PROCESS FOR PREPARING ALKOXYALKYL-SUBSTITUTED PHENOLS

Abstract: Alkoxyalkyl-substd. phenols of formula (I) are prepd. by reacting a phenol, an alcohol and an aldehyde in the presence of a catalyst. Catalyst is pref. a tert. alkylamine and/or a tert. unsubstd. benzylamine, or an alkali metal carbonate and/or alkali metal bicarbonate. In (I), R1, R2 and R3 are each H or an alkyl gp. and R4 is an alkyl gp. The tert. alkylamine is pref. triethylamine, tri-N-butylamine and has formula R5-N(R6)-R7 (II) where R5, R6 and R7 are each 1-20C alkyl gp. (pref. 1-4C alkyl gp.). The tert. unsubstd. benzylamine pref. has formula (III), and can be N,N-diethylbenzylamine (R8 and R9 are each 1-20C alkyl gps. (pref. 1-4C alkyl gp.). The alkali metal in the catalyst is pref. K or Na. The alkali metal carbonate is K2CO3 and/or Na2CO3 and the alkali metal bicarbonate is NaHCO3. The phenol pref. has formula (IV) and is 2,6-di-t-butylphenol, where R1 and R2 are each 1-12C alkyl gps. The aldehyde may be paraformald-hyde. The reaction is carried out at a temp. of 5-250 deg. C (pref. 70-150 deg. C) and at a pressure of 1-200 Kg/cm2G (pref. 5-100 Kg/cm2G) for 0.5-20 hours (pref. 1-10 hours).

Description: This invention relates to a process for producing alkoxyalkyl group substituted phenols represented by the formula (1): (wherein R¹ and R², which may be identical or different, each represent a hydrogen atom or an alkyl group of 1 to 12 carbon atoms, provided that R¹ and R² do not simultaneously represent hydrogen atoms, R³ represents a hydrogen atom or an alkyl group of 1 to 12 carbon atoms and R⁴ represents an alkyl group of 1 to 10 carbon atoms). More particularly, it relates to a process according to which alkoxyalkyl group substituted phenols used as antioxidants, preservatives and starting materials for other chemicals can be produced in high yields and the objective product can be easily separated from catalysts. Backgound Art As antioxidants, preservatives and starting materials for other chemicals, there are generally known alkoxyalkyl group substituted phenols such as, for example, 2,6-di-t-butyl-4-methoxymethylphenol. Hitherto, there have been many processes for producing the alkoxyalkyl group substituted phenols. For example, EP-A-0 116 712 discloses a process which comprises reacting a phenol such as 2,6-di-t-butylphenol, an alcohol and formaldehyde in the presence of a tertiary amine derived from phenols such as, for example, N,N-dimethyl-3,5-di-t-butyl-4-hydroxybenzylamine (Mannich base). However, the yield obtained by this process is about 82% and is not satisfactory. Besides, since the objective product and the catalyst are similar in their structure, separation from each other is not easy. It is also known to react a phenol such as 2,6-di-t-butylphenol, an alcohol and formaldehyde in the presence of a hydroxide of alkali metal to produce an alkoxyalkyl group substituted phenol. However, the yield of alkoxyalkyl group substituted phenol in this process is less than about 50%. U.S.Patent No.2,838,571 discloses a process for the production of alkoxyalkyl group substituted phenols by reacting a 2,6-dialkylphenol, formaldehyde and an alcohol in the presence of a metallic hydroxide. However, the yield of alkoxyalkyl group substituted phenols according to this process is also unsatisfactory. On the other hand, U.S.Patent No.4,633,022 filed on September 16, 1985 in U.S.A. and issued on December 30, 1986 discloses a process for producing a bisether represented by the formula (A): which is different from the objective alkoxyalkyl group substituted phenols of this invention by the reaction of a 2,6-dialkyl substituted phenol with formaldehyde in methyl alcohol in the presence of a tertiary amine. According to the process disclosed in the above U.S. Patent No. 4,633,022, the bisether represented by the above formula can be obtained by reacting a 2,6-dialkyl substituted phenol with formaldehyde in methanol in the presence of a tertiary amine under inert gas atmosphere. However, tracing experiments by the present inventors of examples given in U.S. Patent No. 4,633,022 has revealed that the bisether claimed in U.S. Patent No. 4,633,022 cannot be produced by the process disclosed in U.S. Patent No. 4,633,022. That is, in utterly the same manner as in Example 1 of U.S. Patent No. 4,633,022, 206 g (1 mol) of 2,6-di-t-butylphenol, 500 ml of methanol, 36 g (1 mol) of paraformaldehyde and 125 ml (0.9 mol) of triethylamine were refluxed under nitrogen stream of 1.01 x 10⁵ Pa (1 atm) at 70°C over a period of 16 hours. The reaction mixture was subjected to atmospheric distillation to remove 250 ml of a mixture of methanol and triethylamine and the residue was cooled to 25°C. Crystals separated by this cooling were filtered, washed with 50 ml of methanol five times and then dried. The yield of the resulting crystals was 157.5 g (Yield is 233 g according to the disclosure of U.S. Patent No. 4,633,022). The crude crystals separated after the atmospheric distillation were analyzed by gas chromatography to obtain the GC analysis chart as shown in Fig. 1. The conditions of the gas chromatography are shown below. GC analytical device: SHIMAZU GC-9A (Shimazu Seisakusho, Ltd.) FID Column: 2 m Packing material: Dexsil 300GC Uniport HP Injection temperature: 250°C Column temperature: 70-250°C Heating rate of column: 10°C/1 min for 70-150°C 25°C/1 min for 150-250°C Carrier gas: Nitrogen As shown in Fig 1, 8 peaks were found in the GC analysis chart as a result of gas chromatography analysis. The substances given said 8 peaks were analyzed by GC-MS analysis and were identified as the compounds represented in Table 1. The yield of these compounds is also represented in Table 1. The conditions of this analysis were as follows. GC-MS analytical device Conditions of GC are the same as above. Conditions of MS: HITACHI M80B type double focusing mass spectrometer (Hitachi Limited) Ionization voltage: 70 eV Accelerating voltage: 3 KV Ion source temperature: 200°C Scanning speed: 1-500 n/z (sec) Peak NO. Products Yield (mol%) (1) Methanol (2) Triethylamine (3) 2,6-di-t-butylphenol (4) 2,6-di-t-butyl-p-cresol 2.5 (5) 2,6-di-t-butyl-4-methoxymethylphenol 74.5 (6) 2,6-di-t-butyl-4-hydroxymethylphenol 2.1 (7) 2,6-di-t-butyl-4-hydroxymethoxymethylphenol 1.8 (8) 4,4'-Methylene-bis-(2,6-di-t-butylphenol) 2.5 In this case, the conversion rate of all products was 79.8% based on 2,6-di-t-butylphenol. The present inventors have doubted if there are errors in the results of their tracing experiments of Example 1 of U.S.Patent No.4,633,022 and they carried out a hydrogenation decomposition of the principal product (product shown by peak (5)) obtained by the above GC analysis in the presence of a catalyst. If the product shown by the peak (5) is the bisether disclosed in Example 1 of U.S.Patent No.4,633,022, trisubstituted phenol and water should be produced as shown in the following reaction formula (B). However, according to the experiments conducted by the present inventors, BHT and methyl acetate were produced, although acetic acid was used as a solvent. From the results, it is reasonable to consider that in Example 1 of U.S.Patent No.4,633,022, the bisether as shown by the formula (A) was not produced, but 2,6-di-t-butyl-4-methoxymethylphenol was produced. Moreover, ¹H-NMR analysis of the product indicated by the peak (5) revealed that said product was 2,6-di-t-butyl-4-methoxymethylphenol as shown in Fig.2. The results of elemental analysis of the product shown by the peak (5) are as follows. Elements Found Calculated C 76.52 76.75 H 10.66 10.47 Thus, it was supported that the product was 2,6-di-t-butyl-4-methoxymethylphenol. Therefore, it has been clarified by the present inventors that according to the process disclosed in U.S.Patent No.4,633,022, not bisether, but 2,6-di-t-butyl-4-methoxymethylphenol is produced as a principal product. Moreover, according to Example 3 shown as a comparative example in U.S.Patent No.4,633,022, use of sodium hydroxide in place of triethylamine as catalyst in Example 1 resulted in reduction of yield to 58%. However, U.S.Patent No.2,838,571 and J. Am. Chem. Soc., 5019 (1957) disclose that when 2,6-di-t-butylphenol, methanol and paraformaldehyde are reacted using sodium hydroxide as a catalyst, 2,6-di-t-butyl-4-methoxymethylphenol is produced. As mentioned above, the invention described in U.S.Patent No.4,633,022 does not disclose technical facts. Therefore, the invention described in U.S.Patent No.4,633,022 cannot be prior art. Even if U.S.Patent No.4,633,022 can be prior art, this U.S.Patent No.4,633,022 discloses bisetherification reaction of two molecules of 2,6-dialkyl substituted phenol and this bisetherification reaction is against scientific fact as explained hereabove. This invention has been made under such circumstances. The object of this invention is to provide a process for the production of alkoxyalkyl group substituted phenols in high yields where the objective product and catalyst can be easily separated. Disclosure of Invention As a result of the inventors' intensive research in order to accomplish the above object, it has been found that when an alcohol, a phenol and an aldehyde are allowed to react in the presence of a specific tertiary amine or carbonate or hydrogencarbonate of an alkali metal, an alkoxyalkyl group substituted phenol which is utterly different from the product disclosed in U.S. Patent No. 4,633,022 can be produced in high yields and besides, the objective product and the catalyst can be easily separated and the recovered catalyst can be used as it is. This invention is based on this finding. That is, according to this invention the above object is solved by a process for the production of an alkoxyalkyl group substituted phenol represented by the formula (1): wherein R¹ and R², which may be identical or different, each represent a hydrogen atom or an alkyl group of 1 to 12 carbon atoms, provided that R¹ and R² do not simultaneously represent hydrogen atoms, R³ represents hydrogen or an alkyl group of 1 to 12 carbon atoms, and R⁴ represents an alkyl group of 1 to 10 carbon atoms, by reacting a phenol represented by the formula (4) wherein R¹ and R² are as defined above, with an alcohol represented by the formula R⁴OH, wherein R⁴ is as defined above, and an aldehyde represented by the formula R³CHO, wherein R³ is as defined above, in the presence of a catalyst, characterized by using a catalyst selected from the group consisting of tertiary alkylamines, tertiary unsubstituted benzylamines, mixtures thereof, carbonates and hydrogencarbonates of an alkali metal and mixtures of said carbonates and hydrogencarbonates, wherein said tertiary alkylamines and/or tertiary unsubstituted benzylamines are used in an amount of at least 1/200 mol per 1 mol of said phenol and said carbonates and/or hydrogencarbonates are used in an amount of at least 1/300 mol per 1 mol of said phenol, and wherein said reaction is carried out at a reaction temperature of 0 to 200°C. In this invention, a reaction utterly different from the reaction disclosed in U.S. Patent No. 4,633,022 takes place. That is, one molecule of phenol, one molecule of alcohol and one molecule of aldehyde react to produce the alkoxyalkyl group substituted phenol represented by the above formula (1). Besides, according to this invention, the alkoxyalkyl group substituted phenol can be produced at high conversion rate and selectivity and in high yields. Moreover, since in this invention, tertiary alkylamines and/or tertiary unsubstituted benzylamines which are not similar in structure to the objective alkoxyalkyl group substituted phenol are used as catalyst, separation between the catalyst and the alkoxyalkyl group substituted phenol can be easily performed. Further, in this invention, the catalyst can be used repeatedly and thus this invention is also industrially useful in this regard. Brief Explanation of Drawings Fig.1 is a GC chart which shows the results of tracing experiments of Example 1 of U.S.Patent No.4,633,022 which were conducted by the present inventors. Fig.2 is a ¹H-NMR chart of 2,6-di-t-butyl-4-methoxymthylphenol. Fig.3 is a flow chart which shows steps of the after-treatment after completion of the reaction according to the process of this invention. Best Mode for Carrying Out the Invention The tertiary alkyl amine used in this invention can be represented by the formula (2): (wherein R⁵, R⁶ and R⁷ each represents an alkyl group of 1-20 carbon atoms and R⁵, R⁶ and R⁷ may be identical or different). As the tertiary amine, mention may be made of, for example, N,N-diethyl-laurylamine, N,N-diethyl-tridecylamine, N,N-diethyl-palmitylamine, N,N-ethyl-dihexylamine, N-methyl-dipalmitylamine, trimethylamine, triethylamine, tripropylamine, tributylamine, tripentylamine, trihexylamine, triheptylamine, trioctylamine, trinonylamine, tricaprylamine, trilaurylamine, trimyristylamine, tricetylamine, tristearylamine and triarachylamines. These various tertiary alkylamines may be used alone or in combination of two or more. Among these tertiary alkylamines, preferred are those having lower alkyl groups of 1-4 carbon atoms as R⁵, R⁶ and R⁷ such as trimethylamine, tripropylamine, tributylamine, N,N-dimethyl-ethylamine, N,N-dimethyl-propylamine, N,N-dimethyl-butylamine, N,N-diethyl-methylamine, N,N-diethyl-propylamine, N,N-diethyl-butylamine, N,N-dipropyl-ethylamine, N,N-dipropyl-butylamine, N,N-dibutyl-methylamine, N,N-dibutyl-ethylamine and N,N-dibutyl-propylamine. Especially preferred are those having the same lower alkyl group as R⁵, R⁶ and R⁷ such as triethylamine and tributylamine. The tertiary unsubstituted benzylamine can be represented by the formula (3): (wherein R⁸ and R⁹ which may be identical or different each represents an alkyl group of 1-20 carbon atoms). As the tertiary unsubstituted benzylamine, mention may be made of, for example, N-methyl-N-ethylbenzylamine, N-methyl-N-propylbenzylamine, N-methyl-N-butylbenzylamine, N-ethyl-N-propylbenzylamine, N-ethyl-N-butylbenzylamine, N-propyl-N-butylbenzylamine, N,N-dimethylbenzylamine, N,N-diethylbenzylamine, N,N-dipropylbenzylamine, N,N-dibutylbenzylamine, N,N-dipentylbenzylamine, N,N-dihexylbenzylamine, N,N-diheptylbenzylamine, N,N-dioctylbenzylamine, N,N-dinonylbenzylamine, N,N-dicaprylbenzylamine, N,N-dilaurylbenzylamine, N,N-dimyristylbenzylamine, N,N-benzyldicetylamine, N,N-distearylbenzylamine and N,N-diarachylbenzylamine. Among them, the tertiary unsubstituted benzylamines where R⁸ and R⁹ are the same lower alkyl group of 1-20 carbon atoms are preferred and N,N-diethylbenzylamine and N,N-dibutylbenzylamine are especially preferred. These tertiary unsubstituted benzylamines bay be used alone or in combination of two or more. In the process for the production of alkoxyalkyl group substituted phenols according to this invention, either one of the tertiary alkylamine or the tertiary unsubstituted benzylamine can be used alone or they can be used in combination. The carbonates and hydrogencarbonates of alkali metals include, for example, lithium carbonate, lithium hydrogencarbonate, sodium hydrogencarbonate, cesium carbonate, cesium hydrogencarbonate, rubidium carbonate, rubidium hydrogencarbonate and potassium sodium carbonate. Among these carbonates or hydrogen carbonates of alkali metals, carbonates or hydrogencarbonates of sodium or potassium are preferred and especially preferred is at least one selected from sodium carbonate, sodium hydrogencarbonate and potassium carbonate. The phenols used in this invention are represented by the formula (4): (wherein R¹ and R² are as defined above). As examples of these phenols, mention may be made of o-cresol, m-cresol, p-cresol, ethylphenol, propylphenol, p-tert-butylphenol, p-tert-amylphenol, o-sec-amylphenol, p-octylphenol, o-octylphenol, xylenol, p-nonylphenol, o-nonylphenol, 2,6-diisopropylphenol, 2,6-di-t-butylphenol, di-tert-amylphenol and di-sec-amylphenol. Among them, preferred are those which have an alkyl group of 1-4 carbon atoms as R¹ and R² which are identical and especially preferred is 2,6-di-tert-butylphenol. As the alcohols used in this invention, mention may be made of, for example, methyl alcohol, ethyl alcohol, n-propyl alcohol, isopropyl alcohol, n-butyl alcohol, isobutyl alcohol, sec-butyl alcohol, t-butyl alcohol, pentanol, pentanol-1, pentanol-2, pentanol-3, 2-methylbutanol-1, 2-methylbutanol-2, 2-methylbutanol-3, 2-methylbutanol-4, dimethylpropanol, hexanol-1, hexanol-2, heptanol-1, heptanol-2, octanol-1, octanol-2, 4-ethylhexanol-4, 2-ethylhexanol-1, nonanol-1, nonanol-2, nonanol-3, decanol-1, decanol-2, allyl alcohol, crotyl alcohol, 2-butenol-1, 2-pentenol-1, 3-hexenol-1, 2-heptenol-1, ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol and, glycerin. These alcohols are represented by the formula R⁴OH (wherein R⁴ represents an alkyl group of 1-10 carbon atoms, preferably 1-4 carbon atoms) and methyl alcohol is especially preferred. As the aldehydes used in this invention, mention may be made of, for example, formaldehyde, paraformaldehyde, acetaldehyde, propionaldehyde, n-butylaldehyde, isobutylaldehyde, metacrolein, ethoxyacetaldehyde, n-valeroaldehyde, isovaleroaldehyde, methylethylaldehyde, trimethylacetaldehyde, n-hexaaldehyde, diethylacetaldehyde, dimethylethylacetaldehyde, 2-cyclopentenylacetaldehyde, ethyl-n-butylacetaldehyde, enanthoaldehyde, acrolein, crotonaldehyde, hydroxyaldehyde, salicylaldehyde,, anisaldehyde and vanillin. These aldehydes are represented by the formula R³CHO (wherein R³ represents a hydrogen atom or an alkyl group of 1-12 carbon atoms), and paraformaldehyde is especially preferred. In the process for producing alkoxyalkyl group substituted phenols according to this invention, phenol, alcohol and aldehyde are allowed to react in the presence of a catalyst selected from the group consisting of a tertiary alkyl amine, a tertiary unsubstituted benzyl amine, a mixture of a tertiary alkylamine and a tertiary unsubstituted benzylamine, a carbonate of an alkali metal, a hydrogencarbonate of an alkali metal and a mixture of a carbonate of an alkali metal and a hydrogencarbonate of an alkali metal. The above catalyst may be either one of the tertiary alkyl amine or the tertiary unsubstituted benzylamine or a mixture thereof, either one of the carbonate of an alkali metal or the hydrogencarbonate of an alkali metal or a mixture thereof. In this invention, the above reaction can be shown, for example, by the following reaction formula. (wherein R¹, R², R³ and R⁴ have the same meanings as defined above). The fact that the above reaction proceeds to give an alkoxyalkyl group substituted phenol cannot be easily known from U.S.Patent No.4,633,022 which does not disclose technical facts. In the above reaction, solvents can be used. As the solvents, alcohols represented by the formula R⁴OH which are also reactants in the reaction can be used. Therefore, it is preferred to add the alcohol R⁴OH in an amount of large excess relative to the phenol in the above reaction. The amount of the aldehyde relative to the phenol is 1-6 mols, preferably 2-4 mols per 1 mol of the phenol. When the amount of the aldehyde is less than 1 mol, sometimes the reaction does not proceed and even when more than 6 mols of the aldehyde is used, the yield of the alkoxyalkyl group-containing phenol does not always increase. When tertiary alkyl amines and/or tertiary unsubstituted benzylamines are used as catalyst, the amount thereof is usually 1/200-1 mol, preferably 1/100-1/5 mol per 1 mol of phenol. When carbonates of an alkali metal and/or hydrogencarbonates of an alkali metal are used as catalyst, the amount thereof is usually 1/300-1/5 mol, preferably 1/200-1/10 mol per 1 mol of phenol. For all of these catalysts, when the amount thereof is less than the lower limit of above ranges, the function of the catalyst is not sufficiently developed and thus, sufficient results cannot be obtained with reference to the yield and when the amount thereof is more than the upper limit of above ranges, an increase of the yield corresponding to the amount is not always expectable. The reaction is normally carried out at a reaction temperature of 0-200°C, preferably 20-150°C, more preferably 70-150°C. When it is lower than 0°C, the yield of the objective product is low and industrial operation becomes difficult to continue in the actual production and when it is higher than 200°C, sometimes the catalytic action cannot be sufficiently exhibited. The reaction pressure is within the range of 1.0 x 10⁵ - 197.2 x 10⁵ Pa (0-200 kg/cm²·G), preferably 1.0 x 10⁵ - 99.1 x 10⁵ Pa (0-100 kg/cm²·G). If the pressure is lower than 1.0 x 10⁵ Pa (0 kg/cm²·G), the reaction does not proceed at sufficient velocity and the yield does not increase and when it is more than 197.2 x 10⁵ Pa (200 kg/cm·G), activity of the reaction may not be sufficiently increased. The reaction time is normally 0.5-20 hours, preferably 1-10 hours. If the time is shorter than 0.5 hours, phenols having alkoxyalkyl groups are not sufficiently produced and even if it exceeds 20 hours, the yield does not increase and sometimes the productivity decreases. The reaction can be carried out in either a homogeneous or a heterogeneous system. When lithium hydrogencarbonate, sodium hydrogencarbonate, lithium carbonate or sodium carbonate is used as catalyst, the reaction will be in a heterogeneous system and when potassium hydrogencarbonate, cesium hydrogencarbonate, potassium carbonate, cesium carbonate, tertiary alkyl amine or tertiary unsubstituted benzylamine is used, the reaction will be in a homogeneous system. In case of reaction in heterogeneous system, preferably the treatments as shown in Fig.3 are effected after the reaction. That is, after termination of the reaction, the reaction system is left to stand to cause separation into a liquid phase and a solid phase. Then, these are separated from each other, the resulting liquid phase is cooled, for example, to 0-20°C to crystallize the reaction product alkoxyalkyl group substituted phenol and the crystals are separated. To the solid phase obtained by the above separation into liquid and solid phases are added reaction starting materials such as phenols, alcohols and aldehydes and solvent solution (normally an alcohol which is a starting material) and the reaction of this invention is carried out again with this mixture. In the case of a homogeneous system, the reaction mixture after termination of the reaction is left to stand and simultaneously cooled, for example, to 0-20°C to crystallize the reaction product alkoxyalkyl group substituted phenol and the crystals are separated. The reaction product can be isolated by the crystal separation. Since the catalyst is dissolved in the resulting residue solution, starting materials are further added to the solution and the reaction of this invention is carried out. It is also possible to decompose the objective product by distillation. The process of this invention can be carried out by a batchwise or semibatchwise or a continuous method and these may be optionally combined depending on industrial scale. Example 1 In an autoclave of 250 ml were charged 120 mmols of 2,6-di-tert-butylphenol, 100 ml of methanol, 200 mmols of paraformaldehyde and 30 mmols of triethylamine and reaction was conducted at 125°C, under 6.9 x 10⁵ Pa (6 kg/cm²·G) for 3 hours. After termination of the reaction, the reaction mixture was cooled to 40°C and conversion and selectivity were determined by gas chromatography. The results are shown in Table 1. Example 2 The solution after termination of the reaction in Example 1 was cooled to 25°C and a phenol having an alkoxyalkyl group was separated by filtration as a crystal. The filtrate was put in an autoclave of 250 ml and furthermore, 2,6-di-tert-butylphenol, methanol and paraformaldehyde were supplemented so that the amounts of them reached 120 mmols, 100 ml and 200 mmols, respectively and then reaction was conducted. The results are shown in Table 1. Example 3 Example 2 was repeated except that the solution after termination of the reaction in Example 2 was used in place of the solution after termination of the reaction in Example 1. The results are shown in Table 1. Example 4 Example 2 was repeated except that the solution after termination of the reaction in Example 3 was used in place of the solution after termination of the reaction in Example 1. The results are shown in Table 1. Example 5 Example 2 was repeated except that the solution after termination of the reaction in Example 4 was used in place of the solution after termination of reaction in Example 1. The results are shown in Table 1. Example 6 Example 1 was repeated except that trinormalbutylamine was used in place of triethylamine and the reaction temperature was 100°C and the reaction pressure was 2.97 x 10⁵ Pa (2 kg/cm²·G). The results are shown in Table 1. Example 7 Example 6 was repeated except that benzyldiethylamine was used in place of trinormal butylamine and the reaction temperature was 125°C and the reaction pressure was 6.9 x 10⁵ Pa (6 kg/cm²·G). The results are shown in Table 1 Comparative Example 1 A solution obtained by dissolving 500 mmols of 2,6-di-t-butylphenol in 50 ml of methanol, 220 ml of methanol, 800 mmols of paraformaldehyde and 3.0 g of 40% dimethylamine were charged in an autoclave of 1 liter and after addition in dropwise at 68°C over a period of 3 hours, reaction was effected at 80°C for 4 hours. After termination of the reaction, conversion and selectivity were determined by gas chromatography. The results are shown in Table 1. As is clear from Table 1, when the conventionally used N,N-dimethyl-3,5-di-tert-butyl-4-hydroxybenzylamine was used as the catalyst, both the conversion and the selectivity were lower than those in Examples 1-11. Examples 8, 9 and 11 and Comparative Examples 2 and 3 In a 300 liter flask were charged phenol, alcohol and aldehyde in the amounts as shown in Table 2 and reaction was effected under the conditions as shown in Table 2 (reaction pressure of 1.0 x 10⁵ Pa (0 kg/cm²·G) was not shown). After termination of the reaction, the reaction mixture was cooled to 25°C. A portion thereof was sampled and conversion and selectivity were determined by gas chromatography. The results are shown in Table 2. Example 10 As shown in Fig.3, the solution after termination of the reaction obtained in Example 8 was left to stand to cause separation into a liquid phase and a solid phase. Then, after separation of the solid and liquid phases, the resulting liquid phase was cooled to 0-20°C to crystallize the reaction product phenol containing alkoxyalkyl group and the crystals were separated. To the solid phase obtained by the separation in solid and liquid phases were added starting materials such as phenol, alcohol and aldehyde and solvent solution (normally, alcohol which is a starting material) obtained after separation of the crystals to obtain the ratio as shown in Table 2 and the reaction of this invention was again carried out. After termination of the reaction, the reaction mixture was cooled to 25°C and then, a portion was sampled and conversion and selectivity were determined by gas chromatography. The results are shown in Table 2. As is clear from Table 2, according to this invention, alkoxyalkyl group substituted phenols were produced at sufficiently high conversion and selectivity (at high yield). [Industrial Applicability of the Invention] As explained above, according to the process of this invention, alkoxyalkyl group substituted phenols can be obtained at high conversion and selectivity and in high yield by reaction of phenols, alcohols and aldehydes and besides, the catalyst can be repeatedly reused. Thus, this is an economical process which is industrially advantageous.

Claims: A process for the production of an alkoxyalkyl group substituted phenol represented by the formula (1) wherein R¹ and R², which may be identical or different, each represent a hydrogen atom or an alkyl group of 1 to 12 carbon atoms, provided that R¹ and R² do not simultaneously represent hydrogen atoms, R³ represents hydrogen or an alkyl group of 1 to 12 carbon atoms, and R⁴ represents an alkyl group of 1 to 10 carbon atoms, by reacting a phenol represented by the formula (4) wherein R¹ and R² are as defined above, with an alcohol represented by the formula R⁴OH, wherein R⁴ is as defined above, and an aldehyde represented by the formula R³CHO, wherein R³ is as defined above, in the presence of a catalyst, characterized by using a catalyst selected from the group consisting of tertiary alkylamines, tertiary unsubstituted benzylamines, mixtures thereof, carbonates and hydrogencarbonates of an alkali metal and mixtures of said carbonates and hydrogencarbonates, wherein said tertiary alkylamines and/or tertiary unsubstituted benzylamines are used in an amount of at least 1/200 mol per 1 mol of said phenol and said carbonates and/or hydrogencarbonates are used in an amount of at least 1/300 mol per 1 mol of said phenol, and wherein said reaction is carried out at a reaction temperature of 0 to 200°C. The process according to claim 1, wherein the tertiary alkylamine is represented by the formula (2): wherein R⁵, R⁶ and R⁷, which may be identical or different, each represent an alkyl group of 1 to 20 carbon atoms, and the tertiary unsubstituted benzylamine is represented by the formula (3): wherein R⁸ and R⁹ which may be identical or different, each represent an alkyl group of 1 to 20 carbon atoms. The process according to claim 2, wherein R⁵, R⁶, R⁷, R⁸ and R⁹ each represent an alkyl group of 1 to 4 carbon atoms. The process according to claim 1, wherein the tertiary alkylamine is at least one selected from the group consisting of triethylamine and trinormalbutylamine and the tertiary unsubstituted benzylamine is N,N-diethylbenzylamine. The process according to claim 1, wherein the alkali metal is sodium or potassium. The process according to claim 1, wherein the carbonate of an alkali metal is at least one selected from the group consisting of sodium carbonate and potassium carbonate and the hydrogencarbonate is sodium hydrogencarbonate. The process according to claim 1, wherein the phenol is 2,6-di-t-butylphenol. The process according to claim 1, wherein R⁴ is an alkyl group of 1 to 4 carbon atoms. The process according to claim 1, wherein the alcohol is methanol. The process according to claim 1, wherein the aldehyde is paraformaldehyde. The process according to claim 1, wherein the amount of the aldehyde is 1 to 6 mols per 1 mol of the phenol. The process according to claim 1, wherein the alcohol is used as a solvent. The process according to claim 1, wherein the reaction temperature is 20 to 150°C. The process according to claim 1, wherein the reaction temperature is 70 to 150°C. The process according to claim 1, wherein the reaction pressure is 2 x 10⁵ to 197.2 x 10⁵ Pa (1 to 200 kg/cm² G). The process according to claim 1, wherein the reaction pressure is 5.9 x 10⁵ to 99.1 x 10⁵ Pa (5 to 100 kg/cm² G). The process according to claim 1, wherein the reaction time is 0.5 to 20 hours. The process according to claim 1, wherein the reaction time is 1 to 10 hours.

Inventors: IWAHARA, MASAHIRO
Applicants: IDEMITSU PETROCHEMICAL CO. LTD.
Application year: 1987
Main classification: C07C43
IPC codes: C07C41, C07C43