IMPROVED COBALT CATALYST

Abstract: A process for preparing a cobalt (III) complex is described which comprises: (i) treating a divalent cobalt salt of formula Co<II>X2/n where n is the valency of an anion X, with up to 15 molar equivalents of ammonia or an amine; (ii) oxidising the resulting amine complex; (iii) converting the oxidised complex to the corresponding carboxylate of formula [Co<III>(NR3)5R<1>COO]X2/n where each R, which may be the same or different, represents hydrogen or an optionally substituted hydrocarbon group and R<1> represents an alkyl or alkenyl group of 1 to 18 carbon atoms, at a pH above 8.5; and optionally (iv) replacing the X ion by a different anion by a metathetical reaction.

Description: IMPROVED COBALT CATALYST This invention relates to a process for the preparation of cobalt complexes and to cobalt complexes obtained thereby. Complexes of Co m aα as oxidation catalysts and therefore promote reaction of various oxygen species. These reaαions generally occur in water or an aqueous medium. Thus cobalt complexes are useful as oxidation catalysts or promoters of oxidation reaαions with atmospheric oxygen or oxygen transfer agents such as peroxides, per iodates and amine oxides. A particular use of trivalent cobalt complexes is as bleaching catalysts for the aαivation of, for example, perborates. The cobalt complexes originally proposed possessed an inner chloride anion but these have been found to be to prone to hydrolysis such that the complexes with an acetate inner anion are more useful. These acetato cobalt complexes are preferred for reaαions in water since they give rise to less side reaαions. This is because there is less hydrolysis or degradation of the catalyst and also less precipitation of such produαs which can give rise to fouling etc. A typical acetato cobalt complex has the formula Co(NH 3 ) 5 OCOCH 3 ]Cl 2 (hereafter referred to a PAAC). The starting material for the preparation of such a complex is cobalt chloride which has the formula [Co π (H 2 0) 6 ]Cl 2 . Reaαion with ammonia or an amine gives rise to the correspondmg amino complex which, on oxidation, produces the compound of the formula [Co (NH 3 ) 5 H 2 0]Cl 3 (hereafter referred to as PAQC) together with [Co m (NH 3 )JCl 3 (HAC). Reaαion of PAQC with hot hydrochloric acid gives rise to [Co (NH 3 ) 5 ]Cl]Cl 2 (PACC). This PACC can be converted into the desired PAAC although very dilute solutions have to be used, which are clearly unrealistic on an industrial scale. Clearly it would be much better if a process could be found whereby cobalt chloride is converted into the desired acetato cobalt complex without the need to prepare PACC as an intermediate. Previous attempts at this have, though, been found to be unsatisfaαory and have produced the desired compound in only very small yield. A way has now been found, according to the present invention, whereby such complexes can be prepared in good yield by controlling the amount of ammonia or amine. It has been found that control of the amount of ammonia or amine employed has a significant effeα on the percent conversion to the desired PAAC. According to the present invention, there is provided a process for preparing a cobalt HI complex which comprises: (i) treating a divalent cobalt salt of formula CaPX^ where n is the valency of an anion X, with up to 15 molar equivalents of ammonia or an amine; (ii) oxidising the resulting amine complex; (iii) converting the oxidised complex to the corresponding carboxylate of formula [Co m (NR 3 ) 5 R 1 COO]X 2 n where each R, which may be the same or different, represents hydrogen or an optionally substituted hydrocarbon group and R 1 represents an alkyl or alkenyl group of 1 to 18, especially 1 to 6, carbon atoms, preferably methyl, at a pH above 8.5; and optionally (iv) replacing the X ion by a different anion by a metathetical reaαion. As indicated above, a typical starting material is cobaltous chloride. This has the disadvantage that in the strongly oxidising conditions used to produce cobalt (LU) oxide, the chloride counter ions may reaα to form potentially hazardous chlorine. Accordingly it is preferable to use cobaltous acetate as the starting material. Other starting materials include the oxide and hydroxide. It will be appreciated that the nature of the anion in the starting material is significant. Thus the use of cobaltous chloride will tend to give rise to the produαion of some PACC. The complex typically is an ammonium complex i.e. one in which R represents hydrogen. This is obtained by using ammonia but it will be appreciated that corresponding amino complexes can be obtained by reaction with amines having for example, 1 to 8, especially 1 to 6, carbon atoms, including alkyl amines such as methylamine and ethylamine, aromatic amines such as phenylamine, and cyclic amines such as cyclohexylamine as well as hydroxy amines such as ethanolamine as well as polyamines, typically diamines, such as ethylenediamine. Thus R can represent a hydrocarbon group which may itself be substituted by an amino group in which case the number of R groups present will be reduced below 5 in order to balance the molecule. For simplicity, the expression "amine" will be used herein to denote ammonia as well as aliphatic and aromatic amines. In the step (i) of the process, typically an aqueous ammonia (or amine) solution is used to reaα with an aqueous solution of the cobalt salt. This reaαion should be allowed to proceed slowly since it is significantly exothermic. Desirably an ammonium salt, typically ammonium acetate, is also used; this reduces the pH to, say, 8 to 9 as opposed to 10 or more and enhances oxidation. Consequently the use of such a salt can reduce the amount of oxidising agent necessary in the subsequent step. Clearly the use of all liquid raw materials simplifies produαion. As indicated above, a maximum of 15 molar equivalents of amine species should be used. It has been found that, in general, the best results are obtained by using smaller concentrations of ammonia, typically from no more than 10 molar equivalents and, more particularly, no more than 8 molar equivalents. The resulting amine complex will be produced in aqueous solution generally having a pH from 8 to 10 and preferably from 9 to 10. The amine complex is then oxidised. This is typically performed using hydrogen peroxide although aerial oxidation is also a possibility. 0.5 moles of hydrogen peroxide are required for stoichiometric purposes but, in praαice, an excess of hydrogen peroxide is desirable. It has been found, though, that a large excess of hydrogen peroxide such as 2 moles is generally undesirable. This is because of the potential problem that the counter chloride ions present when cobaltous chloride is used as the starting material may be oxidised to chlorine causing a safety hazard. Thus the amount employed is typically from 0.5 to 1 moles. According to one embodiment of the invention, conversion step (iii) is carried out with the corresponding carboxylic acid anhydride of formula (R'CO^O. Before this step is carried out, it has been found desirable to raise the pH of the solution resulting from step (ii), typically at a temperature from 50°C to 80°C, especially 60 to 65°C, by the addition of an alkali such as sodium hydroxide or, for example, potassium hydroxide. Ammonium hydroxide is generally less desirable to use. This pH is suitably raised from 7 to 8.5 to, say, 9 to 12, preferably 10 to 11.5. It is believed that when the starting material is cobaltous chloride, this addition causes PACC to be converted to PAQC which can more readily be carboxylated. Thus in this preferred embodiment, in step (i) the increased pH due to ammonia addition is neutralised to enhance oxidation by a mildly acidic material while before carboxylation the pH is increased. This solution is then desirably cooled, for example to room temperature (20- 25°C) and then the carboxylic acid anhydride is added. Typically acetic anhydride is used for this purpose although peracetic acid and acetic acid can also be used. It should be added slowly since the reaαion is significantly exothermic and it is desirable to cool the reaαion vessel, for example to keep the temperature from exceeding, say, 40° C. A particular feature of the process for the present invention is that the produα of step (iii) can be obtained with very little impurities. In particular where cobaltous chloride is used as the starting material, little or no PACC is present. This produα generally does not precipitate because of its very high solubility and can be isolated by evaporation. According to a preferred embodiment of the invention, step (iii) is performed by increasing the amount of ammonium carboxylate added to the initial reaαion mixture. Particularly good results are obtained by this method when the cobalt (II) salt is CoζR'COO^, especially where R 1 is methyl, or where the molar ratio of the ammonium carboxylate to the cobalt salt is from 3:1 to 4:1 and/or where the molar ratio of ammonia to the cobalt salt is from 4:1 to 7:1, particularly from 5:1 to 6:1. An advantage of the preferred embodiment of the invention is it does not involve the use of strong bases which have to be used with care because of the danger of decomposition. A further advantage is that the concentration of ammonia used is even less, reducing waste because there is less ammonia to distil off at the end of step (ii) and SUBSTTTUTE SHEET (RULE 26) reducing the amount of washing required to remove the hexa ammonia complex (HAC) because less of this complex is formed. According to another feature of the present invention, the X anion can be replaced by a different anion by a metathetical reaαion in order that a new salt which is less soluble is obtained which may precipitate. In other words by replacing the chloride ion by a different "counter ion" which gives rise to a much less soluble complex it is possible to isolate the complex much more simply, for example by precipitation. Preferably the conversion of the counter ion is carried out before the reaαion solution is allowed to cool. This is advantageous because larger crystal sizes are produced in the precipitate which are easier to filter. Numerous "counter ions" can be used for this purpose, of which the most preferred are the nitrate, fluoroborate and methane sulphonate (PAAN, PAAFB and PAAMS for the acetato complex) along with the perchlorate. Other anions which may be used include the sulphate, carbonate and various phosphates along with a variety of organic anions including the acetate, glutamate, succinate, malonate, fumarate and toluene sulphonate. Typical organic anions include those of the formula R 2 COO where R 2 represents an optionally hydroxy substituted alkyl or alkenyl group 1 to 18, for example 1 to 6, carbon atoms. The presence of a longer hydrocarbon chain will add to the hydrophobicity of the complex which will be useful in certain applications. It will be appreciated that the aim is to obtain a good yield of the salt in a readily colleαable form. The reaαion conditions should be adjusted accordingly. The fluoroborate and methane sulphonate of the pentammonium acetate complex are believed to be novel and form another aspeα of the present invention. When nitrate is to be used as the new counter ion, nitric acid or a suitable nitrate salt (e.g. an alkali metal nitrate) may be used in the conversion reaαion. SUBSTTTUTE SHEET (RULE 26) Preferably the molar ratio of nitric acid or nitrate salt to cobalt (II) starting material is from 2:1 to 5:1, more preferably 2:1 to 3:1. It will be appreciated that the use of less ammonia or amine than has been suggested in the past is beneficial both in terms of processing and in terms of effluent management. Thus effluent which contains less amino compounds presents less of an environmental hazard than effluent containing higher concentrations. Similar comments apply to the use of relatively small concentrations of hydrogen peroxide. This lower concentration aids safety since the addition of large quantities of hydrogen peroxide tends to cause an effervescence which give rise to high oxygen contents in the flue. Although the present discussion principally concerns the acetato cobalt complexes it will be appreciated that similar comments apply to other carboxylato complexes obtained by using higher anhydrides such as propionic anhydride in place of acetic anhydride. The following Examples further illustrate the present invention. Example 1 Preparation of PAAC from cobalt ( D chloride The following material were used: 32% ammonia solution 98-135g (see Table) ammonium acetate 92g 27% CoCl 2 solution 190g 35% H 2 0 2 solution 29g 47% NaOH solution 97-100g (see Table) Total 649-689g The ammonia solution and ammonium acetate were charged to a stirred flask equipped with a condenser; the temperature of the resulting solution was 12-15°C. The cobalt chloride solution was added over 10-15 minutes resulting in an exothermal reaαion which raised the temperature of the solution to 35-46°C (see Table). The peroxide solution was then added over 10-15 minutes resulting in an exotherm to approximately 60°C. The solution was heated to 65°C and the sodium hydroxide was added over 15- 20 minutes exotherming 1-2°C. After stirring 30-45 minutes with a controller set at 65°C PACC was no longer deteαed and the solution was cooled to approximately 25°C and the acetic anhydride was added over 45-60 minutes with cooling applied to keep the temperature below 40°C. The details are given in Table 1. SUBSTTTUTE SHEET (RULE 26) Table 1 Ammonia Cobalt pH pH NaOH pH Final % % t solution/g exo-therm before before solution g before pH Conver¬ PAAC /°C HA NaOH Ac 2 0 sion (25°C) 98 35 8.5 7.5 99 10.9 4.6 80 13.2 107 34 8.7 8.0 98 10.9 4.7 85 13.8 115 43 8.65 8.0 100 10.9 4.75 83 13.7 135 46 8.9 8.4 97 11.0 5.1 75 11.9 A bulk mixture was made from the solutions obtained. It analyzed as 13.7% Wt PAAC. It was used for precipitation trials. Three molar equivalents to Co of the acids shown in Table 2 were added to the solution with stirring; in each case an exotherm was observed. For nitrate and fluoroborate the slurry was gradually cooled to 5°C, filtered, washed with methanol and dried in a fan oven at 80°C. For methanesulphonate approximately 1.5 further mole equivalents of acid were added before precipitation started and the slurry treated as before. The overall yield assumes 85% conversion in solution. Table 2 Solution Acid change Dry Yield Assay as % of soln Overall PAAX PAA yield from isolated CoCl 2 498g 81g 70% 82.0g 98.8% 99.6 85% HN0 3 PAAN 1 498g 197g 40% 79.5g 97.1% 82.3 70% HBF 4 PAAFB 353g 130g 70% 62.4g 93.5% 84.0 71% MeS0 3 H PAAMS The nitrate and fluoroborate additions resulted in immediate precipitation i.e. with the first few drops. The nitrate and methanesulphonate produαs filtered readily in a few minutes whereas the fluoroborate was more difficult to isolate by vac-filtration, taking over an hour. In separate tests we found that the methanesulphonate produα precipitated if less methanesulphonic acid was added so long as an addition of strong acid was made e.g. HCl. We also found that the use of sodium fluoroborate solution as precipitant leads to a big improvement in the ease of isolation of the fluoroborate. We confirmed that the nitrate and fluoroborate could be washed with water; the methanesulphonate cannot be because it has a solubility of approximately 25% compared to < 1% for PAAN and PAAFB at room temperature. Example 2 PAAN Direα Process The following materials were used: 32% ammonia solution 345g ammonium acetate 300g 27% CoCl 2 solution 619g 35% H 2 o 2 solution 95g 47% NaOH solution 320g Ac^O 464g (Sub-total 1) (2143g) 70% HNO. solution 234g Reaαor total 2377g The ammonia solution at 25°C and ammonium acetate were charged to a stirred 31 RB Quickfit flask equipped with a condenser and reaαion temperature-controller; after stirring 5 minutes the resulting solution registered 5°C. The cobalt chloride solution was added over 15 minutes in a steady stream resulting in an exotherm to 41 °C after approximately 3/4 of the addition; at the end of the addition the temperature in the flask was 38°C. After stirring 40 minutes the red solution was at 33°C and registered pH 8.66; a trace of solid was observed in the flask. The hydrogen peroxide solution was added over 50 minutes during which time the temperature in the flask rose to 56°C. Early in the addition each drop produced a vigorous effervescence upon contaα with the flask contents; towards the end the effervescence at the point of contaα diminished significantly being replaced by a gentle effervescence across the surface and the solution developed a more intense red colour. The mantle was set to heat to 65°C; at 60°C the solution registered pH 7.9 and the caustic soda addition was started; it lasted 15 minutes during which time an exotherm was observed and the temperature peaked at 70°C. After stirring a further 30 minutes the temperature had dropped back to 65°C and the solution registered pH 10.6 having peaked at 11.1; no solid was observed in the flask. After cooling to 27°C the solution registered pH 11.2. The acetic anhydride was added over 110 minutes whilst the flask was immersed in a water bath (changed a few times); the maximum temperature observed was 38°C. After the addition there was no evidence of continuing exotherm and the pH was stable at 4.7. The solution was a deep red colour and no solid was observed in the flask. The flask was weighed and found to contain 2134g nett, mass balance - 9g. A small sample was taken and analyzed by HPLC, <0.1%Wt. "PAC" was deteαed and the solution assayed as 14.8% "PAAC" (Conversion - 88% on Co.. The nitric acid solution was added at a steady rate over 35 minutes; an exotherm was observed as the flask contents rose to 45°C with no cooling applied during the addition a red solid precipitated. The slurry was cooled to 23 °C over 60 minutes; it registered pH 3.5. It filtered with ease through a Nol porosity sintered- SUBSTΓΠ TE SHEET (RULE 26) glass Buchner funnel under vacuum. The cake was washed with 2 X approximately 200 mis ice cold water and left in the funnel for approximately 30 minutes. Yield «= 2313g combined liquor; 407g wet-cake The wet-cake was dried in a fan over at 80°C for 2 hours, and ground in a mortar and pestle before analysis; Yield - 351g Assay = 100.2 % as PAAN <0.2% PAC i.e. 1.08 moles; 83% Yield on Cobalt. The liquor registered pH 3.6. It was analyzed by HPLC and found to contain produα equivalent to 20g PAAN, i.e. 5% of Co charge. The nitric acid charge equates to 2 mole equivalents to Co, i.e. 2/3 the amount used in Example 1. In similar experiments from cobalt acetate we observed quantitative precipitation if the solutions were acidified to pHl; the pH drops rapidly below pH 3 so a small increase in nitric acid addition would probably maximise the yield. The liquor has a brown-black colour; it darkens during the nitric acid addition. It has a strong odour of acetic acid and the following approximate composition calculated by difference from the charges and dried produα, assuming for the time being that "non-PAA cobalt" is present as HAC complex; Combined liquor + washings PAAN 0.06 moles 20g 0.87% HAC 0.16 moles 59g 2.5% sodium chloride 1.94 moles 113g 4.9% sodium nitrate 0.44 moles 37g 1.6% sodium acetate 1.42 moles 116g 5.0% ammonium acetate 3.68 moles 283g 12% acetic acid 6.8 moles 408g 18% Total solids 1036g 44.8% The complexes contain lOg cobalt i.e. 0.43% Wt. in the liquor. Example 3 PAAMS Direα Process The following materials were used: 32% ammonia solution 398g ammonium acetate 347g 27% CoCl 2 solution 714g 35% H 2 0 2 solution 109g 47% NaOH solution 370g Ac 536g (Sub-total 1) (2474g) 36% HCl solution 350g 70% MeSO.H solution 411e Reaαor total 3235g There were no significant differences to Example 2 up to the end of the anhydride addition when the flask contained 2461g solution with pH 4.8 and an assay of 14.9% PAAC i.e. 89% conversion from Cobalt. With the flask contents at 26°C the hydrochloric acid addition was made over 20 minutes whilst cooling in a water bath to 24°C when the solution registered pH 3.5. The methanesulphonic acid solution was added over 45 minutes accompanied by a raise in temperature in the flask to 29°C and a drop in pH to < 1. After approximately 80% of the addition the produα "dropped out" of solution and an exotherm was observed to 34°C. After cooling to 15°C the slurry was filtered through two Nol porosity sintered- glass Buchner funnels under vacuum, the cake was washed with a total of 600 mis methanol and left in the funnel overnight then dried for an hour in a fan oven at 80°C, and ground in a mortar and pestle before analysis. Yield = 2313g combined liquor; 440g Dry produα Assay - 97.1% as PAAMS, approximately 3% "PAC" i.e. 1.09 moles; 84% Yield on Cobalt. Example 4 PAAFB Direα Process A batch of solution was prepared as for PAAMS (Example 3) with c. 3.5 hours for the anhydride addition. The yield was 248 lg with pH 4.83 and assay 14.6% PAAC, i.e. 88% conversion. The desired produα was made by sodium fluoroborate precipitation and water washing from a composite sample of "PAA" solutions prepared in the presence of chloride and acetate ions, i.e. samples from both cobalt salts + "opposite" buffering acid. The "PAA" solution assayed 13.0% as PAAC and contained praαically no PACC. The percentage yield for this step was 70%, i.e. percentage of solution "PAA" found in the washed and dried PAAFB; 239g Dry produα; Assay = 101% as PAAFB, <0.2%"PAC". Example 5 A series of experiments were performed on cobalt (II) acetate tetrahydrate with ammonium chloride at the same pH's and temperatures as in Example 1. The conversions were not as good even if water was added to the same overall strength, namely 66% conversion using 'all-crystals' and 75% with added water (either as cobalt acetate solution, or diluted ammonia reaαants + cobalt acetate crystals). The pH's after acetic anhydride addition were approximately 4.5 as expeαed. Further experiments were performed at 8 moles total ammonia species per mole cobalt with other acid buffers to give solutions of Co (II) complexes with pH approximately 8.7 prior to oxidation: Cobalt (II) salt Acid Moles ammonia Moles amm. salt Chloride HCl 5.7 2.3 Chloride AcOH 5.0 3.0 Acetate HCl 5.4 2.6 Acetate AcOH 4.0 4.0 Acetate H 2 S0 4 5.2 1.4 Acetate MeS0 3 H 5.85 2.15 Acetate HN0 3 4.5 3.5 Following the same method as before with all acetate species the following results were obtained; Moles Ac 2 θ:Co pH % Conversion 3 5.6 61 3/5 5.6 75 5 5 78 Experiments with 3 moles anhydride and sulphate or methanesulphonate buffering prepared in-situ resulted in conversions of 61 and 59% respeαively in solutions of pH 4.7 and 4.65. Experiments with ammonium nitrate, added as solid, resulted in precipitation of produα as 'PAA' formed; the final mixtures were acidified to pH 1 when PAAN was colleαed quantitatively, i.e. no 'PAA' remained in the liquors. The best yield was 69% from 3 moles anhydride; the slurry prior to nitric acid addition registered pH 4.8. Example 6 Preparation of PAAN from Cobalt (II) Acetate The following material was used: Ammonium acetate 162g 28% Ammonia Solution 233g Cobalt (II) acetate.4H 2 0 87g 35% H 2 0 2 34g (Solution sub-total) (516g) 45% NaN0 3 265g Total 781e Cobalt acetate was quickly added to freshly prepared ammonia buffer at 11°C to form a clear solution at a temperature of 26°C. The hydrogen peroxide solution was then added over 20 minutes without cooling during which time the temperature of the solution rose from 26°C to 49°C. The solution was then stirred for one hour. After stirring, the temperature of the solution was 33°C. It was then heated to a temperature of 80°C. It was then maintained at this temperature for six hours. After cooling to 21°C, the sodium nitrate solution was added over a period of 20 minutes. 20 minutes after the addition of the sodium nitrate solution, the solution was cooled and after an hour, it was filtered and washed with iced water. The produα filtered slowly and gave a very wet cake (approximately 30% water) which was dried in an oven at 70° C. Results and Analysis The mass balance showed that 83g was lost per mole of cobalt. The conversion of cobalt based on the amount of PAAA obtained was 90.5%. In the assay of the dry produα was found 96.7% by weight of PAAN and 3.9% by weight of HAN dCo m (NH 3 )J(N0 3 ) 3 ). The dry yield of PAAN with respeα to the amount of cobalt used was 86%. The recovery of PAA from solution was 95%. Example 7 Preparation of PAAA from Cobalt (Tfl) Acetate using Aerial Oxidation The following material was used: Ammonium acetate 578g 28% Ammonia solution 835g Cobalt (II) acetate. 4H 2 0 311g Solution total 1724g Cobalt acetate was added quickly to freshly prepared ammonia buffer without cooling. The resultant solution was clear and had a temperature of 23 °C. Air was then bubbled through the solution at a rate of 800ml/mim and was left on overnight. After approximately 20 hours, the air supply was stopped and the solution was heated to 80°C and this temperature was maintained for six hours. At the end of the heating, the solution was cooled. Results and Analysis The mass balance showed that 94g was lost per mole of cobalt in the experiment. The conversion rate of cobalt based on the PAAA assay was 85.8%. Example 8 Preparation of PAAA from Cobalt (TI) Acetate The following material was used: Ammonium acetate 216g 32% Ammonia solution 234g Cobalt ( I) acetate .4H 2 0 199g 35% hydrogen peroxide 58g Solution total 707g Cobalt acetate was added to freshly prepared ammonia buffer quickly without cooling. The resultant solution was clear and had a temperature of 28°C. Peroxide solution was then added over a period of 50 minutes without cooling. The resultant solution which had a temperature of 59°C was then stirred for 40 minutes. The stirred solution was heated to 80°C and this temperature was maintained for six hours. The solution was then cooled. Results and Analysis The mass balance showed that 5g was lost per mole of cobalt in the experiment. The conversion rate of cobalt based on the PAAA assay was 88.9%. Example 9 Preparation of PAAA from Cobalt (ID Acetate The following material was used: Ammonium acetate lOllg 32% Ammonia solution 1095g Cobalt (II) acetate .4H 2 0 934g 35% hydrogen peroxide 219g Solution total 3259g Cobalt acetate was added to freshly prepared ammonia buffer quickly without cooling. The resultant solution had a temperature of 26°C and after 60 minutes, the hydrogen peroxide solution was added over a period of 3 3/4 hours. Frothing was observed towards the end of the peroxide addition and water was used to wash down the condenser. After the addition of peroxide, the solution was maintained at a temperature of 46°C for 20 minutes. It was then heated to 80°C and maintained over night before being cooled. Results and Analysis The conversion rate of cobalt based on the PAAA assay was 86.4%. Example 10 Preparation of PAAA from Cobalt (IT) Acetate using Aerial Oxidation The following material was used: Ammonium acetate 606g 28% Ammonia Solution 657g Cobalt (II) acetate.4H 2 0 560g Solution total 1823e Cobalt acetate was added to freshly prepared ammonia buffer quickly without cooling. The resultant solution was clear and had a temperature of 27°C. After 55 minutes, air was bubbled through the solution at a rate of 1800ml/min and the air was left on overnight. Approximately 20 hours later, the air supply was stopped and the solution was heated to 80°C and maintained at this temperature for 6 hours before being cooled. Results and Analysis The mass balance showed that 32g was lost per mole of cobalt in the experiment. The conversion rate of cobalt based on the PAAA assay was 70.0%. Example 11 Precipitation with sodium nitrate of the produα of Example 9 The following material was used: Example 9 solution 436g 45% sodium nitrate 189g (First aliquot) 45% sodium nitrate 66g (Second aliquot) Slurry total 691g The first aliquot of sodium nitrate was added over a period of 55 minutes without cooling. Precipitation started with the first few drops and was mildly exothermic. The final temperature of the solution was 30°C and an assay of the supernatant after addition of the first aliquot showed that less than 5% of PAA remained in the solution. The second aliquot of sodium nitrate was then added after a wait of 35 minutes over a period of 15 minutes. An assay of the supernatant after the addition of the second aliquot showed that an insignificant amount of PAA remained in the solution. After one hour, the precipitate was filtered and washed with 200ml of ice water. Results and Analysis In the assay of the dry produα was found 92.7% by weight of PAAN and 6.5% by weight of HAN. The dry yield of PAAN with respeα to the amount of cobalt used was 82%. The recovery of PAA from solution was 95%. Example 12 Precipitation with nitric acid of the produα of Example 9 The following material was used: Example 9 solution 523g 68% nitric acid lllg 68% nitric acid 39g Slurry total 673g The first aliquot of nitric acid was added over a period of 20 minutes without cooling. Precipitation started with the first few drops and was highly exothermic. The final temperature was 59°C. An assay of the supernatant after the addition of the first aliquot showed that less than 5% of PAA remained in the solution. Cooling was then applied for \ά hour until a temperature of 18 °C was reached and then the second aliquot was added over a period of 10 minutes. An assay of the supernatant after the addition of the second aliquot showed that an insignificant trace of PAA remained in the solution. The produα was cooled for 40 minutes then filtered and washed with 240ml iced water. Results and Analysis In the assay of the dry produα was found 94.6% by weight of PAAN and 6.8% by weight of HAN. The dry yield of PAAN with respeα to the amount of cobalt used was 86%. The recovery of PAA from solution was 99.5%.

Claims: C L A I M S 1. A process for preparing a cobalt III complex which comprises: (i) treating a divalent cobalt salt of formula Co^. where n is the valency of an anion X, with up to 15 molar equivalents of ammonia or an amine; (ii) oxidising the resulting amine complex; (iii) converting the oxidised complex to the corresponding carboxylate of formula [Co ffl (NR 3 ) 5 R i COO]X 2/-1 where each R, which may be the same or different, represents hydrogen or an optionally substituted hydrocarbon group and R 1 represents an alkyl or alkenyl group of 1 to 18 carbon atoms, at a pH above 8.5; and optionally (iv) replacing the X ion by a different anion by a metathetical reaαion. 2. A process according to claim 1 in which the divalent cobalt salt is cobaltous acetate. 3. A process according to claim 1 or 2 in which ammonia is used in step (i). 4. A process according to claim 3 in which the ammonia is added as ammonium acetate. 5. A process according to claim 3 or 4 in which the molar ratio of ammonia to cobalt salt is from 5:1 to 6:1. 6. A process according to claim 3 or 4 in which the molar ratio of ammonium salt to the cobalt salt is from 3:1 to 4:1. 7. A process according to any one of the preceding claims in which step (ii) is carried out with hydrogen peroxide. 8. A process according to claim 7 in which the hydrogen peroxide is used in an amount from 0.5 to 1 moles per mole of complex. 9. A process according to any one of the preceding claims in which after step (ϋ) and before (iii) the pH is raised to 9 to 12 by the addition of alkali. 10. A process according to any one of the preceding claims in which step (iii) is carried out using the corresponding carboxylic acid anhydride of formula (R'CO^O. 11. A process according to any one of the preceding claims in which R represents methyl. 12. A process according to any one of the preceding claims in which step (iv) is carried out wherein the new ion X is the nitrate, fluoroborate, methane sulphonate or perchlorate. 13. A process according to claim 1 substantially as described in any one of the examples. 14. A cobalt complex of the formula [Co m (NR 3 ) 5 R 1 COO]X 2/n where each R, which may be the same or different, represents hydrogen or an optionally substituted hydrocarbon group, R 1 represents methyl, X represents fluoroborate or methane sulphonate and n is the valency of X.

Inventors: CARR JOHN FREDERICK, PAKENHAM DEREK, CARR, JOHN, FREDERICK, PAKENHAM, DEREK
Applicants: CARR JOHN FREDERICK, PAKENHAM DEREK, RHONE POULENC CHEMICALS, CARR, JOHN, FREDERICK, PAKENHAM, DEREK, RHONE-POULENC CHEMICALS LTD.
Application year: 1996
Main classification: C07F15
IPC codes: B01J31, C07F15