Nickel-based dual catalyst systems effective in suppressing carbon dioxide formation during diethylene glycol amination

Abstract: Carbon dioxide formation is suppressed when a morpholine and a 2-(2-aminoalkoxy) alkanol are simultaneously produced by reacting an anhydrous dialkylene glycol, preferably diethylene glycol, with ammonia in the presence of added hydrogen over a catalyst at a temperature of 150 to 300°C and a pressure of 1.45 to 34.60 MPa, when the catalyst is a nickel-copper-chromium oxide catalyst used in combination with a supported ruthenium catalyst.

Description: This invention relates to the practice of making morpholine and substituted morpholines from dialkylene glycols by an amination reaction. More particularly this invention relates to the use of a dual nickel/ruthenium catalyst system for the selective amination of anhydrous dialkylene glycols, such as diethylene glycol (DEG), to corresponding morpholine derivatives and corresponding amino alkoxy alkanols, such as 2-(2-aminoethoxy)ethanol, wherein the coproduction of CO₂ is significantly suppressed. Surprisingly, it has been found that only certain combinations of nickel/ruthenium dual catalyst systems are effective in suppressing CO₂ formation during this reaction. The practice of making morpholine plus DGA from diethylene glycol and ammonia over an amination catalyst is well-known in the art (see, for example, US-A-3151112). It is also known from US-A-4508896 to carry out such a reaction in the presence of a catalyst comprising oxides of nickel, copper and chromium. The reaction is generally run in an aqueous environment. The indication is that better productivity could be obtained using an anhydrous feed, since water acts as a diluent and takes up space in the reactor. Whether run under aqueous or anhydrous feed conditions, there are two principal gaseous by-products, methane and carbon dioxide. Under aqueous conditions most of the CO₂ is absorbed into the H₂O. Under anhydrous feed conditions, even though water is a reaction by-product (e.g. see Equations 1 and 2), the CO₂ will readily react with the excess ammonia to form ammonium bicarbonate and/or ammonium carbamate, both of which will in the absence of adequate water diluent, form solids which precipitate downstream of the amination reactor, in the heat exchanger, etc., causing additional unit maintenance costs and engineering problems. It would be extremely advantageous if it were possible to operate a morpholine/DGA process using anhydrous diethylene glycol/ammonia feed in such a fashion that CO₂ by-product formation was lowered to below, or close to, threshold levels (i.e. <50 ppm). Such a condition might be achieved by converting the CO₂ into methane (Equation 3), possibly by introducing a methanation catalyst into the process unit, downstream of the diethylene glycol amination step. Particularly useful would be a methanation catalyst that: a) Lowers CO₂ concentration in the morpholine DGA/product effluent to threshold levels. b) Is stable in the high pH, amine, environment of the morpholine DGA/product effluent. c) Remains an active methanation catalyst in said environment for extended periods, particularly at the temperature of DEG amination (190-250°C) d) Does not convert the desired morpholine and DGA into unwanted by-products, as a result of catalyzing secondary reactions in the crude product effluent. CO₂ + 4H₂ → CH₄ + 2H₂O No art has been found dealing with a provision for converting by-product CO₂ into methane when the CO₂ is present in an amination product effluent, particularly where the CO₂ is present in a morpholine DGA product mixture resulting from the amination of diethylene glycol (DEG) with ammonia. It is known that carbon dioxide can be converted into methane by reduction with four moles of hydrogen (Equation 3). This is called the "Sabatier reaction". The mechanism for the reaction is not clear and early researchers assumed that the reaction occurred in stages, but Bardet and Trambouze reported in C.R Hebd. Seances. Acad. Sci., Ser. C. 288 (1979). 101, that it appeared CO₂ methanation had its own mechanism, distinct from CO methanation, and that CO₂ methanation occurs faster and at lower temperatures than methanation of CO. Heterogeneous catalysts have proven best for this process. see "Carbon Dioxide Activation by Metal Complexes," by A. Behr, Chapter 4, p. 85 (1988). The mechanism for hydrogenation of CO₂ on nickel is discussed in an article by G. D. Weatherbee, et al. in J. Catal., 77 , 460-472 (1982). The rate of CO₂ hydrogenation was measured as a function of H₂ and CO₂ partial pressures at 500-600 K, 140 kPa and 30,000-90,000h⁻¹. The data indicated the rate of CO₂ hydrogenation is moderately dependent on CO₂ and H₂ concentrations at low partial pressures, but essentially concentration-independent at high partial pressures. Under typical conditions, CO was observed as a product of the reaction at levels determined by quasi-equilibrium between surface and gas phase CO species. Addition of CO to the reactants above this equilibrium level caused a significant decrease in the rate of CO₂ hydrogenation, apparently as a result of product inhibition. These authors set forth the. following table which in their view summarized the mechanism for CO₂ hydrogenation and accounted for the observations of this study and other recent studies. The authors also noted that kinetic studies of methanation in their laboratory provided evidence that there are several mechanistic regimes, involving different rate controlling steps, the importance of which depends mainly on temperature. The authors proposed that at moderate reaction temperatures (525-575 K), CO dissociation appeared to be rate controlling, while hydrogenation of carbon apparently controlled at higher reaction temperatures (>575 K). This suggested that CO and CO₂ methanation rates on nickel are both controlled by CO dissociation at moderate reaction temperatures (525-575 K), a hypothesis consistent with the observation of nearly identical specific reaction rates in CO₂ and CO methanation on Ni/SiO₂. The authors further proposed that it is possible for the two reactions to follow similar paths and still have different rate determining steps. CO₂ Methanation catalysts are discussed in an article by A.D. Tomsett, et al. in Applied Catal. 26 391 (1986). This investigation was made in the context of identifying highly active catalysts suitable for the second of two stages in a process for the conversion of syngas into substitute natural gas. It was found that supported Ni-La₂O₃-Ru catalysts are effective for CO₂ methanation. These catalysts provided high activity and complete conversion of CO₂ into methane at a temperature as low as 250°C. It was concluded that the high activity of the Ni-La₂O₃-Ru catalysts is mainly ascribable to the larger number of active sites. It is known that methanation reactions are the reverse of reforming reactions. The methanation reactions are exothermic and therefore, since a methanator typically operates at a temperature of 300-400°C, the CO and CO₂ at the inlet should be carefully monitored to avoid damage to catalyst and vessel, see Kirk-Othmer, Encyclopedia of Chem.Tech., 3rd Edition, Vol. 2, p. 494. Related art includes an investigation discussed in an article by H. Baussart, et al. in J. Chem. Soc. Faraday Trans. I, 83 , 1711 (1987). Here Co, K and Cu, as components of catalysts, were investigated for the specific roles each played in the hydrogenation of CO₂. The results indicated, inter alia that a steady state was reached after ca. 30 hours of activation. It was found that the presence of cobalt favoured the formation of alkanes, and that the presence of potassium favoured the formation of CO resulting from a reverse water-gas shift reaction (CO₂ + H₂ --CO + H₂O). Further, it appeared the presence of copper in Russell catalysts increased the activity and the selectivity for CH₄ and reduced the number of products. There is a report on results of investigations into potassium-promoted nickel catalysts by T.K. Campbell, et al. in Applied Catal., 50 , 189 (1989). It was found potassium did not increase selectivity for higher hydrocarbons or olefins, but it changed the CH₄/CO product distribution. It was also found that potassium did not change CO₂ methanation mechanism, and the mechanism appeared to be quite similar to that for CO hydrogenation. This paper presented steady-state kinetic data for CO₂ hydrogenation on Ni/SiO₂ and Ni/SiO₂-Al₂O₃ catalysts for a range of potassium concentrates. It was reported that hydrogenation reactions of CO₂ and CO on potassium-promoted nickel catalysts are similar: The activities and selectivities depend significantly on the support. The rate of methanation on Ni/SiO₂ decreases exponentially for both reactions with potassium addition. The rate of methanation on Ni/SiO₂-Al₂O₃ initially increases for both reactions with potassium addition. US-A-4508896 describes a process for simultaneously producing a 2-(2-aminoalkoxy)alkanol compound and a morpholine compound by contacting an oxydialkanol with ammonia in the presence of a hydrogenation/dehydrogenation catalyst which comprised 60-85 mole% of nickel, 14-37 mole % of copper and 1-6 mole % of chromium, calculated on an oxide-free basis. This work does not address the problem of a methanation catalyst, CO₂ production and its effect in lowering productivity Preoxidized rhodium was studied as a catalyst for methanation of carbon monoxide in an article by A. Amariglio, et al. in J. Catal., 81 247 (1983). The authors confirmed that, according to their experiments, preoxidation of Rh caused a dramatic enhancement of its activity in the methanation of CO₂. They estimated preoxidation allowed the rate to be increased by a factor of 100, at the lowest estimate. The authors also concluded that the deactivation, observed upon prolonged exposures to H₂, must be ascribed to depletion of the preincorporated oxygen. From the art available, it is evident that there are many factors and multiple variables involved in the methanation of CO₂, such that it would be difficult to identify a catalyst which would promote methanation at low temperatures (<250°C) and high pH within a dual catalyst system where the conditions are geared toward a primary reaction, such as amination. It would constitute a distinct advance in the art if a catalyst system were available whereby CO₂ formation could be suppressed during morpholine/DGA amine processing by amination of DEG under anhydrous conditions. It has been discovered that the choice of methanation catalyst is very important. Many known methanation catalysts cannot be used in this fashion because of certain critical factors, particularly those outlined above. Our prior Application No. 91303948.3 (EP-A-0436722) corresponds to US-A-5011926, and is a document in the state of the art according to Article 54(3) EPC. It discloses that carbon dioxide formation can be suppressed in a process for simultaneously producing a morpholine and a 2-(2-aminoalkoxy) alkanol by reacting a dialkylene glycol (especially diethylene glycol) with ammonia in the presence of added hydrogen over a nickel- chromium oxide catalyst when said catalyst is employed in combination with an oxide-supported nickel catalyst. Unexpectedly it has now been discovered that a dual catalyst system comprising a nickel-copper-chromium oxide catalyst in conjunction with a supported ruthenium catalyst is very effective for selective amination of dialkylene glycols to morpholines plus di(alkoxyalkyl)amines, while at the same time significantly suppressing the coproduction of CO₂. One embodiment of this invention provides a process for simultaneously producing a morpholine and a 2-(2-aminoalkoxy) alkanol by reacting an anhydrous dialkylene glycol with ammonia in the presence of added hydrogen over a nickel-copper-chromium oxide catalyst at a temperature of 150 to 300°C and a pressure of 1.45 to 34.60 MPa. According to the invention, the nickel-copper chromium oxide catalyst is used in combination with a supported ruthenium catalyst. Preferably, the dialkylene glycol has the formula: in which each R is independently hydrogen or alkyl, and most preferably, the dialkylene glycol is diethylene glycol. According to the preferred embodiment, oxydiethanol, also known as diethylene glycol, is fed into a reactor under anhydrous conditions and contacted with ammonia and hydrogen in the presence of a catalytically effective amount of a dual catalyst system comprising an amination/hydrogenation/dehydrogenation catalyst and a methanation catalyst, wherein the amination/hydrogenation/dehydrogenation catalyst is most preferably an oxide of 60 to 85 mole% of nickel, 14 to 37 mole% of copper and 1 to 6 mole% of chromium, and the methanation catalyst comprises a supported ruthenium catalyst. The reaction is preferably a continuous process and preferably the molar ratio of ammonia to oxydiethanol is from 4:1 to 8:1. Preferably, the space velocities of the liquid feed material, i.e. ammonia and o xydiethanol, are from 1 to 6g of liquid feed per hour per milliliter of catalyst. The recovered reaction product, consisting primarily of DGA and morpholine, is recovered from the resultant crude reaction product by conventional means, such as distillation or extraction. The oxydialkanol compound that can be utilized in practicing the instant invention can have the general formula: wherein each R is, hydrogen or alkyl for example, methyl or ethyl. The examples demonstrate the effectiveness of oxydiethanol or diethylene glycol. A particularly preferred catalyst comprises mole% of 60-85 mole % of nickel, 14-37 mole% of copper and 1-6 mole % of chromium, with the most preferred proportions being 72-78 mole % of nickel, 20-25 mole % of copper and 1-3 mole % of chromium. A greatly preferred hydrogenation catalyst comprises, as active components, about 75 mole% of nickel, about 23 mole% of copper and about 2 mole% of chromium, in oxide form. A commercially available nickel-copper-chromium oxide catalyst fitting this description is Engelhard Ni-2715 T 3/16" (4.8mm). As mentioned only certain combinations of nickel-ruthenium based dual catalyst systems are effective in suppressing CO₂ formation during morpholine production and it has been surprisingly discovered in the instant invention that an effective methanation catalyst in combination with the nickel-copper-chromium oxide catalyst, is a specified class of supported ruthenium catalyst. The supports may be selected from the elements of the Group II, III and IV or oxides thereof. The preferred supports include carbon, magnesia, alumina, silica, zirconia and titania, as well as mixtures thereof. The most preferred support is carbon. The ruthenium may be added to said support by any of the usual methods and said formulated catalyst may comprise from 0.01 to 30 wt% of ruthenium. The preferred ruthenium loading is 0.1 to 10.0 wt%, and the most preferred catalyst formulation comprises 0.5 to 5.0 wt% of ruthenium-on-carbon. Suitable commercially-available catalysts include Engelhard's 0.5% ruthenium-on-granular carbon. When the support is alumina, the preferred ruthenium loading is 0.1 to 10 wt%. The order of activity of the different ruthenium cocatalysts appears to be 1% Ru/C ∼ 0.5% Ru/C > 5% Ru/Al₂O₃ ≈ 0.5 Ru/Al₂O₃. The combination of nickel/ruthenium dual catalysts used according to the invention may be used in any proportions, except that preferably the nickel-copper-chromium oxide catalyst should contact the diethylene glycol/ammonia feed first, in order to achieve the desired amination (Equations 1 and 2), then after the desired DEG conversion is achieved, the reactant product should contact the supported ruthenium catalyst in order to lower significantly the CO₂ effluent concentration (through Reaction 3). A particularly effective ratio of nickel-copper-chromium oxide catalyst to supported ruthenium catalyst is from 1:1 to 10:1 by volume. The accompanying examples illustrate such a ratio range. A particularly preferred dual nickel catalyst combination is Engelhard Ni-2715 T 3/16" (4.8mm) and 0.5 wt% ruthenium-on-carbon. The ratio of reactant, i.e. the ratio of ammonia to oxydiethanol, or other oxydialkanol generally used in this process is 1:1 to 10:1, although a molar excess of ammonia produces increased yields of the morpholine product. Optimum yields are obtained when the molar ratio of ammonia to oxydiethanol is about 6:1. The space velocities of the feed, namely, the ammonia and the glycol, may generally be from 1, to 6 grams of liquid feed/hour/millilitre of catalyst. As noted above, the temperature range for the present invention is from 150°C to 300°C, and the preferred range is 200 to 250°C, depending upon the reactant ratios utilized. Those skilled in the art will realize that an outstanding advantage of the instant process resides in the fact that the relative yields of morpholine and DGA can be varied by a slight variation of reaction conditions while the production rate of the combined products remains high. Thus, one can achieve a substantial yield of 2-(2-aminoethoxy) ethanol while simultaneously maintaining morpholine production rates comparable to or better than those obtained by previously known methods. The process should be carried out in a reducing atmosphere, using hydrogen for commercial operations. Although small amounts of hydrogen are present during the reaction, from the catalyst materials and as a by-product, it is preferred that hydrogen be added in the feed system in order to achieve CO₂ methanation (Equation 3) and to maintain catalytic activity. The quantity of hydrogen necessary for the practice of this invention is generally from 0.1 to 1000 liters (1) per lb (0.454Kg) of DEG converted, the preferred range is from 10 to 200 liters and H₂ per lb (0.45Kg) of DEG converted. Such a ratio is illustrated in the accompanying examples. Data for the combination of Engelhard Ni-2715T and ruthenium-on-carbon show CO₂ production may be suppressed by a factor of >2 where the DEG conversion is ca. 80% and by a factor of ca. 5, when the H₂ flow rate is raised from 35 liters to 90 liters/hr. The quantity of CO₂ produced in this morpholine/DGA process is normally measured in terms of parts per million (ppm) in the effluent product, and is expressed in terms of Kg of CO₂ generated per 100M lb 100M (10⁵) Kg of DEG converted. The accompanying examples illustrate the following: 1) In Example I, the generation of morpholine plus DGA is demonstrated using a dual catalyst system comprising a nickel-copper-chromium oxide catalyst in combination with a ruthenium-on-carbon to achieve: a) At normal hydrogen flows, there is 81% DEG conversion at 215°C with 248 Kg of CO₂ produced per 10⁵ Kg of DEG converted (see Table I). b) At 2.6 times normal hydrogen flows, there is ca 85% DEG conversion at 215°C with 93-109 Kg CO₂ produced per 10⁵ Kg of DEG converted. 2) In Examples 2 and 3, similar combinations with other ruthenium-on-carbon catalysts typically give: a) At normal hydrogen flow rates, there is 80% DEG conversion at 215°C with 224 Kg of CO₂ produced per 10⁵ Kg of DEG converted (see Table III). b) At 2.6 times normal hydrogen flows, on 90% DEG conversion at 220°C with 88-102 Kg CO₂ produced per 10₅ Kg of DEG converted. 3) In Examples 4 and 5, combinations of the Ni-Cu-Cr catalyst with ruthenium-on-alumina catalyst typically give: a) At normal hydrogen flow rates, there is 75% DEG conversion at 210°C with 251 Kg CO₂ produced per 10⁵ Kg of DEC converted (see Table IV). b) At 2-6 times normal hydrogen flows, there is ca. 88% DEC conversion at 220°C with 226-231 Kg of CO₂ produced per 10⁵ Kg of DEC converted. 4) By comparison, in comparative Example A, using only Ni-2715 T 3/16" (4.8 mm) when DEC is aminated at 220°C with 82% DEG conversion, production of by-product CO₂ is 499 Kg per 10⁵ Kg of DEG converted. 5) In Example 6, combinations of the Ni-Cu-Cr catalyst with ruthenium-on-carbon catalyst provide improved CO₂ suppression during a typical 500 hr experiment. EXAMPLE 1 To a 550cc plug-flow reactor fitted with heating, cooling and pressure control devices and constructed of stainless steel, was charged a combination of 400cc of pelleted nickel-copper-chromium oxide catalyst (in which the active components comprised 71.2 wt% of Ni, 12.3 wt% Cu and 73.3% reduced Ni) and 150cc of granular ruthenium (0.5%) on carbon, 4-12 mesh (1.68-476mm). The pelleted nickel-copper-chromium oxide catalyst was placed in the bottom section of the reactor and the ruthenium-on-carbon at the top. Diethyleneglycol (0.54 Kg/h), ammonia (1.09 Kg/h) and hydrogen (35 liter/h) were fed separately to the reactor system from the bottom of the reactor, in an upflow mode, through the catalyst bed of the reactor. The reactor effluent was cooled and depressurized, and the gaseous and liquid product was analyzed after a 48 hour prerun period to establish steady state conditions. The performance of the dual-catalyst system was tested at a series of operating temperatures (210-230°C) and hydrogen flow rates (35-90 litres/hr) while maintaining a back pressure of 15.27 MPa (2200 psig). Data and results from this run are summarized in Table I. It may be noted that in this run: At an operating temperature 215°C, the DEG conversion is 80.6% and the CO₂ production is 248 Kg per 10⁵ Kg of DEG converted. At 220°C temperature, when the hydrogen flow rate is raised to 90 liters/h, the CO₂ effluent production drops to 93-109 Kg per 10⁵ Kg of DEG converted. EXAMPLES 2-3 Following the operating procedures of Example 1, two combinations of the nickel-copper-chromium oxide catalyst of Example 1 with different ruthenium-on-chromium catalysts were tested for diethylene glycol amination over a range of operating temperatures (210-230°C) and different hydrogen flow rates (35 and 90 liters/h). In Example 2, Table II the catalyst was 0.5% Ru/C, 30 x 40 mesh (0.42-0.595 mm), and in Example 3, Table III, the catalyst was 1% ruthenium-on-carbon, granules. Data and results from these runs are summarized in Tables II and III. It may be noted that: a) At normal hydrogen flow rates, 80% DEG conversion per pass is achieved at 215°C, with 224 Kg of CO₂ produced for each 10⁵ Kg of DEG converted (see Table III). b) At 2.6 times the normal hydrogen flows, ca. 90% DEG conversion is achieved at 220°C, with 88-102 Kg of CO₂ produced per 10⁵ Kg of DEG converted. EX. H₂ Flow Rate (l/hr) Reaction Temp. (°C) DEG Conversion (%) Yield(%) Basis DEG Converted Effluent CO₂ Conc. (ppm) CO₂ (Kg) Per 10⁵ Kg DEG Converted Morpholine DGA 2_ 35 210 67.3 56.1 39.4 112 162 35 215 73.7 62.1 33.1 136 152 35 220 82.5 70.1 24.8 236 237 35 230 91.4 79.7 13.3 790 832 90 220 79.8 72.7 19.9 97 124 90 220 80.8 71.2 19.8 110 140 EX. H₂ Flow Rate (l/hr) Reaction Temp. (°C) DEG Conversion (%) Yield(%) Basis DEG Converted Effluent CO₂ Conc. (ppm) CO₂ (Kg) Per 10⁵ Kg DEG Converted Morpholine DGA 3_ 35 210 72.1 61.2 34.1 102 153 35 215 80.4 68.4 26.6 167 224 35 220 85.2 73.4 21.6 282 344 35 230 95.6 85.2 8.8 931 992 90 220 90.4 77.3 12.9 75 88 90 220 90.4 78.8 11.8 87 102 EXAMPLES 4-5 Following the operating procedures of Example 1, two combinations of the nickel-copper-chromium oxide catalyst of Example 1 with different ruthenium-on-alumina catalysts (5% ruthenium-on-alumina, 1/8" (3.2mm) diameter extrudates in Example 4, Table IV, and 0.5% ruthenium-on-alumina, 1/8" (3.2mm) diameter spheres in Example 5 Table V) were tested for diethylene glycol amination over a range of operating temperatures (210-250°C) and, in one case, different hydrogen flow rates (35 and 90 liters/h). Data and results from these runs are summarized in Table IV and V. It may be noted that typically: a) At normal hydrogen flows, 75% DEG conversion per pass is achieved at 210°C, with 251 Kg of CO₂ produced per 10⁵ Kg of DEG converted (see Table IV). b) At 2.6 times the normal hydrogen flows, ca. 88% DEG conversion is achieved at 220°C, with 226-231 Kg of CO₂ produced per 10⁵ Kg of DEG converted. EX. H₂ Flow Rate (l/hr) Reaction Temp. (°C) DEG Conversion (%) Yield(%) Basis DEG Converted Effluent CO₂ Conc. (ppm) CO₂ (Kg) Per 10⁵ Kg DEG Converted Morpholine DGA 5 a 35 210 52.5 45.7 51.4 90 182 35 220 83.0 75.6 20.7 330 419 35 230 93.0 83.0 11.1 510 531 35 240 94.5 78.0 9.8 2770 3060 35 250 96.7 80.4 7.3 3190 3534 EXAMPLE 6 Following the procedures of Example 1, the combination of nickel-copper-chromium oxide catalyst with 0.5% ruthenium-on-carbon, granular, catalyst was tested for diethylene glycol amination over a period of 500 hrs. Data and results from this run are summarized in Table VI. It may be noted that: 1) The dual Ni-Ru catalyst continues to suppress CO₂ effluent concentrations and actually becomes more effective as the run progresses. After 400 h, the CO₂ effluent concentrations are below normal threshold levels. 2) The DEG conversion level remains high - from ca. 88% to 80% - over the life of the catalyst. EX. Time on stream (hrs) DEG conv. % Product yield, % CO₂ conc. (ppm) CO₂(Kg) per 10⁵ Kg DEG conv. Morpholine DGA 6 22 88.7 78.8 14.6 189 233 70 87.9 79.2 14.5 126 151 100 85.6 75.5 17.9 125 167 171 83.5 73.6 20.1 112 143 203 82.1 72.6 21.5 165 210 203 82.1 72.6 21.5 165 210 273 81.8 72.5 22.0 108 146 303 83.1 73.8 20.0 116 153 375 82.5 72.9 20.9 126 155 401 80.2 68.7 23.9 29 37 449 80.8 70.2 23.6 31 40 484 79.7 69.0 24.9 24 31 COMPARATIVE EXAMPLE A Following the operating procedures of Example 1, the 550 cm³ plug reactor was filled with the nickel-copper-chromium oxide catalyst alone and diethylene glycol amination was conducted at feed rates of 0.54 Kg/h of DEG, 1.09 Kg of ammonia and 35 liters/h of hydrogen. Again the operating temperature and pressure were 220°C and 15.27 MPa (2200 psi) respectively. Analyses of the liquid and gas products show: DEG Conversion 82 % Yield of Morpholine 65.3% Yield of DGA 30.3 % Effluent Conc. CO₂ 689 ppm CO₂ Per 10⁵ Kg of DEG Converted 499 Kg

Claims: A process for simultaneously producing a morpholine and a 2-(2-aminoalkoxy) alkanol by reacting an anhydrous dialkylene glycol with ammonia in the presence of added hydrogen over a nickel-copper-chromium oxide catalyst at a temperature of 150 to 300°C and a pressure of 1.45 to 34.60 MPa, characterized in that the nickel-copper-chromium oxide catalyst is used in combination with a supported ruthenium catalyst. A process according to Claim 1 characterized in that the dialkylene glycol has the formula: in which each R is independently hydrogen or alkyl. A process according to Claim 1 or 2 characterized in that the dialkylene glycol is diethylene glycol. A process according to any one of Claims 1 to 3 characterized in that the ruthenium catalyst comprises 0.01 to 30 wt% of ruthenium. A process according to claim 4 characterized in that the ruthenium catalyst comprises 0.1 to 10 wt% of ruthenium. A process according to Claim 4 characterized in that the ruthenium catalyst comprises 0.5 to 5.0 wt% of ruthenium. A process according to any one of Claims 1 to 6 characterized in that the ruthenium catalyst support is carbon, alumina, silica, titania, zirconium, magnesium or a mixture thereof. A process according to any one of Claims 1 to 7 characterized in that nickel-copper-chromium oxide catalyst comprises: 60 to 85 mole % of nickel, 14 to 37 mole % of copper and 1 to 6 mole % of chromium A process according to Claim 8 characterized in that the nickel-copper-chromium oxide catalyst comprises 72 to 78 mole % of nickel, 20 to 25 mole % of copper and 1 to 3 mole % of chromium. A process according to any one of Claims 1 to 9 characterized in that the ratio of nickel-copper-chromium oxide catalyst to ruthenium-based catalyst is from 1:1 to 10:1 by volume.

Inventors: KNIFTON JOHN FREDERICK, KNIFTON, JOHN FREDERICK
Applicants: HUNTSMAN CORP, HUNTSMAN CORPORATION
Application year: 1991
Main classification: C07D295
IPC codes: C07C213, B01J23, C07D295, C07C217, C07B61