The production of formate salts of nitrogenous bases

Abstract: A formate salt of a nitrogenous base is produced by reacting hydrogen and carbon dioxide with a nitrogenous base in a multi-liquid phase in the presence of a catalyst comprising an inorganic or organometallic compound of a metal of Group VIII of the Periodic Table and a compound of an element of either Group VA or Group VIA of the Periodic Table of the Elements.

Description: The present invention relates generally to the production of formate salts of nitrogenous bases and in particular to the production of formate salts of nitrogenous bases containing a tertiary nitrogen atom and to their conversion into formic acid. The production of formate salts of nitrogenous bases containing a tertiary nitrogen atom is described, for example, in EP-A-0 095 321 and EP-A-0 151 510. EP-A-0 095 321 discloses a process for the production of a formate salt of a nitrogenous base in the presence of a solvent and as catalyst a soluble compound of a transition metal of Group VIII of the Periodic Table according to Mendeleef and separating the formate salt of the base from the reaction mixture. EP-A-0 151 510 discloses a process for the production of a formate salt of a nitrogenous base containing a tertiary nitrogen atom which process comprises reacting hydrogen and carbon dioxide with the nitrogenous base containing a tertiary nitrogen atom in the presence of a solvent and an effective amount of a catalyst characterised in that the catalyst comprises an inorganic or organometallic compound of rhodium and an organophosphorus compound. Both the aforesaid processes are operated in a single liquid phase, generally using a homogeneous catalyst, though heterogeneous catalysts may be employed. The conversion of the formate salts of nitrogenous bases into formic acid is described in EP-A-0 126 524 and EP-A-0 181 078 for example. EP-A-0 126 524 discloses a process for the preparation of formic acid from a formate salt in which the formic acid is combined with a first base characterised in that (1) the formate salt is contacted with a second, weaker and less volatile base under conditions which cause the first base to be displaced by the second base, (2) the formate salt of the second base is subsequently separated from the reaction mixture and (3) the formate salt of the second base is finally decomposed to yield formic acid and the second base. EP-0 181 078 discloses an integrated process for the production of formic acid from carbon dioxide and hydrogen characterised in that (a) in a first stage a nitrogenous base, carbon dioxide and hydrogen are reacted together in the presence of a catalyst to produce a formate salt of the nitrogenous base; (b) in a second stage the catalyst is removed from the formate salt of the nitrogenous base and any low boilers and recycled to the first stage; (c) in a third stage the formate salt of the nitrogenous base is recovered from the low boilers; (d) in a fourth stage the formate salt of the nitrogenous base is reacted with a base having a high boiling point to produce the nitrogenous base and the formate salt of the base having a high boiling point; (e) in a fifth stage the formate salt of the base having a high boiling point is decomposed to the higher boiling base and formic acid. In the first stage (a) of the process of EP-A-0181078 a high-boiling solvent is generally employed. The catalyst is generally a soluble Group VIII transition metal compound. In the second stage (b) of the process the catalyst and the high-boiling solvent is removed from the product of the first stage comprising unreacted materials, the formate salt of the nitrogenous base and catalyst in the high-boiling solvent. In a preferred arrangement the second stage comprises an evaporator wherein (i) the catalyst and high-boiling solvent are separated and recycled to the first stage reactor, and (ii) gaseous components are separated and recycled. A problem can occur in the operation of the evaporator in that under the conditions of elevated temperature and low pressure prevailing therein the presence of catalyst together with the formate salt of the nitrogenous base can cause the reverse reaction to occur, i.e. the decomposition of the formate salt of the nitrogenous base to the nitrogenous base, carbon dioxide and hydrogen, thereby decreasing the yield of the desirable formate salt. This problem is not restricted to operation using an evaporator for separation of the catalyst and high-boiling solvent, but may be encountered in any separation in which the catalyst remains in contact with the formate salt under conditions facilitating formate salt decomposition. Solutions to the problem of formate salt decomposition in the presence of the catalyst used in its preparation have involved the addition of a compound which inactivates the catalyst either temporarily or permanently. Temporary inactivation during catalyst removal is preferred because the catalyst is re-usable on reactivation. Thus, our copending European application No. 89301270.8 describes the addition of a carboxylic acid or a salt thereof, an oxidant and carbon monoxide respectively as the inhibitor. We have now found an alternative process for the production of formate salts of nitrogenous bases which also offers a different solution to the problem of formate salt decomposition during the catalyst separation step of the aforesaid integrated process for the production of formic acid. Accordingly, the present invention provides a process for the production of a formate salt of a nitrogenous base which process comprises reacting hydrogen and carbon dioxide with a nitrogenous base in the presence of a catalyst comprising an inorganic or organometallic compound of a metal of Group VIII of the Periodic Table and a compound of an element of Group VA of the Periodic Table of the Elements - wherein the process is operated in a two phase system comprising two substantially immiscible solvents, a first solvent which preferentially dissolves the catalyst and a second solvent which preferentially dissolves the formate salt of the nitrogenous base, and separating the first solvent phase containing dissolved catalyst from the second solvent phase containing dissolved formate salt of the nitrogenous base. A prime requirement of any solvent for use in the process of the invention is that it must be inert under the reaction conditions. For this reason it is preferred to avoid the use of chlorinated solvents, ketones and aldehydes. As the first solvent which preferentially dissolves the catalyst there may suitably be used an inert organic solvent. Suitable inert organic solvents include both aliphatic, for example paraffinic, and aromatic hydrocarbon solvents. Examples of suitable organic solvents include heptane and toluene. As the first solvent there is preferably used a hydrocarbyl phosphine, suitably of the formula:- either or R¹R²P(CH₂) n PR³R⁴ (II) or wherein R¹ to R⁷ are independently either hydrogen or hydrocarbyl groups containing from 1 to 20 carbon atoms and n is an integer from 1 to 10. In addition, any two of R¹ to R⁷ may together form an organic cyclic ring system bound to phosphorus. Suitably the hydrocarbyl group may be an alkyl, cycloalkyl, aryl or alkaryl group. Alternatively, organophosphorus compounds of the type C₆H₅P[CH₂CH₂P(C₆H₅)₂]₂ (triphos) may be employed. An example of a compound having the formula (I) is tri-n-butyl phosphine. An example of a compound having the formula (II) is 1,2-diphenylphosphinoethane (C₆H₅)₂P(CH₂)₂P(C₆H₅)₂ and an example of a compound having the formula (III) is CH₃C[P(C₆H₅)₂]₃. Preferred hydrocarbyl phosphine solvents useful in the performance of the present invention include tri-n-butylphosphine. As the second solvent which preferentially dissolves the formate salt of the nitrogenous base there may suitably be used either water, glycerol or water in admixture with a solvent comprising an alcohol, a glycol, a polyol, a sulpholane or a mixture of at least two thereof. A preferred second solvent is water. Commercially available hydrogen may be used, with or without further purification. The carbon dioxide may either be carbon dioxide itself, which is widely available on an industrial scale, or a carbonate or a bicarbonate or a mixture thereof. Carbon dioxide may be used as a gas or as a liquid or as a solid, preferably as a gas. Using carbon dioxide gas as the source of carbon dioxide it is preferred to use partial pressures of carbon dioxide and hydrogen which are as high as is practicable and economic. The use of high partial pressures of hydrogen is desirable because the reaction rate and yield of the formate salt increase as the partial pressure increases. The partial pressure of carbon dioxide is less critical but suitably the carbon dioxide partial pressure may be up to 60 bar and the hydrogen partial pressure up to 250 bar. Small amounts of impurities in the carbon dioxide and hydrogen can be tolerated. Suitably the partial pressure of carbon dioxide is from 10 to 50 bar and that of hydrogen from 10 to 150 bar. The ratio of the partial pressure of hydrogen to that of carbon dioxide is preferably at least 1:1 more preferably at least 1.5:1. The nitrogenous base may be a primary, secondary or tertiary amine, which may be substituted by, for example hydroxyl groups, for example alkanolamines. Preferred are nitrogenous bases containing a tertiary nitrogen atom, which may suitably be of the formula:- either or wherein in the formulae, R¹, R² and R³, which may be the same or different, are hydrocarbyl groups or substituted hydrocarbyl groups or any two or all of R¹, R² and R³ may form part of a ring, R⁴ is a hydrocarbyl group or substituted hydrocarbyl group and R⁵ is a divalent organic group or R⁴ and R⁵ may form part of a ring. Suitably the hydrocarbyl group is an aliphatic, cycloaliphatic, aryl or alkaryl group. Substituted hydrocarbyl groups may contain for example nitrogen or oxygen. Preferably the nitrogenous base containing a tertiary nitrogen atom is a trialkylamine, even more preferably a lower trialkylamine, for example a C₁ to C₁₀ trialkylamine. Examples of suitable trialkylamines are trimethylamine, triethylamine, tripropylamine and tributylamine. Examples of other nitrogenous bases which may be employed are amidines, e.g. 1,8-diazabicyclo[5.4.0]undec-7-ene (DBU) and 1,4-diazabicyclo[2.2.2]octane (DABCO). Mixtures of nitrogenous bases may be used if so desired. The nitrogenous base is suitably added in amounts which produce a concentration in the range 1 to 50 mole % based on the total reaction mixture. The formate salt produced by the present process comprises a formate anion and a cation derived from the nitrogenous base by protonation. Thus, for example when the nitrogenous base used is triethylamine, the formate salt produced is triethylammonium formate. As catalyst there is used an inorganic or organometallic compound of a metal of Group VIII of the Periodic Table and a compound of an element of Group VA of the Periodic Table. For the avoidance of doubt the Periodic Table used throughout this specification is that of Cotton and Wilkinson. Suitable Group VIII metals include iron, cobalt, nickel, ruthenium, rhodium, palladium, iridium or platinum. Preferred metals of Group VIII are rhodium and ruthenium. Mixtures of compounds of different Group VIII metals may also be used if desired. The metal may be added in any convenient form whether soluble or insoluble in the initial reaction medium, but preferably in a soluble form. Thus, the metal may be added in the form of a simple salt, for example the halide, nitrate, sulphate or acetylacetonate or in the form of an organometallic complex of the metal or as the elemental metal. Suitably there is used a compound of an element of Group VA of the Periodic Table, for example a compound of nitrogen, phosphorus, arsenic, antimony or bismuth. Preferably there is used an organophosphorus compound. It will be appreciated that the hydrocarbyl phosphine employed as the first solvent as hereinbefore described may serve also as a component of the catalyst. Alternatively, the catalyst may utilise a different organophosphorus compound. Any organophosphorus compound of the formulae (I) to (III) may be employed. A preferred organophosphorus compound is tri-n-butylphosphine. The catalyst may be formed 'in situ' by reacting a metal compound with the organophosphorus compound or the catalyst may be pre-synthesised and isolated before use in the process. The ratio of the organophosphorus compound to the Group VIII metal may vary over a wide range. The process may be operated at a temperature in the range from 15 to 200°C, preferably from 30 to 120°C. The process may be operated batchwise or continuously. At the completion of the reaction using a two-phase system the catalyst is mainly in one phase and the formate salt of the nitrogenous base is mainly in another phase. The catalyst is recovered from the formate salt by separating the phases, which can be accomplished in known manner, for example by decantation, to provide a catalyst-rich solution which may be recycled to the reaction and a formate salt-rich solution, from which the formate salt may be recovered. An advantage of the process of the invention is that the catalyst is not in contact with the formate salt during its separation therefrom and thereby the problem of formate salt decomposition in the presence of the catalyst can be avoided. The process can therefore be utilised to advantage in the integrated process for the production of formic acid. In another aspect therefore the present invention provides a process for the production of formic acid which comprises the steps of:- (1) reacting hydrogen, carbon dioxide and a first nitrogenous base in the presence as catalyst of an inorganic or organometallic compound of a metal of Group VIII of the Periodic Table to produce a formate salt of the first nitrogenous base in a two-phase liquid system comprising two substantially immiscible solvents, the first solvent being one which preferentially dissolves the catalyst and the second solvent being one which preferentially dissolves the formate salt of the first nitrogenous base, (2) separating the first solvent phase containing dissolved catalyst from the second solvent phase containing dissolved formate salt of the first nitrogenous base, (3) recycling the first solvent containing dissolved catalyst in whole or in part to step (1), (4) reacting the formate salt of the first nitrogenous base, either dissolved in the second solvent or separated therefrom, with a second nitrogenous base which is (i) weaker than the first base, and (ii) is less volatile than the first base under conditions to cause the second base to displace the first base and thereby form a formate salt of the second nitrogenous base which is thermally decomposable at a temperature higher than the boiling point of the first base, (5) separating the formate salt of the second nitrogenous base from the first nitrogenous base, and (6) thermally decomposing the formate salt of the second nitrogenous base separated in step (5) to yield formic acid and the second nitrogenous base. In step (1) of the aforesaid process the first nitrogenous base is preferably a nitrogenous base containing a tertiary nitrogen atom as hereinbefore described. The hydrogen, carbon dioxide and catalyst are as hereinbefore described. The first and second solvents are as hereinbefore described, preferred being toluene/water. In step (2) the first solvent phase may be separated from the second solvent phase by means known in the art, for example by decantation. It is an advantage of using a mixture of an organic solvent, for example toluene, and water that the catalyst partitions into the uppermost organic layer and the formate salt into the lowermost water layer, thereby facilitating separation by, for example, a weir arrangement. In step (4), the formate salt of the first nitrogenous base either dissolved in the second solvent or separated therefrom is reacted with a second nitrogenous base. The second solvent containing dissolved formate salt of the first nitrogenous base may be treated with the first solvent before separation or reaction to extract into the first solvent any residual catalyst present therein. It is preferred to separate the formate salt of the first nitrogenous base from the second solvent before reaction with the second nitrogenous base. This may suitably be accomplished by distillation, there being little risk of decomposition in the absence of catalyst provided that the boiling point of the second solvent is below the decomposition temperature of the formate salt under the pressure employed. The second nitrogenous base is selected so that (1) it is weaker than the nitrogenous base used in the first stage of the process (2) its formate salt is thermally decomposable at a temperature higher than the boiling point of the nitrogenous base used in the first stage of the process, and (3) it is less volatile than the nitrogenous base used in the first stage of the process. It will be seen from these criteria that the exact choice of such a base will depend upon which nitrogenous base is used in the first stage of the process. Preferably the second base has a pK a in the range 4.0 to 9.0 and is an imidazole of the general formula: where R₁ is a monovalent hydrocarbon group containing 1 to 12 carbon atoms and R₂ is a hydrogen atom or an R₁ group, the total number of carbon atoms in R₁ and R₂ conveniently being not more than 20 and preferably from 4 to 12. Suitable hydrocarbon radicals on the imidazole derivatives (I) are, in general, alkyl groups of 1 to 8 carbon atoms, cyclopentyl, cyclohexyl, phenyl and methylphenyl groups. Amongst the above, imidazole derivatives where R¹ is n-1-alkyl of 4 to 10 carbon atoms and R² is hydrogen or methyl are particularly suitable. Examples of such compounds are 1-(n-1-butyl)-imidazole (pKa 5.9), 1-(n-1-pentyl)-imidazole (pKa 5.9), 1-(n-1-decyl)-imidazole (pKa 5.75), 1-(n-1-butyl)-2-methylimidazole (pKa 7.0) and 1-(n-1-pentyl)-2-methylimidazole (pKa 6.85). In addition to imidazoles, quinoline and other heterocyclic nitrogenous bases can be used. For a definition of the pKa values, which are a measure of the base strength, reference may be made, for example to Landoldt-Bornstein, 6th edition, 7th part volume II, page 900 et seq. Thereafter, steps (5) and (6) may suitably be carried out in the manner described in the aforesaid EP-A-0 126 524, the content of which is incorporated herein by reference. The invention will now be described by reference to the following Examples. In these Examples, the rate of reaction refers to the rate of production of the formate salt (moles/hr), averaged over the initial 75% of the reaction, divided by the weight of reaction solutions (Kgs) charged. The conversion to formate salt was calculated according to the following equation:- Example 1 Into an autoclave of 300 ml capacity made of stainless steel and fitted with a rotary stirrer were charged 36.3g triethylamine, 27.15 g toluene, 20.1 g water, 2.33 g tri-n-butyl phosphine and 0.2047 g ruthenium trichloride. The toluene and water formed a two-phase system containing the catalyst, the phosphine ligand and the triethylamine. The autoclave was closed and carbon dioxide introduced until a steady pressure of 28 bar was obtained. The system was then heated until a steady temperature of 80°C was achieved and at this point hydrogen was added to give a total pressure of 96 bar. At the end of the reaction period the autoclave was cooled to room temperature and the excess pressure discharged. The product solution formed two phases which were separated using a separating funnel. Formate analysis was carried out on each phase by hydrolysing with Amberlyst ion exchange resin followed by base titration. The data is summarised in Table 1. The rate of reaction was 0.22 mol kg⁻¹h⁻¹ with an overall conversion to triethylammonium formate of 41.5%. Example 2 Into the autoclave used for Example 1, following the same method, were charged 36.1 g triethylamine, 26.3 g toluene, 20.0 g water, 2.3 g tri-n-butyl phosphine and 0.2447 g of rhodium trichloride. The autoclave was closed and carbon dioxide introduced until a steady pressure of 28 bar was obtained. The system was then heated to 40°C and hydrogen was added to give a total pressure of 96 bar. The rate of reaction was 0.07 mol kg⁻¹h⁻¹ with an overall conversion to triethylammonium formate of 18.3%. Example 3 Into the autoclave used for Example 1, following the same method, were charged 36 g triethylamine, 25.5 g toluene, 19.5 g water, 0.2628 g triphenylphosphine and 0.2302 g [Rh(PPh₃)₃Cl]. The autoclave was closed and carbon dioxide introduced until a steady pressure of 28 bar was obtained. The system was then heated to 40°C and hydrogen was added to give a total pressure of 96 bar. The rate of reaction was 0.06 mol kg⁻¹h⁻¹ with an overall conversion to triethylammonium formate of 11.8%. Example 4 Into the autoclave used for Example 1, following the same method, were charged 36.5 g triethylamine, 26.8 g toluene, 20.2 g water and a 1:1 mixture of [RuCl₃(PBu₃ n )₂]₂/[Ru₂Cl₅(PBu₃ n )₄]. The autoclave was closed and carbon dioxide introduced until a steady pressure of 28 bar was obtained. The system was then heated to 80°C and hydrogen was added to give a total pressure of 96 bar. The rate of reaction was 0.34 mol kg⁻¹h⁻¹ with an overall conversion to triethylammonium formate of 42.7%. Example 5 Into the autoclave used for Example 1, following the same method, were charged 36.4 g triethylamine, 25.5 g toluene, 19.8 g water, 0.2627 g triphenylphosphine and 0.4805 g of [RuCl₂(PPh₃)₃]. The autoclave was closed and carbon dioxide introduced until a steady pressure of 28 bar was obtained. The system was then heated to 80°C and hydrogen was added to give a total pressure of 96 bar. The rate of reaction was 1.72 mol kg⁻¹h⁻¹ with an overall conversion to triethylammonium formate of 56.9%. Example 6 Into the autoclave similar to that described in Example 1, except of 100 mml capacity and following the method of Example 1, were charged 18.0 g triethylamine, 13.6 g toluene, 10.1 g water and 0.3154 g [RuCl₃(PMe₂Ph)₃]. The autoclave was closed and carbon dioxide introduced until a steady pressure of 28 bar was obtained. The system was then heated to 80°C and hydrogen was added to give a total pressure of 96 bar. The rate of reaction was 2.45 mol kg⁻¹h⁻¹ with an overall conversion to triethylammonium formate of 70.8%. Example 7 Into the autoclave used for Example 1, following the same method, were charged 36.7 g triethylamine, 25:3 g toluene, 20.1 g water and 1.1084 g [RuCl₂ (p-tolyl)₃P ₃]. The autoclave was closed and carbon dioxide introduced until a steady pressure of 28 bar was obtained. The system was then heated to 80°C and hydrogen was added to give a total pressure of 96 bar. The rate of reaction was 3.61 mol kg⁻¹h⁻¹ with an overall conversion to triethylammonium formate of 64.5%. Example 8 Into the autoclave used for Example 6, following the method of Example 1, were charged 18.9 g triethylamine, 13.6 g toluene, 10.1 g water and 0.6146 g [RuCl₃(PMe₂Ph)₃]. The autoclave was closed and carbon dioxide introduced until a steady pressure of 28 bar was obtained. The system was then heated to 80°C and hydrogen was added to give a total pressure of 96 bar. The rate of reaction was 7.4 mol kg⁻¹h⁻¹ with an overall conversion to triethylammonium formate of 68.5%. Example 9 Into the autoclave used for Example 1 following the same method, were charged 36.9 g triethylamine, 20.2 g heptane, 20.2 g water and 0.6327 g [RuCl₃(PMe₂Ph)₃]. The autoclave was closed and carbon dioxide introduced until a steady pressure of 28 bar was obtained. The system was then heated to 80°C and hydrogen was added to give a total pressure of 96 bar. The rate of reaction was 2.31 mol kg⁻¹h⁻¹ with an overall conversion to triethylammonium formate of 65.9%. Example 10 Into the autoclave used for Example 6, following the method of Example 1, were charged 18.5 g triethylamine, 14.5 g toluene, 10.0 g water and 0.3130 g [RuCl₃(PMe₂Ph)₃]. The autoclave was closed and carbon dioxide introduced until a steady pressure of 28 bar was obtained. The system was then heated to 100°C and hydrogen was added to give a total pressure of 96 bar. The rate of reaction was 6.59 mol kg⁻¹h⁻¹ with an overall conversion to triethylammonium formate of 52.1%. Example 11 Into the autoclave used for Example 6 using the method of Example 1 was charged 13.7 g of the toluene phase from Example 10. This contained the catalyst and 4.9 g of triethylamine ascertained by acid titration. A further 14.8 g triethylamine and 10.0 g water were added to make up a standard charge. The autoclave was closed and carbon dioxide introduced until a steady pressure of 28 bar was obtained. The system was then heated to 100°C and hydrogen was added to give a total pressure of 96 bar. The rate of reaction was 10.99 mol kg⁻¹h⁻¹ with an overal conversion to triethylammonium formate of 48.2%. Example 12 Into the autoclave used for Example 6 using the method of Example 1 was charged 8.8 g of the toluene phase from Example 11. This contained the catalyst and 2.8 g of triethylamine ascertained by acid titration. A further 15.9 g of triethylamine and 10.0 g of water were added to make up a standard charge. The autoclave was closed and carbon dioxide introduced until a steady pressure of 28 bar was obtained. The system was then heated to 100°C and hydrogen was added to give a total pressure of 96 bar. The rate of reaction was 11.80 mol kg⁻¹h⁻¹ with an overall conversion to triethylammonium formate of 50.0%. Example 13 Into the autoclave used for Example 6, following the method of Example 1, were charged 17.83 g triethylamine, 13.82 g toluene, 16.93 g glycerol and 0.4627 g [RuCl₂(PPh₃)₃]. The autoclave was closed and carbon dioxide introduced until a steady pressure of 28 bar was obtained. The system was then heated to 80°C and hydrogen was added to give a total pressure of 96 bar. The rate of reaction was 2.16 mol kg⁻¹h⁻¹ with an overall conversion to triethylammonium formate of 46.7%. Example 14 Into an autoclave of 300ml capacity made of stainless steel and fitted with a rotary stirrer were charged under strictly anaerobic conditions the following degassed materials:- 28.72g triethylamine, 49.21g tri-n-butyl phosphine, 31.24g water and 0.3011g rhodium trichloride trihydrate. The autoclave was closed and carbon dioxide introduced until a steady pressure of 28 bar was obtained. The system was then heated until a steady temperature of 100°C was achieved and at this point hydrogen was added to give a total pressure of 96 bar. At the end of the reaction period the autoclave was cooled to room temperature, the excess pressure discharged and the products collected again under strictly anaerobic conditions. The product solution formed two phases which were separated under anaerobic conditions via cannula transfer to a separate vessel. Formate analysis was carried out on each phase by hydrolysing with Amberlyst ion exchange resin followed by base titration. The data is summarised in Table 2. The rate of the reaction was 5.32 mol kg⁻¹ h⁻¹ with an overall conversion to triethylammonium formate of 68.4%. Example 15 Into the autoclave used for Example 14 using the method of Example 14 was charged 49.84g of the tri-n-butyl phosphine (TNBP) phase from Example 14. This contained the catalyst and 0.90g of triethylamine ascertained by acid titration. A further 25.27g of degassed triethylamine and 31.56g of degassed water were then added under strictly anaerobic conditions to make up a standard charge. The autoclave was closed and carbon dioxide introduced until a steady pressure of 28 bar was obtained. The system was then heated to 100°C and hydrogen added to give a total pressure of 96 bar. The rate of reaction was 6.83 mol kg⁻¹ h⁻¹ with an overall conversion to triethylammonium formate of 61.9%. Example 16 Into the autoclave used for Example 14 using the method of Example 14 was charged 45.34g of the TNBP phase from Example 15. This contained the catalyst and 1.56g of triethylamine ascertained by acid titration. A further 24.58g of degassed triethylamine and 30.55g of degassed water were then added to make up a standard charge. The autoclave was closed and carbon dioxide introduced until a steady pressure of 28 bar was obtained. The system was then heated to 100°C and hydrogen added to give a total pressure of 96 bar. The rate of reaction was 7.70 mol kg⁻¹ h⁻¹ with an overall conversion to triethylammonium formate of 73.2%. Example 17 Into the autoclave used for Example 14 using the method of Example 14 was charged 42.62g of the TNBP phase from Example 16. This contained the catalyst and 1.18g of triethylamine ascertained by acid titration. A further 24.42g of degassed triethylamine and 30.58g of degassed water were then added to make up a standard charge. The autoclave was closed and carbon dioxide introduced until a steady pressure of 28 bar was obtained. The system was then heated to 100°C and hydrogen added to give a total pressure of 96 bar. The rate of reaction was 8.00 mol kg⁻¹ h⁻¹ with an overall conversion to triethylammonium formate of 75.5%. Example 18 Into the autoclave used for Example 14 using the method of Example 14, were charged 29.35g triethylamine, 48.13g tri-n-butyl phospine, 30.23g water and 0.295g ruthenium trichloride trihydrate. The autoclave was closed and carbon dioxide introduced until a steady pressure of 28 bar was obtained. The system was then heated to 100°C and hydrogen was added to give total pressure of 96 bar. The rate of reaction was 3.71 mol kg⁻¹ with an overall conversion to triethylammonium formate of 53.8%. Example 19 Into the autoclave used for Example 14 using the method of Example 14 was charged 46.74g of the TNBP phase from Example 18. This contained the catalyst and 1.28g of triethylamine ascertained by acid titration. A further 25.57g of degassed triethylamine and 31.21g of degassed water were then added to make up a standard charge. The autoclave was closed and carbon dioxide introduced until a steady pressure of 28 bar was obtained. The system was then heated to 100°C and hydrogen added to give a total pressure of 96 bar. The rate of reaction was 2.31 mol kg⁻¹ h⁻¹ with an overall conversion to triethylammonium formate of 60.3%. Example 20 Into the autoclave used for Example 14 using the method of Example 14 was charged 44.64g of the TNBP phase from Example 19. This contained the catalyst and 1.17g of triethylamine ascertained by acid titration. A further 25.23g of degassed triethylamine and 30.88g of degassed water were then added to make up a standard charge. The autoclave was closed and carbon dioxide introduced until a steady pressure of 28 bar was obtained. The system was then heated to 100°C and hydrogen added to give a total pressure of 96 bar. The rate of reaction was 0.69 mol kg⁻¹ h⁻¹ with an overall conversion to triethylammonium formate of 64.8%.

Claims: A process for the production of a formate salt of a nitrogenous base which process comprises reacting hydrogen and carbon dioxide with a nitrogenous base in the presence of a catalyst comprising an inorganic or organometallic compound of a metal of Group VIII of the Periodic Table and a compound of an element of Group VA of the Periodic Table of the Elements - wherein the process is operated in a two phase system comprising two substantially immiscible solvents, a first solvent which preferentially dissolves the catalyst and a second solvent which preferentially dissolves the formate salt of the nitrogenous base, and separating the first solvent phase containing dissolved catalyst from the second solvent phase containing dissolved formate salt of the nitrogenous base. A process according to claim 1 wherein the first solvent is an inert organic solvent, which is either an aliphatic or aromatic hydrocarbon solvent. A process according to claim 2 wherein the inert organic solvent is either heptane or toluene. A process according to claim 2 wherein the first solvent is a hydrocarbyl phosphine. A process according to claim 4 wherein the hydrocarbyl phosphine is of the formula:- either or R¹R²P(CH₂) n PR³R⁴ (II) or wherein in the formulae (I) to (III) R¹ to R⁷ are independently either hydrogen or hydrocarbyl groups containing from 1 to 20 carbon atoms and n is an integer from 1 to 10, or any two of R¹ to R⁷ may together form an organic cyclic ring system bound to phosphorus. A process according to either claim 4 or claim 5 wherein the first solvent is tri-n-butyl phosphine. A process according to any one of claims 1 to 6 wherein the second solvent is either water, glycerol, or water in admixture with a solvent comprising an alcohol, a glycol, a polyol, a sulpholane or a mixture of at least two thereof. A process according to any one of claims 1 to 6 wherein the second solvent is water. A process according to any one of the preceding claims wherein the nitrogenous base is one containing a tertiary nitrogen atom and is of the formula: either or wherein in the formulae (IV) and (V) R¹, R² and R³, which may be the same or different, are hydrocarbyl groups or substituted hydrocarbyl groups or any two or all of R¹, R² and R³ form part of a ring, R⁴ is a hydrocarbyl group or substituted hydrocarbyl group and R⁵ is a divalent organic group or R⁴ and R⁵ form part of a ring. A process according to claim 9 wherein the nitrogenous base is a C₁ to C₁₀ trialkylamine. A process according to any one of the preceding claims wherein in the catalyst the metal of Group VIII is either rhodium or ruthenium. A process according to any one of the preceding claims wherein in the catalyst there is used an organophosphorus compound. A process according to claim 12 wherein the organophosphorus compound is an organophosphorus compound used as the solvent. A process according to any one of the preceding claims wherein the reaction is effected at a temperature in the range from 15 to 200°C. A process for the production of formic acid which comprises the steps of:- (1) reacting hydrogen, carbon dioxide and a first nitrogenous base in the presence as catalyst of an inorganic or organometallic compound of a metal of Group VIII of the Periodic Table to produce a formate salt of the first nitrogenous base in a two-phase liquid system comprising two substantially immiscible solvents, the first solvent being one which preferentially dissolves the catalyst and the second solvent being one which preferentially dissolves the formate salt of the first nitrogenous base, (2) separating the first solvent phase containing dissolved catalyst from the second solvent phase containing dissolved formate salt of the first nitrogenous base, (3) recycling the first solvent containing dissolved catalyst in whole or in part to step (1), (4) reacting the formate salt of the first nitrogenous base, either dissolved in the second solvent or separated therefrom, with a second nitrogenous base which is (i) weaker than the first base, and (ii) is less volatile than the first base under conditions to cause the second base to displace the first base and thereby form a formate salt of the second nitrogenous base which is thermally decomposable at a temperature higher than the boiling point of the first base, (5) separating the formate salt of the second nitrogenous base from the first nitrogenous base, and (6) thermally decomposing the formate salt of the second nitrogenous base separated in step (5) to yield formic acid and the second nitrogenous base. A process according to claim 15 wherein in step (1) the first nitrogenous base is a C₁ to C₁₀ trialkylamine, the metal of Group VIII is ruthenium, the first solvent is tri-n-butyl phosphine and the second solvent is water. A process according to either claim 15 or claim 16 wherein in step (2) the first solvent phase is separated from the second solvent phase by decantation. A process according to any one of claims 15 to 17 wherein in step (4) the formate salt of the first nitrogenous base after separation from the second solvent is reacted with the second nitrogenous base which is an imidazole of the general formula: wherein in the formula (VI) R¹ is a monovalent hydrocarbon group containing 1 to 12 carbon atoms and R² is a hydrogen atom or an R¹ group, the total number of carbon atoms in R¹ and R² being from 4 to 12.

Inventors: BEEVOR ROBERT GEORGE BP CHEMIC, GULLIVER DAVID JEFFREY BP CHEM, KITSON MELANIE BP CHEMICALS LI, SORRELL ROBERT MICHAEL BP CHEM, BEEVOR, ROBERT GEORGE BP CHEMICALS LIMITED, GULLIVER, DAVID JEFFREY BP CHEMICALS LIMITED, KITSON, MELANIE BP CHEMICALS LIMITED, SORRELL, ROBERT MICHAEL BP CHEMICALS LIMITED
Applicants: BP CHEM INT LTD, BP CHEMICALS LIMITED
Application year: 1989
Main classification: C07C209
IPC codes: C07C51, C07C211, C07C53, C07C67, C07C209, C07B61, B01J31