Process for making a polymer-supported catalyst

Abstract: The present invention provides a polymer support catalyst containing, as polymerized units, units derived from a polymerizable chelated metal species coordinated to one or more polydentate ligands to provide three or more chelate bonds to the metal atom.

Description: The present invention is concerned with a process for making polymer-supported catalysts and to an ester exchange process using such polymer-supported catalysts. A catalyst may be defined as a substance which changes the rate of a chemical reaction without undergoing any net change itself. Many times only trace amounts of the catalytic material are sufficient to bring about manifold changes in the rate of chemical reaction. Although the phenomenon of catalysis was recognised in the mid 1850 ' s, many challenges still exist in the development of efficient catalyst systems. Over 40% of all petroleum products and 50% of all organic chemicals are dependent upon catalysts for their commercial production. The widespread use of catalysts in organic processes is largely due to their amenability to continuous processes with decreased labour costs. Oftentimes, higher purity and greater uniformity of product also result from the choice of catalysts. Catalytic reactions are of two general types; homogenous catalysis and heterogenous catalysis. Catalysts that operate in the same phase as the reactants are known as homogeneous catalysts while catalysts that operate in a separate phase from the reactants are known as heterogeneous catalysts. In heterogeneous systems there is a distinct interface between catalyst and reactants. Catalysts speed up a reaction by lowering the activation energy. There have been many attempts to prepare useful heterogeneous catalysts Bhadure, S., et. al., J Chem. Soc., Dalton Tran. 1982, 445-450 prepared heterogeneous catalysts from divinylbenzene cross-linked polystyrene beads which were functionalised to support 2,4-pentanedionato complexes of certain metals. These metals included iron, cobalt, copper, vanadium and zirconium. Cross-linked polystyrene beads were chloromethylated and treated with 2,4-pentanedione and sodium ethoxide in tetahydrofuran. The functionalized beads were then heated with 2,4-pentanedionato metal complexes such that ligand exchange reactions resulted in polymer anchored metal complexes. These catalysts suffer drawbacks when used as heterogeneous catalysts for liquid-phase transesterification reactions. The reason for the poor performance of these catalysts is that the metal leaches from the polymer into the reaction solution. In typical polymer-supported metal catalysts, the metal is attached to the polymer support by weak bonds which are ineffective at preventing the metal from leaching into the reaction solutions. Depletion of the metal in the heterogeneous catalyst results in decreased heterogeneous catalyst activity and may lead to undesired homogeneous catalysis. The present invention overcomes the metal leaching problem by incorporating into the polymerization process a metal coordinated to one or more polydentate ligands to provide three or more chelate bonds to the metal, each of said polydentate ligands containing one or more pendant sites of ethylenic unsaturation. The catalysts of this invention are found to readily tolerate levels of water in alcohol of 200-500 ppm with no significant decrease in activity, in contrast to many other catalysts. According to the present invention there is provided a process for making a polymer-supported catalyst, which comprises copolymerizing a suspended mixture comprising: (a) vinyl monomer; and (b) crosslinking monomer; and (c) polymerizable chelated metal species wherein the metal species is coordinated to one or more polydentate ligands to provide three or more chelate bonds to the metal, each of said polydentate ligands containing one or more pendant sites of ethylenic unsaturation and wherein the metal is selected from aluminum, antimony, copper, chromium, hafnium, iron, ruthenium, palladium, lead, nickel, tin, titanium, vanadium, and zirconium. The polymerizable chelated metal species has ethylenic unsaturation capable of reacting with other monomers to form polymer beads. The polymer-supported catalysts made according to the invention may be used as high activity heterogeneous catalysts in the production of a variety of esters, particularly methacrylate- and acrylate-based esters, by a transesterification process. In one embodiment of the present invention, the metal species is selected from antimony, aluminum, copper, chromium, hafnium, iron, lead, nickel, tin, titanium, vanadium, and zirconium. For example, the metal species may be selected from aluminum, copper, chromium, hafnium, iron, lead, nickel, tin, titanium, vanadium, and zirconium. Preferably, the metal species is zirconium. In another embodiment of the present invention the vinyl monomer is monovinyl aromatic monomer present in an amount of up to 99.9 weight % of the suspended mixture, the crosslinking monomer has at least two active vinyl groups polymerizable with the monovinyl aromatic monomer and is present in an amount of up to 60 weight % of the suspended mixture, and the polymerizable chelated metal species is present in an amount of from 0.1 to 20 weight % of the suspended mixture. The polymer-supported catalyst may comprise, as polymerized units, units derived from (a) up to 99.9 weight % of monovinyl aromatic monomers, (b) up to 60 weight % of the crosslinking monomer, the crosslinking monomer having at least two active vinyl groups polymerizable with monovinyl aromatic monomers, and (c) from 0.1 to 20 weight % of the polymerizable chelated metal species. The monovinyl monomer may be selected from styrene, vinyl toluene, vinyl naphthalene, ethyl vinyl benzene, vinyl chlorobenzene, and chloromethyl styrene. The crosslinking monomer may be selected from divinyl benzene, trimethylol propane trimethacrylate, ethylene glycol dimethylacrylate, divinyl toluene, trivinylbenzene, divinyl chlorobenzene, diallyl phthalate, divinylpyridine, divinylnaphthalene, ethylene glycol diacrylate, neopentyl glycol dimethacrylate, diethylene glycol divinylether, bisphenol-A-dimethacrylate, pentaerythritol tetra- and trimethacrylates, divinylxylene, divinylethylbenzene, divinyl sulfone, divinyl ketone, divinyl sulfide, allyl acrylate, diallyl maleate, diallyl fumarate, diallyl succinate, diallyl carbonate, diallyl malonate, diallyl oxalate, diallyl adipate, diallyl sebacate, diallyl tartrate, triallyl silicate, triallyl tricarballylate, triallyl aconitate, triallyl citrate, triallyl phosphate, N,N ' -methylene-diacrylamide, N,N ' -methylene dimethacrylamide, N,N ' -ethylene-diacrylamide, trivinyl naphthalene, polyvinyl anthracenes and the polyallyl and polyvinyl ethers of glycol, glycerol, pentaerythritol, resorcinol and the monothio and dithio derivatives of glycols, and mixtures thereof. In a further embodiment of the present invention, the polydentate ligands are selected from vinylbenzyl acetylacetonate and 2-[(meth)acrylamidomethyl]-1,3-diketone. In a still further embodiment of the present invention, the catalyst contains not less than 0.1 weight % metal species. A typical process using the catalysts made according to the present invention may be illustrated by the following transesterification process using unsaturated esters as illustrative starting materials: In the process, suitable starting esters include the acrylate or methacrylate esters, where R is H or CH 3 and R' is alkyl of from 1 to 4 carbon atoms, and preferably 1 or 2 carbon atoms; a suitable starting alcohol is represented by the formula R''OH, where R'' may be alkyl or cycloalkyl, for example alkyl and cyclo alkyl containing from 3 to 20 carbon atoms. R'' may also be alkoxyalkyl, alkylphenoxyalkyl, alkylpolyphenoxyalkyl, phenylalkyl, alkylphenylalkyl, alkylmorpholinoalkyl, alkylpiperidinoalkyl, haloalkyl, cyanoalkyl, alkylthioalkyl, alkylimidazolidinones, alkyl oxazolidines, hydroxy alkyl such as hydroxyethyl or hydroxybutyl, for example those derived from ethylene glycol, butanediol or polyoxyethyleneols. Preferred are those alcohols wherein the alkyl portions described in the above compounds is alkyl having from 2 to 20 carbon atoms. Examples of alcohols include butanol, pentanol, isodecyl alcohol, lauryl alcohol, cetyl alcohol, stearyl alcohol, alkyl ether of polyoxyethylene, 2(N-oxazolidinyl)ethyl alcohol, 2(N-morpholino)ethyl alcohol, and dicyclopentenyloxyethyl alcohol. The example process described above is also applicable to saturated starting materials, particularly acetates, propionate, and butyrates. The polymerizable chelated metal species comprises a central metal ion attached by coordinate links to one or more chelate ligands. Heterocyclic rings are formed with the central metal atoms as part of each ring. Ligands offering two bonds for attachment to the metal are termed " bidentate " . Examples of polymerizable chelated metal species suitable for use in preparing the polymer-supported catalysts may be represented schematically by the following general formulae: where M is a metal species selected from aluminum, antimony, copper, chromium, hafnium, iron, lead, nickel, tin, titanium, vanadium and zirconium. X is a monodentate ligand, typically an alkoxide ligand. L is a polydentate ligand having more than one bond with the metal. Furthermore, L contains at least one site of ethylenic unsaturation capable of reacting with other L moieties or other copolymerisable monomers. Suitable copolymerizable monomers include: monovinyl aromatic monomers, e.g. styrene, vinyl toluene, vinylnaphthalene, ethyl vinyl benzene and acrylates, with one or more polyvinyl compounds having at least two active vinyl groups, e.g., divinylbenzene, polymerizable with the monovinyl monomer to form a crosslinked insoluble copolymer. The suspension polymers produced according to the present invention can be in the form of gellular or macroreticular beads. Preferably the heterogeneous catalysts made according to the present invention are macroreticular. The catalyst materials made according to the present invention are an improvement over previously known heterogeneous catalysts because leaching of the metal from the polymeric support is negligible. In order to prevent the leaching of the metal from the heterogeneous catalyst into the reaction solution it is critical that the chelated metal species has one or more polymerizable ligands. This is accomplished by using a metal species having chelate ligands containing a site of ethylenic unsaturation. The site of ethylenic unsaturation (or polymerizable unit) in the chelated metal species is capable of undergoing free-radical addition with itself or other monomers or crosslinkers during the polymerization process such that the chelated metal species becomes incorporated into the polymer. By having one or more ligands which provide three or more chelate bonds to the metal, as well as providing a site of attachment to the polymeric backbone, the leaching of the metal in the reaction solution is minimized. For example, zirconium n-tetrabutoxide may be reacted with 3-vinylbenzyl acetylacetone (VBA) to provide a polymerizable chelated metal species that may be represented by the diagrammatical representation (I) where the bracketed structure represents the polymerizable chelate ligand 3-vinylbenzyl acetylacetonate and OR represents n-butoxide ligands. The substitution pattern on the benzene ring of the 3-vinylbenzyl acetylacetonate ligand is shown as meta although para substitution is equally applicable. X and Y are integers and refer to the number of 3-vinylbenzyl acetylacetonate and n-butoxide ligands, respectively, where X is at least 2. The activity of the catalyst is enhanced by the coordination of the bidentate acetylacetonate ligand. Coordination of the acetylacetonate ligands reduces the extent of self-oligomerization of the metal species and provides accessible coordination sites for catalysis to occur. The resulting species M(VBA) x (OR) y (X≥2) is stable with respect to hydrolysis. Other preferred transition metal species that may be incorporated into the catalysts by the method of this invention include 3-vinylbenzyl acetylacetonate complexes with metal alkoxides M(OR)x, metal chlorides M(Cl) x , metal acetates M(CH 3 COO) x , and metal oxides M(O) x . Transition metal species, which may be used in forming the polymerizable chelated metal species of the invention, are typically good Lewis acid catalysts and possess exchangeable ligands and accessible coordination sites. Preferably, the catalyst made according to the present invention is based on chelated species of metals and/or mixed chelated alkoxide species of metals represented by the following general formula (II). where M is a metal selected from aluminum, antimony, copper, chromium, hafnium, iron, ruthenium, palladium, lead, nickel, tin, titanium, vanadium and zirconium, where X is greater than or equal to 2 and Y plus 2X equals the coordination number of the metal; and R 1 , R 2 and R 3 are each selected from hydrogen, C 1 - C 10 alkyl, C 2 - C 10 alkenyl, phenyl, C 1 - C 8 alkyl substituted phenyl, C 2 - C 8 alkenyl substituted phenyl, halogen substituted phenyl, (meth)acrylamide, and C 1 -C 8 substituted (meth)acrylamide such that one or more of R 1 , R 2 and R 3 contain one or more sites of ethylenic unsaturation. The OR substituent may be a combination of alkoxide groups, or composed of one or more of the following: a precursor alkoxide used in a prior generation of a chelate the alkoxide formed from the alcohol having a carbon content higher than the alkyl group of the alkyl ester, that is, the transesterifying alcohol. Structure (II) is presented as a likely and reasonably hypothesized structure of the metal chelate alkoxide complex. Suitable chelate ligands may vary depending on the particular metal selected. In general, any chelating metal species that provides an environment where the polymerization initiator will not react with the metal and is sufficiently hydrophobic will be suitable. In addition, the metal species containing the polymerizable ligand(s) shall be capable of being copolymerized with any monomers used in the preparation of the catalyst. A preferred polydentate ligand for the listed metals is 3-vinylbenzyl acetylacetonate. Additional suitable polymerizable polydentate ligands include those 2-[(meth)acrylamidomethyl]-1,3 diketones disclosed in EP-A-0 345 573. These 1,3-diketones may be represented by the general formula: wherein the R, R 1 , R 2 and R 3 , independently of each other, have the following meanings: R is a hydrogen atom or a methyl group, preferably a hydrogen atom; R 1 is a hydrogen atom or a methyl or ethyl group, preferably a hydrogen atom; R 2 and R 3 are alkyl groups with 1 to 6 carbon atoms or unsubstituted or, for example, alkyl, aryl or halogen-substituted aryl groups with 6 to 20 carbon atoms, R 2 and R 3 being equal to or different from each other. Examples of R 2 and R 3 groups in general formula III are: methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl, tert.butyl, 1-pentyl, 2-pentyl and 3-pentyl, 1-hexyl, 2-hexyl and 3-hexyl, phenyl, 2-, 3- and 4-methylphenyl, 2,4-dimethylphenyl, 4,tert.-butyl, 4-chlorophenyl, 4-bromophenyl, 4-phenyl-1-phenyl (biphenyl), 4-(4 ' -phenyl-1 ' phenyl)-1-phenyl (triphenyl), 1- and 2-naphthyl, 7-phenanthrenyl, 1-anthracenyl, 2-fluorenyl and 3-perylenyl. Methyl, ethyl, n-propyl and phenyl are preferred, methyl and phenyl being particularly preferred. These compounds with the 1-3-diketo group are free radical-polymerizable and provide the polydentate ligand bonds to keep the metal from leaching from the polymerized catalyst. The catalysts of this invention have been successfully prepared by suspension polymerization of a number of polymerizable chelated metal species. The catalysts made according to this invention are active for the production of (meth)acrylic esters as well as acetates by transesterification processes. The success of the catalyst can be attributed to the chelate effect created by the polymerization technique described herein. Using this technique, we have been able to reduce the deactivation of the polymer catalyst caused by the leaching of the metal into the reaction solution. Preparation of Polymer Beads The following is a general description of a method according to the present invention for preparing the polymer-supported catalysts. The techniques of preparing crosslinked vinyl copolymers in bead form (generally used as precursors for conversion into ion exchange resins) by free-radical catalyzed polymerization of the monomer mixture in aqueous dispersion are well known. The term " cross-linked vinyl copolymer " and the like is used for the sake of brevity herein to signify copolymers of a major proportion, e.g., from 50 upwards to about 99.5 weight percent, preferably 80 to 99 weight %, of monovinyl aromatic monomers, e.g., styrene, vinyl toluene, vinyl naphthalene, ethyl vinyl benzene, vinyl chlorobenzene or chloromethyl styrene, with a minor proportion, e.g., of from about 0.5 up to 80 weight percent, preferably 10 to 50 weight percent, of polyvinyl compounds having at least two active vinyl groups polymerizable with the aforesaid monovinyl monomer to form a crosslinked, insoluble, infusible copolymer, for example, divinyl benzene, trimethylol propane trimethacrylate, ethylene glycol dimethacrylate, divinyl toluene, trivinyl benzene, divinyl chlorobenzene, diallyl phthalate, divinylpyridine, divinylnaphthalene, ethylene glycol diacrylate, neopentyl glycol dimethacrylate, diethylene glycol divinylether, bisphenol-A-dimethcarylate, pentaerythritol tetra- and trimethacrylates, divinylxylene, divinylethylbenzene, divinyl sulfone, divinyl ketone, divinyl sulfide, allyl acrylate, diallyl maleate, diallyl fumarate, diallyl succinate, diallyl carbonate, diallyl malonate, diallyl oxalate, diallyl adipate, diallyl sebacate, diallyl tartrate, triallyl silicate, triallyl tricarballylate, triallyl aconitate, triallyl citrate, triallyl phosphate, N,N ' -methylene-diacrylamide, N,N ' -methylene dimethacrylamide, N,N ' -ethylene-diacrylamide, trivinyl naphthalene, polyvinyl anthracenes, the pollyallyl and polyvinyl ethers of glycols, glycerol, pentaerythritol, resorcinol, and the monothio and dithio derivatives of glycols. The copolymer may also have incorporated therein polymerized units of up to about 5 mole percent of other vinyl monomers which do not affect the basic nature of the resin matrix, for example, acrylonitrile, butadiene, methacrylic acid and others known in the art. In one embodiment of this invention, the polymerizable chelated metal species, the vinyl monomer, the crosslinking monomer and other optional monomer or monomers, are polymerized via free-radical initiation as an aqueous dispersion. The polymerization is normally carried out at temperatures ranging from about 30° to about 95° C., preferably 45° to 85° C., and more preferably from 50° to 75°C. It is desirable to employ lower temperatures of reaction in the initial stages of the polymerization, that is until at least about 50% of the monomer(s) in the dispersion are reacted, preferably 75% or more. The free radical initiator used in the process is one capable of catalyzing polymerization at the aforesaid temperatures. Representative initiators are di-(4-t-butylcyclohexyl) peroxydicarbonate, dicyclohexylperoxydicarbonate, di-(sec-butyl)peroxydicarbonate, di-(2-ethylhexyl) peroxy dicarbonate, dibenzyl peroxydicarbonate, diisopropyl peroxydicarbonate, azobis (isobutyronitrile), azobis (2,4-dimethylvaleronitrile), t-butyl peroxypivalate, lauroyl peroxide, benzoyl peroxide, t-butyl peroctoate and t-butyl peroxyisobutyrate. The preferred initiator is lauroyl peroxide. The amount of initiator employed is normally from about 0.1 to about 2 weight percent, based on total monomer weight, preferably 0.3 to 1 wt %. The aqueous media in which the polymerization is conducted in dispersion form will typically contain minor amounts of the conventional suspension additives, that is, dispersants such as xanthan gum (biosynthetic polysaccharide), poly(diallyl dimethyl ammonium chloride), polyacrylic acid (and salts), polyacrylamide, magnesium silicate and hydrolysed poly(styrene-maleic anhydride), protective colloids such as carboxymethyl cellulose, hydroxyalkyl cellulose, methyl cellulose, polyvinyl alcohol, gelatin, and alginates, buffering agents such as phosphate and borate salts, and pH control chemicals such as sodium hydroxide and sodium carbonate. The crosslinked, high-molecular weight copolymers are preferably recovered from the reactor as hard, discrete catalytic beads of particle size within the range of about 0.02 to 2 mm, average particle size being on the order of 0.2 to 1 mm. The beads will typically contain from about 0.1 to about 20.0 weight percent metal, preferably from about 2.0 to about 8.0 weight percent metal. Typically, the catalytic beads of this invention are prepared by suspension polymerization as described above. The term " suspension polymerizing " is a term well-known to those skilled in the art and comprises suspending droplets of the monomer or monomer mixture in a medium in which the monomer or monomer mixture is substantially insoluble. This may be accomplished by adding the monomer or monomer mixture, with any additives, to the suspending medium which contains a dispersing or suspending agent, such as, in the case of an aqueous suspending medium, the ammonium salt of a styrene-maleic anhydride copolymer, carboxymethyl cellulose, bentonite or a magnesium silicate dispersion. When this medium is agitated, the monomer phase disperses into droplets the size of the droplets depending on a number of factors, such as amount of dispersing agent and type and rate of agitation. Agitation is continued at reaction temperature until polymerization is complete. The polymerized droplets, generally termed " beads " , are then separated from the suspending medium and further processed, if desired. The aqueous phase for carrying out the suspension polymerization reaction generally includes water, one or more dispersing agents, a pH buffer system and one or more stabilizers. The water is deionized. The dispersing agents may be any surface active agents compatible with the aqueous phase and organic phase reactants. The pH buffer system is preferably boric acid and sodium hydroxide as necessary. Stabilizer may be any of those used in suspension polymerization reaction mixtures. The organic phase will contain reactants including the initiators for making the beads as described above. The metal-containing complexes described above will be included in the organic phase. The copolymerization may be conducted: (a) while the monomer mixture is dissolved in 25 to 150% by weight, based on monomer weight, of an organic liquid which is a solvent for said monomer mixture but is unable to substantially swell the copolymer resulting from the copolymerization, or (b) by aqueous phase suspension polymerization including one or more dispersing agents, a pH buffer system and one or more stabilizers. The present invention further provides an ester exchange process, which comprises: preparing an ester of a saturated or unsaturated carboxylic acid by reacting an alkyl ester of an alcohol in the presence of a polymer supported catalyst according to the invention or a resin according to the invention. The following Examples are presented to illustrate certain embodiments of the present invention. Unless otherwise specified, all parts are parts by weight. In the formation of the aqueous phase in Examples 1 to 16 the dispersing agent initially added was Pharmagel (gelatin), and the additional or second dispersing agent was poly(dimethyl diallyl ammonium chloride). Examples 1 to 15 The organic phase was prepared by placing in a flask the 3-vinylbenzyl acetylacetone to which was added zirconium n-tetrabutoxide. If desired, the butanol by-product can be removed by suitable methods such as distillation. The solution was stirred and divinylbenzene, styrene and diisobutyl ketone (DIBK) were added. After about 10 minutes of stirring, the initiator, lauroyl peroxide was added. Addition of DIBK to the zirconium n-tetrabutoxide prior to the addition of 3-vinylbenzyl acetylacetone should be avoided. Zirconium alkoxide complexes are reactive with many ketones, however, the zirconium vinylbenzylacetylacetonate complexes are quite stable in the presence of ketones. The organic phase should not be allowed to stand for long periods of time, for example, not more than a few minutes to avoid polymerization. In the preparation of the aqueous phase, deionized water and dispersing agent were added to a reaction flask. The solution was stirred for about 15 minutes to dissolve the dispersing agent. A slight warming of the solution to about 40°C may be necessary to get the dispersing agent to completely dissolve. After the dispersing agent was dissolved, additional dispersing agent was added and the solution was again stirred gently for about 15 minutes. Boric acid was then added and the pH measured after about 15 minutes. A typical pH was about 4. Sodium hydroxide solution was then added to obtain a pH of slightly greater than 7. The organic phase was then slowly added to the aqueous phase in the reaction flask. The phases remained separate with the organic layer being the upper layer. A nitrogen sweep was applied over the solution and gentle stirring begun at about 70 rpm. The solution was then heated to about 45° C. Formation of translucent beads was observed. After about 10 minutes the stirring rate was increased stepwise in 20 rpm increments from 30 rpm to a rate of 130 rpm and the pot temperature was slowly increased to 75° C. This temperature was held overnight. As the polymerization progressed the beads became noticeably more opaque. The next morning the heat was removed and the beads/water mixture allowed to cool. The solution was decanted and the beads rinsed with three volumes of deionized water. The beads were then placed in a SOXHLET extraction apparatus and extracted with methanol overnight. The bead products were then isolated and dried in a vacuum oven at 50° C. Table I below illustrates preparation of catalyst beads containing zirconium, copper, iron and hafnium according to the above procedure. In the Examples the following abbreviations are used DEGDVE is diethyleneglycol divinylether DVB is divinylbenzene VBA is vinylbenzylacetylacetone CATALYST BEAD PREPARATIONS Example # % DVB % DEGDVE %Styrene % VBA % Metal (Exp.) 1 22 0 18 38 Zr=4 2 32 0 0 38 Zr=12 3 15 0 13 54 Zr=17 4 19 0 16 46 Zr=8 5 19 0 16 46 Zr=9 6 17 3 16 46 Zr=5 7 22 0 18 38 Zr=9 8 22 0 18 38 Zr=15 9 19 4 18 38 Zr=5 10 22 0 19 40 0 11 19 4 18 38 Cu=.23 12 29 4 18 38 Zr=4.7 13 40 2 6 38 Zr=5.2 14 41 2.1 6.6 40 Fe=0.33 15 19 4 18 37 Hf=7.3 Table II below shows the relationship of cross-linked DVB to catalyst Bead physical parameters. Example %Zr %DVB Crosslinked Surface Area Porosity Av.Pore Diameter 9 5.0 19 123 m2/g 0.47 cm3/g 151Å 12 4.7 29 180 m2/g 0.64 cm3/g 135Å 13 5.2 40 330 m2/g 0.70 cm3/g 82Å The quantities of materials used in Examples 1 to 15 can be calculated by a direct ratio of the component percent from Table 1 with the component percent and the amounts from the tables headed "Organic Phase" and "Aqueous Phase" in Example 16. For example, to calculate the proper quantity of divinylbenzene in Example 3, the percent from Table 1 (i.e. 15%) is compared with the percent from the "Organic Phase" table of Example 16 (i.e. 30%). The ratio is 1 /2, therefore, the amount of divinylbenzene to use in Example 3 is half of the quantity from the "Organic Phase" table of Example 16 (i.e. 1/2 of 61.5 g), or 30.75 g. Example 16 Preparation of 3-vinylbenzyl acetylacetone To 308 g of sodium acetylacetonate and 30 g of sodium iodide in 100 mL acetone (dried over 3A molecular sieves) was added dropwise 282 ml vinylbenzyl chloride (70% Meta, 30% Para), in 600 ml acetone. An ice bath was used to keep the pot temperature below 50°C during the addition. The solution was maintained at 45-50° C until NMR samples showed no residual vinylbenzyl chloride (about 1 hour). The pot was then cooled to room temperature and placed in the refrigerator overnight. The sodium chloride was then filtered and the acetone removed at room temperature under reduced pressure. The crude product was then added to an excess of toluene (800 ml) to precipitate any remaining sodium salts. The solution was again filtered and the toluene was removed at temperatures below 50°C under reduced pressure. Preparation of polymerizable chelated metal species To a solution containing 30 g of Zr(OBu) 4 ·BuOH and 15.9 g of 3-vinylbenzyl acetylacetone (prepared above) was added 200 g of heptane. The solution was heated under reduced pressure and the butanol:heptane azeotrope removed overhead (the butanol:heptane azeotrope has a b.p. of 50° C at 153 mm Hg with a composition of 10.3 wt.% heptane in butanol). The remaining heptane was then stripped and the pot solution cooled to room temperature. Any butanol remaining was estimated from NMR integrations. Catalyst Beads A general preparation of the heterogeneous catalyst is now described. Preparation of the organic phase: To a 500 mL Erlenmeyer Flask was added the polymerizable chelated metal species (prepared above). The solution was stirred and the divinylbenzene, styrene, and DIBK were added. The solution was stirred for an additional 10 min. The lauroyl peroxide initiator was then added and stirred until dissolved. To avoid polymerization, the organic phase should not be allowed to stand for long periods. Organic Phase Charges wt% 3-vinylbenzyl acetylacetone 60.3 g 29.4% Zr(OBu) 4 -BuOH 32.9 g 15.6% Divinylbenzene 61.5 g 30.0% Styrene 28.7 g 14.0% Diisobutyl ketone (DIBK) 20.5 g 10.0% Lauroyl peroxide 2.0 g 1.0% Total: 205.g 100 % Preparation of the aqueous phase To a one litre 4 neck round bottom reaction flask equipped with a condenser, stirrer, and thermocouple/temperature controller and heating mantle were added deionized water and dispersing agent. The solution was stirred for 15 minutes. If the dispersing agent did not completely dissolve, the solution was warmed slightly (to about 40° C). A second dispersing agent was added and the solution was stirred gently for another 15 min. Boric acid was added and the pH was checked after 15 min (Typically ca. 4). NaOH (50% soln) was added (>5 g) to obtain a pH slightly greater than 7. Acidic conditions are to be avoided since such condition may cleave the ligand from the metal with resulting hydrolysis. Aqueous Phase Charges Wt. % Deionized H 2 O 283.4 g 93.0 % Dispersing Agent 17.5 g 5.7 % Boric Acid 2.9 g 1.0 % NaOH (50% soln.) As necessasy 0.3% Total: 303.8 g 100 % Procedure : The organic phase was slowly added to the aqueous phase in the reaction flask. The phases remained separated with the organic layer being the upper layer. A N 2 sweep was applied over the solution and gentle stirring was initiated (70 rpm). The solution was then heated to 45° C. The formation of translucent beads could be observed shortly after stirring was started. The stirring rate was increased stepwise at 10 minute intervals by 30 rpm to a rate of 130 rpm. At this time, the pot temperature was slowly increased to 65° C and controlled at this temperature overnight. As the polymerization progressed, the beads became noticeably more opaque. The next morning the heat was removed and the beads/water mixture allowed to cool. The solution was decanted and the beads rinsed with 3 bed volumes of deionized water. The beads were then placed into a Soxhlet extraction thimble and extracted with methanol overnight. The beads were then isolated and dried under vacuum. Catalyst Evaluation The catalyst beads were evaluated in a transesterification reactor. Reactions were run using excess ester (5:1 or 2:1 ester:alcohol mole ratios) to ensure sufficient solvent for removal of the ester: alcohol azeotrope as well as to keep pot temperatures below 115°C in the case of the high boiling alcohols, e.g., lauryl alcohol. All final conversions reported were obtained from GLC analysis of pot samples and comparison of the ratio of starting alcohol:product ester. The overhead was also monitored and sampled to corroborate the pot analyses and to give information concerning the relative rates of reaction. For all methacrylate transesterification reactions the starting ester:alcohol mixes were dehydrated in a separate step prior to reaction by removal of the water as an ester: H 2 O azeotrope. For the acetate reactions anhydrous ethyl acetate, anhydrous 1-butanol, and 1-dodecanol were used as supplied. The following Examples compare heterogeneous catalysts made as described above (Example 16) when used in transesterification reactions showing that very small amounts of the zirconium are released by the catalyst and lost in the liquid solution. Example 17: Butyl Acetate Two hundred twenty three grams (2.5 moles) of ethyl acetate, 37g (0.5 moles) butanol, and 30 grams of the heterogeneous zirconium vinylbenzyl acetylacetonate/styrene/divinylbenzene catalyst were added to a 500 ml flask equipped with an agitator, thermocouple, and a 10-tray Oldershaw fractional distillation column. The mixture was heated to reflux at atmospheric pressure while an azeotropic mixture of ethyl acetate and ethanol was removed from the upper part of the fractionating column. The reaction was continued in this manner for approximately 6 hours while the temperature at the top of the column was 72-74°C and the temperature in the pot was 82-85°C. In the transesterification reaction gas-liquid chromatography analysis showed 80% conversion of BuOH with a selectivity to butyl acetate of >99%. The liquid solution was analyzed for Zr and found to contain <1 ppm Zr. The solution was decanted and a fresh charge of ethyl acetate and BuOH were added. The catalyst was used in 12 similar batch cycles with no apparent decrease in activity. Example 18 : Dodecyl Acetate Two hundred fourteen grams (2.4 moles) of ethyl acetate, 86 g of 1-dodecanol (0.46 moles), and 30 grams of the heterogeneous zirconium vinylbenzyl acetylacetonate/styrene/divinylbenzene catalyst were added to a 500 ml flask equipped with an agitator, thermocouple, and a 10-tray Oldershaw fractional distillation column. The mixture was heated to reflux at atmospheric pressure while an azeotropic mixture of ethyl acetate and ethanol was removed from the top of the distillation column. The reaction was continued for 6 hours while the temperature at the top of the column was 72-74° C and the temperature in the pot was 82-85°C. Gas liquid chromatography (GLC) analysis showed 37% conversion of 1-dodecanol with a selectivity of >95%. Example 19: Butyl Methacrylate Two hundred six grams of a methyl methacrylate/1-butanol reaction mix (5:1 molar ratio of methyl methacrylate: 1-butanol), and 100 ppm phenothiazine as inhibitor, were added to a 500 ml flask equipped with an agitator, thermocouple, and a 10-tray Oldershaw fractional distillation column. Thirty grams of the heterogeneous zirconium vinylbenzyl acetylacetonate/styrene/divinylbenzene catalyst was added. The mixture was heated to reflux at atmospheric pressure while an azeotropic mixture of methyl methacrylate and methanol was removed from the upper portion of the fractionating column. The reaction was continued in this manner for 6 hours while the temperature at the column was 64-67°C and the temperature in the pot was 101-107°C. Gas liquid chromatography (GLC) analysis showed 60% conversion of 1-butanol with a selectivity to butyl methacrylate of 99%. The liquid solution was analyzed for Zr and found to contain <2ppm Zr. Example 20 : Dodecyl Methacrylate Two hundred six grams of a methyl methacrylate/1-dodecanol reaction mix (5:1 molar ratio of methyl methacrylate: 1-dodecanol), and 100 ppm phenothiazine as inhibitor were added to a 500 ml flask equipped with an agitator, thermocouple, and a 10-tray Oldershaw fractional distillation column. Thirty grams of the heterogeneous zirconium vinylbenzyl acetylacetonate/styrene/divinylbenzene catalyst was added. The mixture was heated to reflux at atmospheric pressure while an azeotropic mixture of methyl methacrylate and methanol was removed from the upper portion of the fractionating column. The reaction was continued in this manner for 6 hours while the temperature at the column was 64-67°C and the temperature in the pot was 101-107°C. Gas liquid chromatography (GLC) analysis showed 30% conversion of 1-dodecanol with a selectivity to dodecyl methacrylate of 95%. The liquid solution was analyzed for Zr and found to contain <2 ppm Zr. Comparative Examples (a) Following the teachings of S. Bhaduri, et. al., cited above, a polymer containing the pentane-2,4-dionato zirconium moiety was prepared in a stepwise fashion. First, a polymer containing the 2,4-pentanedionato unit was prepared from known methods. In a separate second step the zirconium was incorporated through a ligand-exchange process. This stepwise procedure provides for only two chelate bonds to the zirconium because the 2,4-pentanedionato units are spatially fixed in the first step. This is in contrast to the catalyst prepared in the present invention where the polymerizable chelated metal species is directly incorporated into the polymerization process and the metal is attached through three or more chelate bonds. The former catalyst shows a significant loss of the zirconium into the solution. (b) Vinylbenzyl acetylacetone/styrene/divinylbenzene polymer beads were prepared as described in the catalyst preparation except no Zr(OBu) 4 ·BuOH was used. These polymer beads (13.7 g) were then evaluated in transesterification reactions of solution containing 617 g of 5:1 mole ratio methyl methacrylate: 1-butanol to which homogeneous 0.925 g Zr (OBu) 4 . BuOH and 500 ppm of monomethyl ether of hydroquinone as inhibitor were added. After six hours a 1-butanol conversion of 67% was achieved. For comparison, homogeneous Zr(OBu) 4 ·BuOH yields < 10% conversion over the same time period, suggesting that the Zirconium has been incorporated into the 2,4-pentanedione containing polymer beads. The reaction solution was decanted and a fresh charge of 617 g 5:1 methyl methacrylate: 1-butanol was added. After six hours <5% conversion was achieved. Analysis of the initially decanted solution showed that >90% of the Zr was in solution and, therefore, not incorporated into the polymer beads. Subsequent runs using the polymer beads showed no activity. Thus, the zirconium had been leached from the beads during the reaction leaving the polymer beads with little or no catalytic activity.

Claims: A process for making a polymer-supported catalyst, which comprises copolymerizing a suspended mixture comprising: (a). vinyl monomer; (b). crosslinking monomer; and (c). polymerizable chelated metal species wherein the metal species is coordinated to one or more polydentate ligands to provide three or more chelate bonds to the metal, each of said polydentate ligands containing one or more pendant sites of ethylenic unsaturation and wherein the metal is selected from aluminum, antimony, copper, chromium, hafnium, iron, ruthenium, palladium, lead, nickel, tin, titanium, vanadium, and zirconium. A process as claimed in claim 1, wherein the vinyl monomer is monovinyl aromatic monomer present in an amount of up to 99.9 weight % of the suspended mixture, the crosslinking monomer has at least two active vinyl groups polymerizable with the monovinyl aromatic monomer and is present in an amount of up to 60 weight % of the suspended mixture, and the polymerizable chelated metal species is present in an amount of from 0.1 to 20 weight % of the suspended mixture. A process as claimed in claim 1 or claim 2, wherein the metal species is selected from aluminum, antimony, copper, chromium, hafnium, iron, lead, nickel, tin, titanium, vanadium, and zirconium. A process as claimed in claim 3, wherein the metal is zirconium. A process as claimed in any preceding claim, wherein the polydentate ligand is selected from vinylbenzyl acetylacetonate and 2-[(meth)acrylamidomethyl]-1,3-diketone. A process as claimed in any preceding claim, wherein the crosslinking monomer is selected from divinyl benzene, trimethylol propane trimethacrylate, ethylene glycol dimethylacrylate, divinyl toluene, trivinyl benzene, divinyl chlorobenzene, diallyl phthalate, divinylpyridine, divinylnaphthalene, ethylene glycol diacrylate, neopentyl glycol dimethacrylate, diethylene glycol divinylether, bisphenol-A-dimethacrylate, pentaerythritol tetra- and trimethacrylates, divinylxylene, divinylethylbenzene, divinyl sulfone, divinyl ketone, divinyl sulfide, allyl acrylate, diallyl maleate, diallyl fumarate, diallyl succinate, diallyl carbonate, diallyl malonate, diallyl oxalate, diallyl adipate, diallyl sebacate, diallyl tartrate, triallyl silicate, triallyl tricarballylate, triallyl aconitate, triallyl citrate, triallyl phosphate, N,N'-methylene-diacrylamide, N,N'-methylene dimethacrylamide, N,N'-ethylene-diacrylamide, trivinyl naphthalene, polyvinyl anthracenes and the polyallyl and polyvinyl ethers of glycol, glycerol, pentaerythritol, resorcinol and the monothio and dithio derivatives of glycols, and mixtures thereof. A process as claimed in any preceding claim, wherein the suspended mixture further comprises (d) 25 to 150 % by weight, based on monomer weight, of an organic liquid which is a solvent for the monomers but is unable to substantially swell a copolymer resulting from the copolymerization. A process as claimed in any preceding claim, wherein the vinyl monomer is selected from styrene, vinyl toluene, vinyl naphthalene, ethyl vinyl benzene, vinyl chlorobenzene and chloromethyl styrene. An ester exchange process, which comprises: preparing an ester of a saturated or unsaturated carboxylic acid by reacting an alkyl ester of an alcohol in the presence of a polymer-supported catalyst prepared by a process as claimed in any preceding claim. Use, in an ester exchange process, of a polymer-supported catalyst prepared by a method as claimed in any of claims 1 to 8.

Inventors: DOBSON JOHN CARROLL, MCDADE CHRISTINE, MIRABELLI MARIO GUISEPPE LUCIA, VENTER JEREMIA JESEJA, DOBSON, JOHN CARROLL, MCDADE, CHRISTINE, MIRABELLI, MARIO GUISEPPE LUCIANO, VENTER, JEREMIA JESEJA
Applicants: ROHM & HAAS, ROHM AND HAAS COMPANY
Application year: 1993
Main classification: B01J31
IPC codes: B01J31, C08F30, C08F12, C07F7, C07B61