PRODUCTION OF HYDROFLUOROCARBONS FROM alpha -FLUOROETHERS AND alpha -FLUOROETHERS

Abstract: A process for the production of a hydro(halo)fluorocarbon which comprises heating an alpha -fluoroether in the vapour phase at elevated temperature. alpha -fluoroethers are obtained by reacting a non-enolisable aldehyde with hydrogen fluoride to form an intermediate and reacting the intermediate with an alcohol or a halogenating agent. Novel alpha -fluoroethers are also provided.

Description: Production of Hydrofluorocarbons from ot-Fluoroethers and ctrFluoroethers This invention relates to a process for the production of hydrofluorocarbons from α-fluoroethers and a process for the production of α-fluoroethers 5 and novel α-fluoroethers suitable for use in the production of hydrofluorocarbons , particularly to a process for the production of hydrofluoroalkanes . In recent years chlorofluorocarbons , which are used on a large scale around the world, have been J ^Q perceived as having an adverse effect on the ozone layer and/or as contributing to global warming. Chlorofluorocarbons are used, for example, as refrigerants, as foam blowing agents, as cleaning solvents and as propellants for aerosol sprays in 5 which the variety of applications is virtually unlimited. Consequently, much effort is being devoted to finding suitable replacements for chlorofluorocarbons which will perform satisfactorily in the many applications in which chlorofluorocarbons 0 are used but which will not have the aforementioned environmentally harmful effects. One approach in the search for suitable replacements has centred on fluorocarbons which do not contain chlorine but which may contain hydrogen, that is hydrofluorocarbons, of 5 which many have been proposed as suitable replacements . Several methods for the preparation of hydrofluorocarbons are known but many of these methods involve the use of chlorine-containing starting materials and the production of chlorine-containing by-products. The present invention provides a chlorine-free process for the production of hydro luorocarbons and a process for the production of hydrohalofluorocarbons _ According to the. present invention there is provided a process for the production of a hydro(halo)fluorocarbon which comprises heating an α-fluoroether in the vapour phase at an elevated temperature. By an α-fluoroether there is meant an ether having a fluorine atom attached to a carbon atom in the α~position relative to the oxygen atom, that is an ether containing the group -C-O-CF- and thus an ether having the general formula R-0-CF?_ R2, wherein R, R.1 and R^ are as hereinafter defined. We have found that α-fluoroethers of formula R-O-CF-R^R^ may be caused to breakdown upon heating to yield a hydro(halo} luorocarbon R-F and a compound containing a carbonyl group, usually an aldehyde R^-R^CO. The ether apparently breaks down by transference of an α-fluorine atom from one α-carbon atom to the other α-carbon atom to yield a hydro(halo)fluorocarbon R-F (referred to hereafter as the fluorine-exchange product). The ether may in some cases also break down by transference of an α-hydrogen atom so that a hydro(halo)fluorocarbon R-H (referred to hereafter as the hydrogen-exchange product) may also be produced, α-fluoro-ethers may therefore be utilised as useful starting materials for the production of hydro(halo)fluoroalkanes . In the α-fluoroether R-0-CF-R 1 R 2 , the group R may generally take any form provided that it comprises at least one carbon atom, and the group R may for example be saturated or unsaturated, cyclic or acyclic. Furthermore, the group R may be aliphatic or aromatic and it may be a substituted group such as a halo-substituted group. The process of the invention is useful in particular for the production of hyir fluoroalkanes from ethers in which the R group is an alkyl group which may comprise one, two or even more carbon atoms, say up to 6 or even more carbon atoms. The alkyl group R will usually be a straight chain alkyl group although it may also be a branched chain alkyl group.The group R may comprise only carbon and hydrogen although it may contain other atoms such as halogen atoms; usually the group R will be a fluorinated group. The α-fluoroether will typically be an α-fluoroalkyl ether, that is an ether of formula R-0-CF-R 1 R 2 wherein R 1 and R 2 each represents a hydrogen atom or an alkyl or substituted alkyl group which may comprise one, two or even more carbon atoms, say up to 6 or even more carbon atoms, provided that where R! and R 2 both are hydrogen, R is not the -CH2F group. The alkyl groups R 1 and R 2 will usually be straight chain alkyl groups although they may also be branched chain alkyl groups. The groups R 1 and R 2 may comprise only carbon and hydrogen although they may be substituted alkyl groups; usually the groups R 1 and R 2 will be fluorinated groups. Typically at least one of Rl and R 2 will be a hydrogen atom. According to a preferred embodiment of the invention there is provided a process for the production of hydro(halo)fluoroalkanes which comprises heating an α-fluoroether having the formula R-0-CF-R^R 2 wherein R is an alkyl or substituted alkyl group comprising from 1 to 6 carbon atoms and R 1 and R 2 each is H or an alkyl group containing from 1 to 6 carbon atoms. The α-fluoroether is preferably an α-fluoromethylether, R-O-CFH 2 , or a tetra luoroethylether R-O-CFH-CF3, since these α-fluoroethers are readily prepared and on heating in the vapour phase to elevated temperature yield particularly useful hydrofluorocarbons. The α-fluoromethylether may be, for example, FCH2-O-CH3 (fluoromethyl- ethylether) , FCH2-O-CH CF2H (1,1,-difluoroethyl-fluoromethyl ether), or FCH2-O-CH2CF3 (1,1,1-trifluoroethyl- fluoromethylether) , which when heated in the vapour phase to elevated temperature may give the following hydrofluoroalkanes respectively, CH3F, CHF2CH2F and CF3CH2F. The tetrafluoroethylether may be, for example, CF3CHF-O-CH2CF3 or CF3CFH-O-CH3 (which upon heating in the vapour phase to elevated temperature may yield 1,1,1,2-tetrafluoroethane) or CF3CFH-O-CFHCF3 or CF3CHF-O-CH2F (which upon heating in the vapour phase to elevated temperature may yield CF 3 CF2H and/or CF3CFH2). According to an embodiment of the invention there is provided a process for the production of 1,1,1,2-tetrafluoroethane comprising heating an α-fluoroalkylether selected from the group consisting of FCH2-O-CH2CF3 , FCH2-O-CHFCF 3 , CF 3 CHF-O-CH2CF3 and CF3CFH-O-CH3 in the vapour phase at an elevated temperature. According to another embodiment of the invention there is provided a process for the production of pentafluoroethane comprising heating CF 3 CFH-O-CFHCF 3 or CF 3 CFH-O-CH 2 F in the vapour phase at an elevated temperature. Heating of the α-fluoroether may advantageously be carried out in the presence of hydrogen fluoride vapour since we have found that the presence of hydrogen fluoride may, at least with certain α-fluoroethers, tend to increase the yield of hydro(halo)fluorocarbon obtained . Heating of the α-fluoroether may also advantageously be performed in the presence of a catalyst. The conversion of the α-fluoroether and selectivity to the hydro(halo)fluoroalkane are dependent in particular upon the catalyst in the presence of which the α-fluoroether is heated; we have found that certain catalysts promote a high degree of selectivity to the fluorine-exchange product whilst other catalysts promote a high degree ' of selectivity to the hydrogen exchange product and still other catalysts yield mixtures of both the fluorine-exchange and hydrogen- exchange products. Furthermore, whether the fluorine-exchange product or hydrogen exchange product is promoted by a particular catalyst is also dependent at least to some extent upon the particular α-fluoroether . Thus with certain α-fluoroethers a particular catalyst may promote fluorine-exchange whilst the same catalyst may promote hydrogen-exchange with other α-fluoroethers. It is to be understood that the process of the invention may lead to a product comprising a mixture of hydro(halo)fluoroalkanes from a single α-fluoroether. Thus, for example, where the α- luoroether is CH2F-O-CH2CF3 the product may be a mixture of CH3CF3 and CF3CH2F. Furthermore, desirable mixtures of hydrofluoroalkanes may be produced, as desired, by employing mixtures of α-fluoroethers. Thus, for example, where a mixture of CH2 -O-CH2 and CF3CH2-O-CH2F is heated to elevated temperature, the product may comprise a mixture of CH2 2. CH3F and CF3CH2F. The catalyst may be for example, a metal, for example a metal selected from the group consisting of nickel, iron, copper and chromium, or an alloy, oxide, fluoride or oxyfluoride thereof, for example chromia or alumina, aluminium or chromium fluoride, ' or a metal oxyfluoride. We have found that in general the fluorine-exchange product may be produced with very high selectivity where the catalyst employed is a metal selected from the group consisting of nickel, iron, copper or chromium and in particular where the catalyst is an alloy of at least one of these metals. We especially prefer to employ an alloy of all these metals, for example Hastelloy or stainless steel. Furthermore we prefer that the alloys are air treated prior to use, that is the alloys are heated to elevated temperature in the presence of air, for example a temperature in the range from 300°C to 500°C. Alternatively or additionally, the catalyst pre- reatment may comprise heating the catalyst in the presence of hydrogen fluoride. A further preferred catalyst is chromia which although it may not promote a very high degree of selectivity to the fluorine-exchange product, is a very robust catalyst. Chromia may also be given a pre-treatment prior to its use. Catalysts which in general lead to the production of the hydrogen-exchange product with a high degree of selectivity include for example catalysts comprising zinc on chromia or zinc impregnated chromia. The temperature to which the α-fluoroether is heated to produce a hydro(halo)fluoroalkane is such that the α-fluoroether is in the vapour phase and the temperature will therefore depend at least to some extent on the particular α-fluoroether employed. Generally the temperature will be at least 80°C, usually at least 200°C and preferably at least 350°C. The temperature need be no higher than about 500°C although higher temperatures, say up to about 700°C, may be used if desired. The temperature to which the α-fluoroether is heated is also dependant at least to some extent on whether the heating is effected in the presence or absence of a catalyst. Where the heating is effected in the presence of a catalyst the preferred temperature is dependent on the particular catalyst used; generally where one of the aforementioned metals or alloys is present the temperature need not be as high as when one of the aforementioned metals or alloys is not present. Typically the temperature need be no higher than about 450°C where a catalyst is used in the presence of hydrogen fluoride. Thus, for example, where the heating is effected in the presence of stainless steel and hydrogen fluoride the temperature is preferably at least about 250°C and more preferably at least 300°C but need be no higher than about 400°C, generally no higher than about 350°C. However, where the fluorination catalyst is chromia in the presence of hydrogen fluoride the temperature is preferably from about 180°C to about 320°C, more preferably from about 200°C to about 280°C. The process of the invention is conveniently carried out at about ambient pressure although superatmospheric or subatmosphe ic pressures may be used if desired. Superatmospheric pressures up to about 10 bar at lower temperatures are generally preferred since the yield of hydro(halo)fluorocarbons is often Increased under such conditions. After completion of the reaction, the hydro(halo)fluorocarbon may be isolated from unchanged starting materials and undesired by-products using conventional procedures, for example distillation. It is particularly convenient to operate the process of the invention as a continuous process wherein unchanged α-fluoroether and any hydrogen fluoride present in the hydro(halo)fluorocarbon product stream are recycled to the reaction zone. Q _ A particularly convenient and thus preferred general method for the production of the α-fluoroether is by reacting a non-enolisable aldehyde with hydrogen fluoride (in the liquid phase or in the vapour phase) and reacting the resulting intermediate with an alcohol or a halogenating agent to form an α-fluoroether . A non-enolisable aldehyde is required in order that the aldehyde is not polymerised in hydrogen fluoride when the two are reacted together. According to a preferred embodiment of the invention there is provided a process for the production of a hydro (halo )fluorocarbon which comprises (a) reacting a non-enolisable aldehyde with hydrogen fluoride to form an intermediate and reacting the intermediate with an alcohol or a halogenating agent to produce an α-fluoroether and (b) treating the α-fluoroether whereby to form a hydro(halo)fluoroalkane . The treatment of the α-fluoroether whereby to form a hydro (halo ) fluoroalkane may be, for example, as hereinbefore described by heating to elevated temperature in the vapour phase. The intermediate obtained by reacting the non-enolisable aldehyde with hydrogen fluoride may be reacted with the alcohol or halogenating agent in a number of ways. The aldehyde and the hydrogen fluoride may be reacted in the presence of alcohol or halogenating agent. Alternatively the aldehyde and the hydrogen fluoride may be reacted to form an equilibrium mixture containing the intermediate and the alcohol or halogenating agent may be added to the equilibrium mixture. In a modification of this alternative, the intermediate may be separated from the equilibrium mixture before it is reacted with the alcohol or halogenating agent. i is to be understood that the intermediate derived from the non-enolisable aldehyde and hydrogen fluoride may itself be an α-fluoroether and that incomplete reaction of such an intermediate with the alcohol or halogenating agent may therefore result in a mixture of α-fluoroethers. Whilst an intermediate α-fluoroether is not the starting material for use in the process for producing a hydro(halo) fluorocarbon according to the invention, a mixture of α-fluoroethers containing unreacted intermediate α-fluoroether is a suitable starting material for use in the invention. α-fluoroethers containing halogen other than fluorine, particularly chlorine or bromine, may be employed as starting materials for the production of hydrohalofluorocarbons containing a halogen atom other than fluorine. Such α-fluoroethers may be produced by reacting the intermediate derived from a non-enolisable aldehyde and hydrogen fluoride with a suitable halogenating agent to effect exchange of fluorine by halogen other than fluorine. The halogenating agent may be a halogen-containing Lewis acid such as antimony pentachloride, niobium pentachloride , aluminium chloride and sodium bromide. The non-enolisable aldehyde is preferably formaldehyde or trifluoroacetaldehyde; formaldehyde is particularly preferred. In an embodiment of the invention both formaldehyde and trifluoroacetaldehyde are reacted with hydrogen fluoride to produce a mixture of CF 3 CFH-O-CH2F and CH2F-O-CH 2 F. The mixture of aldehydes generates an alcohol in situ and the resulting α-fluoroether mixture may be converted to hydrofluoroalkanes . If desired, a separate alcohol may be added to the mixture to produce further α-fluoroethers. In the embodiment of the invention, comprising the steps of (a) producing an α-fluoroether and (b) heating the α-fluoroether in the vapour phase at an elevated temperature to form a hydro(halo)fluorocarbon, both of steps (a) and (b) employ elevated temperature and both may employ a catalyst so that in practice at least' a part of the α-fluoroether produced in step (a) may be converted to a hydro(halo)fluorocarbon (step b) without a change in reaction conditions. However, we have found that for optimum results different catalysts are preferred in step (a) and step (b); the process then comprises operation of step (a) using a first catalyst to produce an α-fluoro- ether and a hydro(halo)fluorocarbon and operation of step (b) using a second catalyst to convert unreacted α-fluoroether from step (a) to the hydro(halo)fluorocarbon. The non-enolisable aldehyde may be provided in any of its known forms. Thus formaldehyde may be provided, for example, in one of its polymeric forms, paraformaldehyde or trioxane , or in its monomeric form which may be provided, for example, from a process stream in which it has been freshly made, for example by the oxidation of methanol. Trifluoroacetaldehyde may be provided, for example, in its hydrated form CF3CH(OH 2 ~> r -*>- itε deydrated form CF3CHO. Accordingly, whenever used herein the term non-enolisable aldehyde is to be understood as including non-enolisable aldehydes in any of their known forms. In general, where formaldehyde is used as the non-enolisable aldehyde, a polymeric form of formaldehyde such as paraformaldehyde is preferred where the formaldehyde is dissolved in liquid hydrogen fluoride. Paraformaldehyde and trioxane dissolve readily in liquid hydrogen fluoride and the production of the intermediate for the α-fluoroether may be conveniently carried out by dissolving paraformaldehyde or trioxane in liquid hydrogen fluoride at about room temperature and at about atmospheric pressure. The molar ratio of the non-enolisable aldehyde to hydrogen fluoride may vary considerably, for example in the range about 1:0.5 to 1:50 but in general a εtoichiometric excess of hydrogen fluoride is preferred. Typically, the molar ratio of non-enolisable aldehyde to hydrogen fluoride will be in the range about 1:2 to about 1:10. In one embodiment of the invention the non-enolisable aldehyde is reacted with hydrogen fluoride in the presence of an alcohol. In this case, the alcohol may be generated in situ. Thus, for example, reaction of the non-enolisable aldehyde trifluoroacetaldehyde with hydrogen fluoride is believed to yield an alcohol CF 3 CHFOH which may then condense to give the α-fluoroether CF CFH-O-CFHCF 3 . A wide range of α-fluoroethers may be produced by adding a separate alcohol. Where a separate alcohol is added, it may be added at the same time as the hydrogen fluoride and non-enolisable aldehyde, or it may be added subsequently to the mixture of aldehyde and hydrogen fluoride. Furthermore the alcohol may be first added to the hydrogen fluoride and the aldehyde may then be added to this reaction mixture. Thus the order of addition of the hydrogen fluoride, aldehyde and alcohol is not critical. Where the alcohol is added separately, a primary alcohol is preferred which may have the general formula R-OH where R is as hereinbefore described. The alcohol must be inert to hydrogen fluoride and the α-fluoroether. The group R becomes the R group of the ether produced having the general formula R-O-CF-RiR 2 , the groups R 1 and R 2 being as hereinbefore described. The group R will usually be a straight chain alkyl or substituted alkyl group although it may also be a branched chain group. The R group may comprise only hydrogen and carbon, for example the R group may be CH3 or C2H5. Preferably however, the R group will be fluorinated, for example the R group may be FCH2CH2-. HCF 2 CH 2 -. CF3CH2-. (CF 3 ) 2 CH-, or CF2HCF2CH2-- The alcohol R-OH is preferably a primary alcohol and may be, for example, methanol, ethanol, 2-monofluoroethanol , 2,2-difluoroethanol , 2 , 2 ,2-trifluoroethanol , hexafluoroisopropanόl or 1,1.2,2-tetrafluoropropanol. Some at least of the alcohols may be generated in situ, for example by adding an epoxide to the non-enolisable aldehyde/hydrogen fluoride mixture. Thus for example, 2-monofluoroethanol may be generated in situ by the addition of ethylene glycol which reacts with hydrogen fluoride to produce 2-monofluoroethanol . Where the alcohol is added separately, it may be added in similar proportions as the non-enolisable aldehyde, that is In the molar ratio of alcohol to hydrogen fluoride in the range about 1:0.5 to 1:50 but in general a stoichiometric excess of hydrogen fluoride Is preferred. The optimum pronortion of alcohol added may depend upon the particular alcohol used since we have found that with certain alcohols. the addition of too great a proportion of the alcohol leads to the formation of an undesirable acetal rather than the required α-fluoroether. Typically the molar ratio of alcohol to hydrogen fluoride will be in the range of from about 1:2 to about 1:10. A number of the α-fluoroethers produced by the process of the invention are novel compounds and the following α-fluoroethers are provided according to the invention:- Fluoromethyl-fluoroethyl ether of formula CH2 CH2OCH2 whose mass spectrum is shown in Figure 1 of the drawings. Fluoromethyl-difluoroethyl ether of formula CHF2CH2OCH2 whose mass spectrum is shown in Figure 2 of the drawings. Fluoromethyl-trifluoroethyl ether of formula CF3CH2OCH whose mass spectrum is shown in Figure 3 of the drawings. - ι: Fluoromethyl-tetrafluoropropyl ether of formula CH 2 2CH2OCH2 whose mass spectrum iε shown in Figure 4 of the drawings. Fluoroethyl-tetrafluoroethyl ether of formula CF3CHFOCH2CH2F whose mass spectrum is shown in Figure 5 of the drawings. Fluoromethyl-chloromethyl ether of formula CH2 OCH2CI whose mass spectrum is shown in Figure 6 of the drawings. Fluoromethyl-bromomethyl ether of formula CH2 0CH2Br whose mass spectrum is shown in Figure 7 of the drawings . Figure 8 of the drawings shows the mass spectrum of fluoromethyl-tetrafluoroethyl ether of formula CF3CHFOCH2F. This ether has been isolated from the mixture in which it was produced and its boiling point was determined as 47.5°C. The α-fluoroether may be isolated from the mixture in which it is produced, and any by-products, before the α-fluoroether is heated to elevated temperature. The ether may be isolated, for example, by adding alkali to the mixture and heating the resulting alkaline solution, for example up to about 50°C, in order to drive off the α-fluoroether . Alternatively the α-fluoroether may conveniently be isolated by contacting the product stream with water at a temperature in the range from about 50°C to about 80°C. The α-fluoroether may then be collected in a cold trap or passed directly to the heating zone. The α- f luoroe the r may be introduc ed into the heating zone in undiluted f orm although it i s generally convenient to introduce it in conjunction with a diluent such as an inert carrier gas, for example nitrogen. In the embodiment of the invention wherein the α-fluoroether is generated by dissolving a non-enolisable aldehyde in liquid hydrogen fluoride and reacting the resulting intermediate with an alcohol, the α-fluoroether and the hydrogen fluoride in which it Is dissolved may be vaporised toεet-her into the heating zone together with any unreacted aldehyde in the solution. In this case it may be a mixture of α-fluoroethers which is vaporised into the heating zone, so that a mixture of hydrofluoroalkanes are produced by heating the mixture of α-fluoroethers to elevated temperature. We especially prefer that the α-fluoroether and optionally hydrogen fluoride are separated from water which is also produced by tne reaction of the non-enolisable aldehyde with hydrogen fluoride. Thus the α-fluoroether and optionally hydrogen fluoride are preferably passed to the heating zone in the substantial absence of water. Separation of the α-fluoroether and optionally hydrogen fluoride from water may be achieved in any suitable manner, conveniently for example by vaporising the α-fluoroether and optionally hydrogen fluoride from the product mixture or by contacting the product mixture with a solid drying agent. Thus for example a stream of an inert gas, for example nitrogen may be sparged through the product mixture. Accordingly, in a further embodiment of the invention there is provided a process for the production of a hydrofluoroalkane which comprises the steps of (a) reacting a non-enolisable aldehyde with liquid hydrogen fluoride and reacting the resulting intermediate with an alcohol to produce an α-fluoroether, (b) separating at least some water from the product of step (a) and (c) passing the α-fluoroether and hydrogen fluoride from step (b) in the vapour phase into a reaction zone at elevated temperature . In the embodiment where the non-enolisable aldehyde, hydrogen fluoride and alcohol are reacted in the vapour phase to produce the α-fluoroether, the product stream may be passed directly to a second reaction zone, after drying if desired, optionally together with additional hydrogen fluoride and a diluent such as nitrogen gas. Where the α-fluoroether is generated in the liquid phase, the non-enolisable aldehyde/hydrogen fluoride/alcohol liquid mixture is preferably held in the liquid phase in order to prevent any premature decomposition of the α-fluoroether such as may occur in the vapour phase. The temperature of the liquid mixture is therefore conveniently maintained below the boiling point of the product mixture, preferably at a temperature from about -10°C to about 20°C. The invention is illustrated, but not limited, by the following examples. PRODUCTION OF α-FLUOROETHERS EXAMPLE 1 24g of anhydrous liquid hydrogen fluoride were added with cooling to 5g of trioxane and to this mixture was added 0.042 moles of methanol. The mixture was sampled immediately and analysed by Gas chromatography/Mass Spectrometr . The volZ composition of the mixture was determined to be: Component volZ composition methanol 1.61 CH3-O-CH2F 14.4 CH2F-O-CH2F 66.8 CH3-O-CH2-O-CH3 13.7 Trioxane 3.4 EXAMPLE 2 The procedure of example 1 was repeated except that 0.073 moles of ethanol were employed. The volume Z composition of the mixture was determined to be: Component volZ composition ethanol 5.7 CH3CH2-O-CH2F 17.8 CH2F-O-CH2F 36.5 CH3CH2-O-CH2-O-CH2CH3 35.2 Trioxane 2.1 EXAMPLE 3 The procedure of example 1 was repeated except that 0.073 moles of 2-fluoroethanol were employed. The volume Z composition of the mixture was determined to be: Component volZ composition 2-fluoroethanol 5.7 CH 2 FCH2-0-CH 2 F 29.0 CH 2 F-0-CH 2 F 45.0 CH2FCH2-O-CH2-O-CH2CH2F 10.0 Trioxane 4.7 EXAMPLE 4 The procedure of example 1 was repeated except that 0.073 moles of 2, 2-difluoroethanol were employed. The volume Z composition of the mixture was determined to be: Component volZ composition 2,2-difluoroethanol 4.7 CF 2 HCH2-0-CH 2 F 59.2 CH 2 F-0-CH 2 F 30.8 CF2HCH2-O-CH2-O-CH2CF2H 3.6 Trioxane 0.0 EXAMPLE 5 The procedure of example 1 was repeated except that 0.073 moles of 2 , 2 , 2-trifluoroethanol were employed. The volume Z composition of the mixture was determined to be: Component volZ composition 2,2, -trifluoroethanol 11.1 CF3CH2-O-CH2F 62.3 CH 2 F-0-CH 2 F 17.0 CF3CH2-O-CH2-O-CH2CF3 9.5 Trioxane 0.0 EXAMPLE 6 The procedure of example 1 was repeated except that 0.042 moles of 1,1, 2, 2-tetrafluoropropanol were employed. The weight Z composition of the mixture was determined to be: Component volZ composition 1,1,2,2-tetrafluoropropanol 7.85 CF2HCF2CH2-O-CH2F 59.6 CH2F-O-CH2F 29.3 CF2HCF2CH2-O-CH2-O-CH2CF2CF2H 1.4 Trioxane 1.9 EXAMPLE 7 O.Scms 3 of trifluoroacetaldehyde in the form of its hydrate CF3CH(0H)2 was added to 6 cms 3 of anhydrous liquid hydrogen fluoride and the mixture was analysed by nuclear magnetic resonance. Analysis indicated that the ether CF3CHF-O-CHFCF3 was the major product. EXAMPLE 8 6 cms 3 of anhydrous liquid hydrogen fluoride were added with cooling to 1.25g of paraformaldehyde and to this mixture was added 0.5 cms 3 of CF3CH(0H)2> Gas chromatography and Mass spectrometry indicated that the ethers CF3CHF-O-CH2F and CH2F-O-CH2F were the main products. DECOMPOSITION OF ETHERS EXAMPLE 9 The product mixture of example 1 was sparged with nitrogen at a flow rate of 50cms 3 per minute and the sparged mixture was fed to an Inconel tube packed with 200cms 3 of Hastelloy C mesh and heated to an elevated temperature. The off gas was scrubbed with water and analysed by Gas chromatography. At 257°C the composition of the off gas was: Component. Z v/v. CH3F 19.2 CH2F2 60.8 CH2F-O-CH2F 20.0 EXAMPLE 10 The procedure of example 9 was repeated except that the product mixture of example 5 was sparged with nitrogen and the Inconel tube was packed with 200cms 3 of chromia pellets. At 350°C the composition of the off gas was: Component- Z v/v CH 3 F 31.5 CH2F2 46.6 CF3CH2F 13.9 CF3CH3 0.4 CH2F-O-CH2F 1.0 Others 6.6 EXAMPLE 11 The procedure of example 9 was repeated except that the product mixture of example 6 was sparged with nitrogen. Mass spectrometry indicated that 1,1,2,2, 3-pentafluoropropane was the major product. EXAMPLE 12 The procedure of example 9 was repeated except that the product mixture of example 4 was sparged with nitrogen and the Inconel tube was packed with 115ml (70g) stainless ' steel rings which had been air-treated by heating the rings to 350°C in a stream of air for 4 hours. At 350°C, the composition of the off gas was: Component Z v/v CH 2 F 2 4.5 CF2HCH2F 23.8 CF 2 HCH 2 0H 4.2 CH2F-O-CH2F 44.5 CF 2 HCH2-0-CH 2 F 21.1 Others 1.9 EXAMPLE 13 0.4g (0.012 moles) of methanol were added to 1.7g (0.021 moles) of BFME with stirring and cooling 10 ml (0.5 moles). HF or 98Z H2SO were added and the mixture stirred at room temperature prior to analysis by gas chromotography and mass spectrometry. Found: Z (by GC) Bis-fluoromethyl ether (BFME) 55.0 Fluoro methyl ether 27.3 Methanol 7.05 Bis ( fluoromethoxy)methane 0.62 Dimethoxy methane 8.0 Trioxane 1.64 EXAMPLE 14 Trioxane (10g,0.33 moles) was added to HF (48g,2.4 moles) with stirring. Ethanol (1.72g, 0.037 moles) was carefully added dropwise, with stirring and cooling. Analysis of the products by mass spectrometry showed the main components to be BFME and the acetal diethoxymethane. Fluoromethyl ethyl ether, C2H5OCH2F, was also identified. EXAMPLE 15 2-fluoroethanol (4.67g, 0.073 moles) was added to a mixture of trioxane (5g, 0.167 moles) in HF (24g, 1.2 moles). After stirring for 30 minutes, the products were analysed: Found Z (by GC) BFME 32.1 Fluoromethyl methyl ether 1.4 2-fluoroethanol 58.5 Fluoromethyl 2-fluoroethyl ether 6.3 Bis(fluoromethoxy)methane 0.06 Trioxane 1.0 EXAMPLE 16 1.5g (0.018 moles) 2,2-difluoroethanol was added to 1.7g (0.021 moles) BFME. 0.25 ml (0.0125 moles) HF or 98Z H2SO were added and the mixture stirred for 20-30 minutes before sampling Found: Z (by GC) BFME 31.8 Fluoromethyl2,2-difluoroethyl ether 27.3 2,2difluoroethanol 1.6 Bis (fluoromethoxy)methane 3.1 CHF2CH2OCH2OCH2F 3.9 Trioxane 1.2 EXAMPLE 17 3.7g (0.037 moles) of 2 , 2 , 2-trifluoroethanol were added to 3.4g (0.021 moles) BFME with cooling and stirring. 0.3 ml (0.015 moles) HF or 98Z H2SO4 were added and the mixture sampled after stirring at room temperature for 20-30 minutes. Found: Z (by GC) BFME 15.9 Fluoro methyl2,2 , 2-trifluoroethyl ether 63.4 Trifluoroethanol 1.5 CF3CH2OCH2OCH2F 5.8 CF3CH2OCH2OCH2OCH2F 12.3 EXAMPLE 18 lOg of 1H 1H 3H-tetrafluoropropanol were added to a mixture of 6g trioxane in 20g HF. After stirring the mixture was analysed. Found: Z (by GC ) BFME 23.6 Fluoromethyl 2,2,3,3 tetrafluoropropyl- ether 67.0 1H, 1H, 3H-tetrafluoropropanol 4.3 Bis (fluoromethoxy)methane 1.3 CF2HCF2CH2OCH2OCH2F 2.15 Trioxane 1.5 EXAMPLE 19 Trioxane (lg, 0.033 moles) was added to HF (5g, 0.25 moles) and the mixture cooled. Hexafluoroisopropanol (2.38g, 0.0142 moles) was added and the products analysed after 5 minutes stirring. Found: Z (by GC) ° BFME 22.2 (CF3)2CH0CH 2 F 4.9 Hexafluoroisopropanol 71.6 (CF 3 )2CH0CH 2 0CH 2 F 1.3 EXAMPLE 20 SbCls (l.lg, 0.0051 moles) was added to a cooled vessel containing BFME (2.0g, 0.0244 moles) and stirred. The contents of the head above the solution were analysed after 1 hour. The experiment was then repeated, with the addition of 2g HF. Found: BFME Dif luoro e thane Methyl chloride Chlorof luoromethane Dichlorome thane Chloromethyl flurαmethyl- ether Bis(chloromethyl)ether EXAMPLE 21 bCls (0.3g, 0.0016 moles) was added to BFME (1.7g, 0.021 moles) and the head soace analysed afte: stirring for about an hour. Found: Z (by infra red) BFME 88.6 Difluoromethane 0.034 Methyl fluoride 0.012 Fluoromethyl methyl ether 0.57 Chloromethyl fluromethyl- ether 10.5 Bis (chloromethyl)ether 0.28 EXAMPLE 22 Aluminium chloride (0.5g, 0.06 moles) was added to BFME (2.0g, 0.0244 moles) with stirring. The head space was analysed by infra red spectroscopy. The experiment was then repeated with the further addition of HF (0.2g, 0.01 moles). Found: Z (by infra red) without HF with HF BFME 97.57 87.0 Difluoromethane 0.044 0.17 Methyl fluoride - 0.014 Fluoro methyl ether 0.024 0.056 Dichloromethane - 0.09 Bis(fluoromethoxy)methane 0.17 0.1 Chloromethyl fluromethyl- ether 2.19 12.56 EXAMPLE 23 lOg of paraformaldehyde were added to 48g HF and the mixture stirred. 15g of sodium bromide were added, 5g at a time. On addition of the final 5g, the mixture separated into two layers. The bottom layer was analysed and found to contain a mixture of BFME, bromomethyl fluoromethyl ether and bis(bromomethyl) ether. The experiment was repeated using BFME and HBr. HBr was bubbled through BFME (4g, 0.049 moles) for 5-10 minutes. One layer was observed; this was analysed by mass spectroscopy and found to contain BFME and bromomethyl fluoromethyl ether as the main products, with a small amount of bis(bromomethoxyJmethane also present. EXAMPLES 24-27 In these examples ethers were sparged directly from trioxane/HF equilibrium mixture + alcohol and as such were co-fed with BFME. Reaction products therefore contain CH2F2 and CH3F from this source. EXAMPLE 24 The following composition was sparged over a Hastelloy C (20 ml) catalyst held in a 1" tube at 257°C. Percentage CH3OH 1.61 BFME 66.8 CH 3 0CH 2 F 14.4 Dimethoxymethane 13.7 Trioxane 3.4 The off gases were scrubbed with water prior to analysis by GC . Found CH3F CH 2 F 2 BFME EXAMPLE 25 The following composition was sparged over stainless steel rings (115 1) at 324°C:- Z BFME 14.5 2,2 difluoroethanol 42.3 Fluoromethyl 2,2- difluoroethyl ether 41.4 Found Z (by GC) CH 2 F 2 ' 4.4 CH 2 FCHF 2 23.5 BFME 44.05 Fluoromethyl methyl- ether 1.9 2,2 difluoroethanol 4.1 Fluoromethyl 2,2,- difluoroethyl ether 20.9 EXAMPLE 26 The following composition was sparged over chromia catalyst (200 ml) at 350°C:- Z CF3CH2OCH2F 61.3 BFME 16.8 Trifluoroethanol 11.0 CF3CH2OCH2OCH2F 9.4 Trioxane 1.6 Found Z (by GC) CH3F 31.5 CH F2 46.6 BFME 1.0 CH3CF3 0.4 CF3CH2F 13.9 Others 6.6 EXAMPLE 27 The ether/BFME was separated from equilibrium mixture and CF2HCF2CH2OH and the following composition sparged over Hastelloy C ^120 ml) at 259°C. Z (by infra red) BFME 4.1 Fluoromethyl 2,2,3,3- tetrapropyl ether 68.5 Bis (fluoromethoxy)- ether 2.1 1H, 1H, 3H tetra- fluoropropanol 4.3 CF2HCF2CH2OCH2OCH2F 20.8 Found Z (by infra red) Fluoromethyl 2,2,3,3- tetrafluoropropyl- ether 60.3 1H, 1H, 3H tetra- fluoropropanol 1.0 CH3F 1.2 CH2 2 0.7 CH2FCF 2 CH 2 F 12.8 Others 24.0 EXAMPLE 28 Fluoral hydrate (0.5g, 0.0043 moles) was added to a mixture of paraformaldehyde (1.25g, 0.0417 moles) and HF (6.0g, 0.3 moles) and the mixture analysed after stirring for 30 minutes. Found Z (by mass spec) BFME 59.5 Fluoral hydrate 0.37 CF 3 CHFOCH 2 F 27.8 CF3CHFOCH2CH3 0.29 CH2FOCH OCH2F 1.5 Trioxane 1.79 EXAMPLE 29 Methanol (0.6g, 0.0187 moles) was added to fluoral hydrate (1.7g, 0.0146 moles) with stirring and cooling. HF (2.2g, 0.11 moles) was added and the reaction product analysed after stirring. Found Z (by infra red) Methanol 3.6 Fluoral hydrate 46.4 Methyl 1,2,2,2- tetrafluoroethyl- ether 48.3 Ethyl 1,2,2,2- tetrafluoroethyl ether 1.7 EXAMPLE 30 Ethanol (1.9g, 0.041 moles) was added to fluoral hydrate (2.6g, 0.022 moles) with stirring and cooling. HF (2.0g, 0.1 moles) was then added and the mixture analysed after 30 minutes stirring. Found Z (by infra red) Ethanol 94.9 Fluoral hydrate 1.6 Ethyl 1,2,2,2- tetrafluoroethyl- ether 3.65 EXAMPLE 31 2-fluoroethanol (3.0g, 0.047 moles) was added to fluoral hydrate (4.3g, 0.037) with stirring and cooling. HF (5.0g, 0.25 moles) was added and the mixture was analysed after stirring for 30 minutes. Found Z (infra red) Fluoral hydrate 65.1 Methanol 3.5 Acetaldehyde 2.8 Trifluoroethanol 0.8 2-fluoroethanol 27.2 2* -fluoroethyl- } 1,2,2,2 tetrafluoro- } 0.62 ethyl ether } EXAMPLE 32 PREPARATION OF FLU0R0METHYL-2,2,2-TRIFLU0R0ETHYL ETHER lOOg of anhydrous HF were added to 20g of trioxane in a plastic bottle cooled in crushed ice. To the solution was added 50g of trifluoroethanol. The resulting solution was added slowly to 500 ccs of crushed ice to produce an aqueous and an organic layer. The organic layer was separated off and distilled to give 99Z pure ether (G.C/MS . ,NMR) . PREPARATION OF CATALYST FOR DECOMPOSITION OF ETHER The catalysts were sieved to give particles in the range 1.18 mm to 0.25 mm and then packed into a stainless steel tube. They were prefluorinated by sparging HF with nitrogen at a flow rate of 50 ccs per min and passing the vapours over the catalyst at 350 C C for 4 hours. DECOMPOSITION OF ETHER 5g of ether were dissolved in 15g of HF and sparged over the catalyst with nitrogen at a flow rate of 20 cc per min. The off gas was scrubbed with water and analysed by G.C. 143a 5.5Z 32 11.4Z 41 1.9Z CO 3.0Z 90Z Fe 203 unchanged ether 16.3Z 10Z Cr 203 134a 43Z 6 500°C 143a 4.7Z lOcc 32 7.7Z 41 9.3Z CO 16.4Z 42Z CuO 58Z Cr203 unchanged ether <1Z 6 400°C 134a 52Σ lOcc 143a 26Z 32 8Z 41 ∑ CO 7Z EXAMPLE 33 PREPARATION OF FLϋOROMETHYL-1, 2, 2, 2-TETRAFLU0R0ETHY ETHER, CF 3 CHF0CH F Trioxane (lOg, 0.33 moles) was added to anhydrous HF (150g, 7.5 moles) with stirring and cooling. Fluoral hydrate (lOg, 0.086 moles) was added to the mixture which was analysed after 24 hours. Found (Z by mass spectrometry) BFME 46.6 CF3CHFOCH2F 41.05 CF3CHFOCH2OCH2 5.8 Unknown 5.2 CF3CHFOCH3 1.3 EXAMPLE 34 Ethanol (3.24g, 0.0704 moles) was added to a cooled, stirred mixture of trioxane (5g, 0.166 moles) in HF (24g, 2,2 moles). The products were analysed by GC and mass spectrometry. Found (Z by mass spec.) BFME 36.5 Diethoxy ethane 35.2 Fluoromethyl ether ether 17.8 Ethanol 5.7 BFMM 2.8 Trioxane 2.06 EXAMPLE 35 Hexafluoroisopropanol (2.38g, 0.02 2 moles) was added to a cooled, stirred mixture of trioxane (lg, 0.0133 moles) in HF (5g, 0.25 moles). After stirring for 5 minutes, the mixture was analysed by mass spectrometry. Hexafluoroisopropanol 71.6 BFME 22.2 (CF3) 2 CH0CH 2 F 4.9 (CF3 )2Choch2θch2f 1.3 SUBSTITUTESHEET

Claims: CLAIMS 1. A process for the production of a hydro(halo)fluorocarbon which comprises heating an α-fluoroether in the vapour phase at an elevated temperature. 2. A process as claimed in claim 1 wherein the α-fluoroether has the formula R-O-CFR^R 2 where R represents an aliphatic, substituted aliphatic, aromatic or substituted aromatic group and R^ and R 2 each represents hydrogen or an alkyl or substituted alkyl group. 3. A process as claimed in claim 2 wherein the group -CFR^R 2 is the -CH2F group or the -CHF-CF 3 group. 4. A process as claimed in claim 1, 2 or 3 wherein the α-fluoroether is heated in the presence of hydrogen fluoride. 5. A process as claimed in any one of claims 1 to 4 wherein the α-fluoroether is heated in the presence of a catalyst. 6. A process as claimed in claim 5 wherein the catalyst comprises a metal selected from the group consisting of nickel, iron, copper and chromium or an alloy, oxide, fluoride or oxyfluoride thereof. 7. A process as claimed in any one of the preceding claims wherein the α-fluoroether is heated at a pressure of from 1 to 10 bar. 8. A process as claimed in any one of the preceding claims for the production of 1,1,1,2-tetrafluoroethane wherein the α-fluoroether is at least one of FCH2-O-CH2CF3 , FCH2-O-CHFCF3 , CH3CHF-O-CH2CF3 and CF3CHF-O-CH3. 9. A process as claimed in any one of claims 1 to 7 for the production of pentafluoroethane wherein the α-fluoroether is at least one of CF3CHF-O-CHFCF3 and CF 3 CHF-0-CH 2 F. 10. A process as claimed in any one of the preceding claims wherein the desired hydro(halo) fluorocarbon( s ) is/are separated from the product stream which is then recycled to the reaction zone. 11. A process for the production of an α-fluoroe h p r suitable for use in the process claimed in any one of claims 1 to 10 which comprises reacting a non-enolisable aldehyde with hydrogen fluoride to form an intermediate and reacting the intermediate with an alcohol or a halogenating agent to form an α-fluoroether. 12. A process as claimed in claim 11 wherein the non-enolisable aldehyde is reacted with the hydrogen fluoride in the presence of the alcohol or halogenating agent. 13. A process as claimed in claim 11 wherein the non-enolisable aldehyde is reacted with the hydrogen fluoride to form an equilibrium mixture containing the intermediate and the alcohol or halogenating agent is added to the equilibrium mixture. 14. A process as claimed in claim 11 wherein the intermediate is isolated and is subsequently reacted with the alcohol or halogenating agent. 15. A process as claimed in any one of claims 11 to 14 wherein a primary alcohol is employed. 16. A process as claimed in any one of claims 11 to 15 wherein the non-enolisable aldehyde is formaldehyde or trifluoroacetaldehyde . 17. A process for the production of a hydro (halo)fluorocarbon which comprises treating the product α-fluoroether of the process as claimed in any one of claims 11 to 16 to convert the α-fluoroether to a hydro(halo )fluorocarbon. 18. A process as claimed in claim 17 wherein the t reatment of the α-fluoroether comprises heating it in the vapour phase at an elevated temnerature . 19. A process as claimed in any one of claims 1 to 10 for the production of a hydro(halo) fluorocarbon wherein the α-fluoroether is produced by a process as claimed in any one of claims 11 to 16. 20. A process as claimed in claim 17. 18 or 19 wherein the α-fluoroether is separated from the reaction mixture in which it is produced before it is treated to convert it to a hydro(halo) fluorocarbon. 21. A process as claimed in claim 17, 18 or 19 wherein the α-fluoroether is treated to reduce the water content before the α-rfluoroether is treated to convert it to a hydro(halo)fluorocarbon. 22. A process as claimed in any one of claims 17 to 21 wherein the α-fluoroether is treated in the substantial absence of water to convert it to a hydro(halo)fluorocarbon. 23. Fluoromethyl-fluoroethyl ether of the formula CH2FCH2OCH2F. 24. Fluoromethyl-difluoroethyl ether of the formula CHF2CH2OCH2 . 25. Fluoromethyl-trifluoroethyl ether of the formula CF3CH2OCH2F. 26. Fluoromethyl-tetrafluoropropyl ether of the formula CHF2CF2CH2OCH2F. 27. Fluoroethyl-tetrafluoroethyl ether of the formula CF 3 CHFOCH2CH2F. 28. Fluoromethyl-chloromethyl ether of the formula CH2FOCH2CI. 29. Fluoromethyl-bromomethyl ether of the formula CH 2 FOCH 2 Br.

Inventors: BURGESS LESLIE, BUTCHER JANE LESLEY, CLAYTON PETER PAUL, RYAN THOMAS ANTHONY, BURGESS, LESLIE, BUTCHER, JANE, LESLEY, CLAYTON, PETER, PAUL, RYAN, THOMAS, ANTHONY
Applicants: ICI PLC, IMPERIAL CHEMICAL INDUSTRIES PLC
Application year: 1992
Main classification: C07C19
IPC codes: C07B61, C07C17, C07C19, C07C41, C07C43