Esterification process

Abstract: The invention provides a process for the esterification of a C₂-C₂₄ monocarboxylic acid with a C₁-C₅ monoalcohol in a reactor at an increased reaction temperature and increased pressure which is carried out in the absence of any esterification catalyst whilst continuously feeding in the alcohol during the reaction and removing a gaseous alcohol/water mixture. Preferably the process is carried out in countercurrent in column reactor which is packed or contains plates. The reaction temperature is usually between 200 and 260°C at a pressure between 0.5 and 1.5 MPa. There is a C₆-C₂₀ monocarboxylic acid and monoalcohol a C₁-C₃ monoalcohol. More preferably the process is carried in two steps with a first step as described above and a second step in which further reaction to a conversion of at least 99% is carried out in the presence of an esterification catalyst at a temperature below 100°C.

Description: The present invention relates to a process for the esterification of a carboxylic acid with an alcohol at an elevated temperature and pressure in a reactor by continuously feeding the more volatile reactant in the gaseous phase and the other reactant in the liquid phase to the reactor and continuously removing therefrom a gaseous mixture comprising the more volatile reactant and water. Such a process is known from British Patent Specification GB-A-465,983 (Continental Oil Company). In this patent a process for the manufacture of esters from an organic carboxylic acid and a monohydric alcohol is described, in which the more volatile of the two reactants is passed into the other reactant in the form of superheated vapours. Usually, the monohydric alcohol is the more volatile component. Although this process can be effected in the absence of an esterification catalyst, all the examples given illustrate the use of such a catalyst and in the description almost exclusively reference is made to the use of a catalyst. The use of a catalyst is almost mandatory, however, because at the relatively low temperatures indicated in the examples (104-135°C), the conversion without the use of a catalyst would be economically unacceptable. A similar process has also been described in German Patent Application DE-A-1,908,517 (E. Boeri), in which the esterification of alcohols with acids or acid anhydrides is said to proceed faster and a purer product will be obtained, if the amount of alcohol in the reaction mixture is kept at a minimum. Although one of the features of the process is that it can be effected in the absence of any esterification catalyst, also a number of examples has been given in which an esterification catalyst is used. If no catalyst is used, the time to produce di(2-ethylhexyl)maleinate is 6 hours at 300°C and if the reaction is carried out continuously in a column provided with plates, the esterification of butanol with stearic acid requires 4 hours at 190°C and then the crude butyl stearate needs to be distilled which will take an additional 2 hours. Finally, in American Patent Specification US-A-2,411,536 (Continental Research Corp.) a mixture of fatty acids and resin acids, such as tall oil fatty acids is esterified in the absence of a catalyst. In order to arrive at practical results an excess of alcohol is used, and since the temperature used is below 200°C, pressure needs to be applied so as to achieve economically acceptable esterification rates, but the esterification rates are still very low, ranging from 6 to 23 hours for a more or less complete esterification. It is known in the art to carry out esterification reactions in the presence of an esterification catalyst whilst dosing carboxylic acid and alcohol in countercurrent in a column reactor. The catalyst is usually an acidic catalyst such as a sulfonic acid, a base such as an alkalihydroxide or an alkali alcoholate, a metal oxide or a metal alkylate. Such processes are disclosed inter alia in DE-A-2 503 195 (Henkel) and EP-A-334 154 (Henkel). It has been found that the esters prepared by these processes, especially when prepared at elevated reaction temperature and/or at elevated pressure, as a rule contain appreciable amounts of contaminants caused by presence of the catalyst. For instance sulphur compounds from customar sulphonic acid type catalysts may be present. Also, especially when acid catalysts are used, as a side-reaction dehydration of the alcohol occurs, leading to the production of alkenes and/or ethers, which reaction is favoured by the increased reaction temperature and increased pressure. Elaborate purification processes have been necessary, especially when the catalyst was soluble in the reaction mixture. In a few cases the prior art discloses a process for the esterification of a monocarboxylic acid with a lower alcohol at elevated temperature and under pressure in the absence of any esterification catalyst, but these processes normally result only in partial conversion of the carboxylic acid into ester. With a considerable excess of alcohol a conversion of 95% appears to be typical. Such processes are disclosed for instance in NL-B- 92 089 (Société Belge de l'azote..) and in Chemical Abstracts 72, 022792y (1968). In order to obtain purer esters it has also been proposed to carry out the esterification reaction in the presence of an enzyme such as lipase. Although such processes yield very good quality esters they are not easy to operate. Processes of this type are disclosed inter alia in WO-A-88/02775 (Novo Industries). The present invention provides a process for the esterification of a carboxylic acid with an alcohol at an elevated temperature and pressure, which is effected in two steps, in which in the first step the esterification is effected in the absence of a catalyst at a relatively high rate, after which in a second stage an esterification catalyst is used at low temperatures so that almost no side reactions occur. Therefore, the present invention relates to a process for the esterification of a carboxylic acid with an alcohol at an elevated temperature and pressure in a reactor by continuously feeding the more volatile reactant in the gaseous phase and the other reactant in the liquid phase to the reactor and continuously removing therefrom a gaseous mixture comprising the more volatile reactant and water, which is characterized in that the esterification is carried out in two steps in which the first step is effected in the absence of a catalyst and the reaction temperature is at least 200°C resulting in a conversion of the non-volatile reactant into ester of at least 85%, followed by a second step in which further reaction to a conversion of at least 99% is carried out in the liquid phase with an excess of the more volatile reactant in the presence of an esterification catalyst at a temperature below 100°C. Thus it follows that the process is applicable where one reactant is more volatile than the other and that at the temperature and pressure at which the process is carried out, the more volatile reactant is in the gaseous phase while the less volatile reactant is in the liquid phase. By the term "catalyst" is to be understood inorganic materials, organo metal compounds, and organic compounds such as enzymes (biocatalysts). In such a process the excess volatile reactant is used as an entraining agent to remove the water of reaction and this technique therefore can yield very high conversion percentages. Moreover the amount of contaminants formed is small because the reaction is carried out in the absence of any catalyst. Either the carboxylic acid or the alcohol constitutes the more volatile reactant. The carboxylic acid may be a monocarboxylic acid. In one embodiment the carboxylic acid is a monocarboxylic acid present as a liquid in an autoclave and alcohol vapour is passed through or over the liquid, the excess alcohol vapour entrails the water of reaction formed so that the reaction is driven to completion. Very high conversion percentages can be obtained this way. In a preferred embodiment of the invention the esterification is carried out in countercurrent in column reactor which is packed or contains plates. The plates may have holes or bubble caps to facilitate contact between the reactants and improves mass transport. In a preferred embodiment the reaction temperature during the esterification is between 200 and 260°C and the pressure between 0.5 and 1.5 MPa. Preferably, the carboxylic acid is a monocarboxylic acid. Suitable monocarboxylic acid starting materials contain 2 to 24, preferably 6 to 20 carbon atoms in the molecule. The carboxylic acid may contain one or more double bonds in the molecule and usually it is a straight chain carboxylic acid. Suitable non-volatile carboxylic acids are caprylic acid, capric acid, lauric acid, myristic acid, palmitic acid, stearic acid, oleic acid, linoleic acid as well as dimeric and trimeric fatty acids. Mixtures of the above acids as can be used. When the carboxylic acid is the volatile reactant, suitable examples include acetic acid and propanoic acid. Carboxylic acids of intermediate volatility, such as valeric acid, may act as the volatile or the non-volatile component according to the temperature and pressure at which the esterification reaction is carried out. The alcohol starting material is preferably a monohydric or dihydric alcohol. Suitable volatile alcohols contain 1 to 5, preferably 1 to 3 carbon atoms in the molecule. Preferably the alcohol is a primary alcohol. Suitable volatile alcohols are methanol, ethanol, propanol, isopropanol, a butanol, a pentanol or 2-ethyl hexanol. When the alcohol is the non-volatile component, suitable monoalcohol examples have from 12 to 24 carbon atoms such as lauryl alcohol, myristyl alcohol, and cetyl alcohol, while suitable polyol examples include ethylene glycol, trimethylene glycol, tetramethylene glycol, neopentylglycol, pentamethylene glycol and glycerol. It is generally preferred to add the volatile reactant to the non-volatile reactant in the form of a heated vapour. In this invention, the process is carried in two steps with a first step in the absence of any esterification catalyst and a reaction temperature of at least 200°C resulting in a conversion of the non-volatile reactant into ester of at least 85%, such as at least 93%, preferably at least 96%, followed by a second step in which further reaction to a conversion of at least 99% is carried out with an excess of the volatile reactant in the liquid phase in the presence of an esterification catalyst at a temperature below 100°C. In view of the presence of the catalyst and the required further esterification of at most some 7% of residual non-volatile reactant in the second step only a relatively short residence time at a relatively low reaction temperature is needed, so that contamination of the ester with the products of side-reactions and fragments of the catalyst is minute. Very high conversion percentages of more than 99% can thus be achieved. The catalyst employed in this second step is preferably an acidic esterification catalyst. Also preferably the catalyst is insoluble in the reaction medium. clearly suitable catalysts are certain acids, bases and oxides. Insoluble materials e.g. resins containing sulfonic acid groups are very suitable. Examples are certain cation exchange resins such as sulfonated styrene, p.toluenesulfonic acid attached to Teflon etc. In a further preferred embodiment of this invention the esterification of step 2 is carried out with excess dry or water-free volatile reactant, which is recovered in aqueous form from step 2 and recirculated to step 1. The invention will now be illustrated by the following non-limiting examples. Example 1 A technical grade mixture of fatty acids, consisting of 70% oleic acid with about 10% stearic acid and linoleic acid each and 6% of palmitoleic acid and an acid value of 200, was fed continuously at the top tray of a total of nine trays of a stainless steel bubble cap column. Methanol vapour was fed also continuously into the bottom section of the column just below the bottom tray. The temperature of the liquid on the trays in the column was kept at 240°C and the pressure was kept at 1 MPa. From the top of the column a vapour mixture of methanol and water emitted, which was condensed and collected as a liquid. The product from the bottom of the column was cooled to 50 - 70°C and collected. At a molar ratio of fatty acid to methanol of 1:6 and a residence time of the liquid of 3 hours a methyl ester with an acid value of 4.2 was obtained. Under the same conditions and a residence time of 5 hours a product with an acid value of 1.8 was obtained. Example 2 By using the procedure of Example 1 an ester was produced having an acid value of 6.5. This ester was mixed with excess of dry liquid methanol (water content 0.02% w.w.) and fed to a packed bed of 450 ml strongly acidic ion exchange resin at a temperature of 50°C. The residence time of the ester/methanol mixture calculated on the void fraction of the bed was 20 minutes. At methanol/ester ratios of 2:1, 3:1, and 4:1 respectively esters with acid values of 0.58, 0.43 and 0.74 were obtained.

Claims: A process for the esterification of a carboxylic acid with an alcohol at an elevated temperature and pressure in a reactor by continuously feeding the more volatile reactant in the gaseous phase and the other reactant in the liquid phase to the reactor and continuously removing therefrom a gaseous mixture comprising the more volatile reactant and water, characterized in that the esterification is carried out in two steps in which the first step is effected in the absence of a catalyst and the reaction temperature is at least 200°C resulting in a conversi of the non-volatile reactant into ester of at least 85%, followed by a second step in which further reaction to a conversion of at least 99% is carried out in the liquid phase with an excess of the more volatile reactant in the presence of an esterification catalyst at a temperatur below 100°C. A process according to Claim 1, in which the carboxylic acid has from 2 to 24 carbon atoms. A process according to Claim 1, in which the carboxylic acid is a monocarboxylic acid having from 6 to 20 carbon atoms. A process according to Claim 1, in which the alcohol is a monohydric alcohol having from 1 to 5 carbon atoms. A process according to Claim 1, in which the more volatile reactant is a monohydric alcohol having from 1 to 3 carbon atoms. A process according to Claim 1, in which in the first step the process is carried out in countercurrent in a column reactor which is packed or contains plates. A process according to Claim 1, in which in the first step the reactic temperature is between 200°C and 260°C. A process according to Claim 1, in which in the first step the pressur is between 0.5 and 1.5 MPa.

Inventors: KLOK ROBERT, VAN DEN BERG HENDRIKUS J, KLOK, ROBBERT, UNILEVER RESEARCH VLAARDINGEN LAB., VAN DEN BERG, HENDRIKUS JACOBUS
Applicants: UNICHEMA CHEMIE BV
Application year: 1990
Main classification: C07C67
IPC codes: C07C67