstic acid were added to a flask, and 288 parts of an LBB gas (isobutene content, 45%) was bubbled into the mixture over 5 hours with stirring while maintaining the temperature at from 45°to 55°C. The weight of the resulting reaction mixture was 190.9 parts. Separately from this, 30 parts each of water was added to the mixer and settler of a vertical-type mixer/settler two-stage assembly, and the above reaction mixture was continuously supplied to the assembly at a rate of 150 parts/hour over 12.5 hours to recover the silicotungstic acid catalyst into the aqueous layer. The silicotungstic acid concentration of the aqueous layer in the first stage was 24.0%, and the weight of the layer was 39.5 parts. The same concentration of the aqueous layer in the second stage was 0.65%, and the weight of the layer was 30.2 parts (total percent recovery of silicotungstic acid, 98.5%). Additional water was continuously supplied to the first stage because water in the assembly decreased in solution in the reaction mixture. The oily layer was washed with a small amount of aqueous alkali,and its composition was analyzed by gas chromatography to obtain the following result : Unreacted cresol 0.6% 2-Tert-butyl-4-methylphenol 17.2% 6-Tert-butyl-3-methylphenol 3.2% 2,6-Di-tert-butyl-4-methylphenol 47.3% 4,6-Di-tert-butyl-3-methylphenol 25.6% Others 6.6% Example 30 4.2 Parts of the aqueous silicotungstic acid solution recovered in Example 31 and 100 parts of a cresol mixture (p-cresol, 70%; m-cresol, 30%) were added to a flask. Reaction was carried out in the same manner as in Example 29 to obtain 190.8 parts of a reaction mixture. The silicotungstic acid catalyst was extraction-recovered with water in the same manner as in Example 29 except that the aqueous layer in the second stage in Example 29 was used as water to be added to the first stage. The silicotungstic acid concentration of the aqueous layer in the first stage was 24.5%, and the weight of the layer was 39.2 parts. The same concentration of the aqueous layer in the second stage was 0.70%, and the weight of the layer was 30.1 parts (total percent recovery of silicotungstic acid, 97.2%). The oily layer was treated in the same manner as in Example 29 and analyzed for the composition by gas chromatography to obtain the following result. By repeating the procedures of Examples 29 and 30, the expensive silicotungstic acid catalyst can be recovered and re-used. Unreacted cresol 1.0% 2-Tert-butyl-4-methylphenol 15.6% 6-Tert-butyl-3-methylphenol 2.0% 2,6-Di-tert-butyl-4-methylphenol 49.8% 4,6-Di-tert-butyl-3-methylphenol 27.2% Others 3.8% Example 31 Two parts of the aqueous silicotungstic acid solution recovered in Example 29 and 100 parts of m-cresol were added to a flask. Thereafter, 109.5 parts of an isobutene gas was bubbled into the mixture over 10 hours with stirring while maintaining the temperature at from 50° to 55°C. After completion of the reaction, 1.5 parts of water was added to dissolve the precipitated silicotungstic acid in water, and the reaction mixture was separated into two layers to obtain 1.93 parts of an aqueous solution containing 23.9% of silicotungstic acid (total percent recovery of silicotungstic acid, 96.1%). The oily layer was washed with a small amount of aqueous alkali to obtain 198.7 parts of an oily product. The composition of this oily product was analyzed by gas chromatography to obtain the following result : Unreacted m-cresol 0.9% 6-Tert-butyl-3-methylphenol 8.4% 4,6-Di-tert-buty1-3-methylphenol 86.7% Others 4.1% Further, reaction was repeated in the same manner as above except that 2 parts of the 23.9% aqueous silicotungstic acid solution recovered above and 100 parts of m-cresol were added to the flask. The silicotungstic acid catalyst was extraction-recovered with water, and the oily layer was washed with aqueous alkali to obtain 198.5 parts of an oily product. The composition of this oily product was analyzed by gas chromatography to obtain the following result : Unreacted m-cresol 1.1% 6-Tert-butyl-3-methylphenol 8.7% 4,6-Di-tert-butyl-3-methylphenol 86.3% Others 3.8% Thus, 1.92 parts of a 23.7% aqueous silicotungstic acid solution was obtained (total percent recovery of silicotungstic acid, 95.2%). By repeating the procedure of this example, the expensive silicotungstic acid catalyst can be recovered and re-used. Example 32 100 Parts of p-cresol and 0.4 part of phosphotungstic acid were added to a flask, and reaction was carried out by bubbling 288 parts of an LBB gas (isobutene content, 45%) into the mixture over 5 hours with stirring while maintaining the temperature at from 50° to 55°C. The weight of the reaction product after completion of the bubbling was 207.6 parts. This reaction product was washed with two 100-part portions of 80°C warm water to separate 194.1 parts of an oily layer. Analysis of the composition of this oily layer by gas chromatography showed that the content of 2,6-di-tert-butyl-4-methylphenol was 77.7%. This oily layer was rectified under reduced pressure to obtain 146.3 parts of a fraction having a boiling point of 142-147°C/20 torr (corresponding to 2,6-di-tert-butyl-4-methylphenol). The yield was 71.8%. The yield of the desired product further more increases by re-reacting 2-tert-butyl-4-methylphenol obtained as a forerun (120-135°C/20 torr). Example 33 100 Parts of a cresol mixture (p-cresol, 70%; m-cresol, 30%) and 0.15 part of silicotungstic acid were added to a flask, and reaction was carried out by bubbling 288 parts of an LBB gas ( isobutene content, 45%) into the mixture over 10 hours with stirring while maintaining the temperature at from 45° to 55°C. The weight of the reaction product after completion of the bubbling was 210.3 parts. This reaction product was neutralized by washing with 60 parts of a 3% aqueous sodium hydroxide solution ( 60°C), and then washed with 60 parts of 60°C warm water to separate 192.5 parts of an oily layer. The composition of this oily layer was analyzed by gas chromatography to obtain the following result : 2-Tert-butyl-4-methylphenol 15.1% 6-Tert-butyl-3-methylphenol 4.7% 2,6-Di-tert-butyl-4-methylphenol 52.5% 4,6-Di-tert-butyl-3-methylphenol 24.1% This oily layer was rectified under reduced pressure to obtain firstly 99.0 parts of 2,6-di-tert-butyl-4-methylphenol and subsequently 48.6 parts of 4,6-di-tert-butyl-3-methylphenol (165-168°C/20 torr). The yield of 2,6-di-tert-butyl-4-methylphenol was 69.4% based on p-cresol. The yield further more increases by re-reacting 2-tert-butyl-4-methylphenol and 6-tert-butyl-3-methylphenol obtained as a forerun (118-135°C/20 torr). Example 34 100 Parts of p-cresol and 0.05 part of phosphomolybdic acid were added to a flask, and reaction was carried out by bubbling 288 parts of an LBB gas (isobutene content, 45%) into the mixture over 7 hours with stirring while maintaining the temperature at from 70° to 75°C. The weight of the reaction product after completion of the bubbling was 203.1 parts. This reaction product was washed with two 100-part portions of 60°C warm water (contact time, 20 minutes) to separate 190.6 parts of an oily layer. The composition of this oily layer was analyzed by gas chromatography to obtain the following result : 2,6-Di-tert-butyl-4-methylphenol 74.4% 2-Tert-butyl-4-methylphenol 21.1% p-Cresol 1.0% Others 3.5% The oily layer was rectified under reduced pressure on a distillation tower having 25 theoretical plates to obtain 140.2 parts of a fraction having a boiling point of 145-147°C/20 torr (corresponding to 2,6-di-tert-butyl-4-methylphenol). The yield was 68.8%. Comparative example 1 100 Parts of a cresol mixture (p-cresol, 70%; m-cresol, 30%)and 2.0 parts of conc. sulfuric acid were added to a flask, and 288 parts of an LBB gas (isobutene content, 45%) was bubbled into the mixture over 8 hours with stirring while maintaining the temperature at from 60° to 65°C. The weight of the reaction mixture was 208.3 parts. The reaction product was washed with water and aqueous alkali to obtain 191.0 parts of an oily product. The composition of this oily product was analyzed by gas chromatography to obtain the following result : Unreacted cresol 1.3% 2-Tert-butyl-4-methylphenol 8.5% 6-Tert-butyl-3-methylphenol 9.3% 2,6-Di-tert-butyl-4-methylphenol 54.0% 4,6-Di-tert-butyl-3-methylphenol 15.0% Others 11.9% The content of isobutene dimer and isobutene trimer of the unreacted gas was 5.9%. Comparative example 2 100 Parts of p-cresol and 3.0 parts of conc. sulfuric acid were added to a flask, and 110 parts of an isobutene gas was bubbled into the mixture over 5 hours with stirring while maintaining the temperature at from 55°to 65°C. The weight of the reaction mixture was 207.0 parts. This reaction product was washed with water and aqueous alkali to obtain 198.8 parts of an oily product. The composition of this oily product was analyzed by gas chromatography to obtain the following result : Unreacted p-cresol 1.5% 2-Tert-butyl-4-methylphenol 6.0% 2,6-Di-tert-butyl-4-methylphenol 79.7% Others 12.8% The content of isobutene dimer and isobutene trimer of the unreacted gas was 5.6%. Comparative example 3 208.3 Parts of the reaction product obtained in Comparative example 1 was neutralized by washing with 200 parts of a 20% aqueous sodium hydroxide solution (80°C) (contact time, 60 minutes), and then washed with 100 parts of 80°C warm water to separate 187.0 parts of an oily layer. The composition of this oily layer was analyzed by gas chromatography to obtain the following result : 2,6-Di-tert-butyl-4-methylphenol 55.9% 4,6-Di-tert-butyl-3-methylphenol 15.8% 2-Tert-butyl-4-methylphenol 8.5% 6-Tert-butyl-3-methylphenol 9.3% Unreacted cresol 0.3% Others 10.2% The oily layer was rectified under a reduced pressure of 20 torr. When the temperature in the still reached about 90°C, debutylation occurred and evolution of an isobutylene gas began. The weight of desired 2,6-di-tert-butyl-4-methylphenol was 10.2 parts and the yield thereof was 7.2% based on p-cresol. Comparative example 4 100 Parts of p-cresol and 5.0 parts of p-toluenesulfonic acid were added to a flask, and reaction was carried out by bubbling 288 parts of an LBB gas (isobutene content, 45%) into the mixture over 10 hours with stirring while maintaining the temperature at from 70°to 75°C. The weight of the reaction product after completion of the bubbling was 205.1 parts. This reaction product was neutralized by washing with 200 parts of a 20% aqueous sodium hydroxide solution (80°C) (contact time, 60 minutes), and then washed with 100 parts of 80°C warm water to separate 188.7 parts of an oily layer. Analysis of the composition of this oily layer by gas chromatography showed that the layer containe 75.1% of 2,6-di-tert-butyl-4-methylphenol. This oily layer was rectified under reduced pressure in the same manner as in Comparative example 3. When the temperature in the still reached about 90°C, evolution of an isobutylene gas began. The weight of desired 2,6-di-tert-butyl-4-methylphenol was 13.5 parts, and the yield thereof was 6.6%.

Claims: A process for producing a hydroxy-containing alkylated aromatic compound which comprises reacting aromatic compound having at least one hydroxyl group and selected from monohydric phenols, polyhydric phenols and naphthols with alkylating agent selected from unsaturated hydrocarbons containing at least one double bond, the reaction being carried out in the liquid phase and at a temperature of 30°C to 150°C, in the presence of heteropoly acid catalyst and an amount of water which is 0.001 to 0.05 times the weight of the aromatic compound, and the molar ratio of alkylating agent to aromatic compound being (1-20):1. A process according to claim 1 wherein the heteropoly acid is at least one member selected from phosphomolybdic acid, silicomolybdic acid, arsenomolybdic acid, telluromolybdic acid, aluminomolybdic acid, silicotungstic acid, phosphotungstic acid, borotungstic acid, titanotungstic acid and stannotungstic acid. A process according to claim 1 or 2 wherein the aromatic compound is o-cresol, m-cresol, p-cresol or a cresol mixture containing p-cresol. A process according to claim 1 or 2 or 3 wherein the alkylating agent is isobutene or isobutene-containing gas. A process according to any preceding claim wherein the heteropoly acid is separated after the reaction for re-use. A process according to claim 5 wherein the separation of the heteropoly acid is conducted by treating the reaction mixture with water to obtain an aqueous layer containing the heteropoly acid, or by precipitating the heteropoly acid in the reaction system. A process according to claim 6 wherein the content of the heteropoly acid in the aqueous layer is no less than 20% by weight. A process according to any preceding claim wherein the alkylation reaction temperature is 40-90°C. A process according to any preceding claim wherein the alkylating agent comprises at least one compound selected from (a) those of formula (I) : R₁ - CH = CH₂ (I) wherein R₁ represents hydrogen or a straight or branched hydrocarbon residue having 1-10 carbon atoms; (b) those of formula (II): R₂ - CH = CH - CH₃ (II) wherein R₂ represents a straight or branched hydrocarbon residue having 1-9 carbon atoms; and (c) cyclic unsaturated hydrocarbons having up to 10 carbon atoms.

Inventors: FUJII TAKEO, MASAKI SHINZABURO, MURAKAMI AKIRA, TAKESHITA AKIRA, TOKUMARU TOORU, FUJII, TAKEO, MASAKI, SHINZABURO, MURAKAMI, AKIRA, TAKESHITA, AKIRA, TOKUMARU, TOORU
Applicants: SUMITOMO CHEMICAL CO, SUMITOMO CHEMICAL COMPANY, LIMITED
Application year: 1987
Main classification: C07C37
IPC codes: C07C39, B01J23, C07B61, C07B31, C07B37, C07C37, C07C67, B01J27, C07C27