PROCESS FOR THE CARBONYLATION OF ETHYLENICALLY UNSATURATED COMPOUNDS

Abstract: The invention provides a process for the carbonylation of ethylenically unsaturated compounds by reaction thereof with carbon monoxide and a coreactant in the presence of a catalyst system obtainable by combining (a) a source of a Group VIII metal cation, (b) a phosphine, arsine or stibine compound acting as a ligand; and (c) a source of anions, other than halide anions, carried out in the presence of substoichiometric amounts of halide anions and/or - in case of a coreactant other than an aromatic alcohol - in the presence of a phenolic promoter. It also provides novel alkylphenol esters that find use as synthetic lubricant.

Description: PROCESS FOR THE CARBONYLATION OF ETHYLENICALLY UNSATURATED COMPOUNDS The invention relates to a process for the carbonyla- tion of ethylenically unsaturated compounds by reaction with carbon monoxide and a coreactant in the presence of a homogeneous catalyst system comprising a source of Group VIII metal cation and a ligand. It also relates to alkylphenol esters so produced and to the use of alkylphenolesters m automotive and industrial applications . Carbonylation reactions are known m the art. For instance, in EP-A-0, 495, 547 several examples are dis¬ closed wherein olefins are converted into (thio) esters, acids, anhydrides, and amides, etc., depending on the nature of the coreactant. Similarly, in WO 94/18154, a process modification is disclosed, based on the presence of an amme, whereby the rate of the carbonylation reaction as described m EP-A-0, 495, 547 is increased. Whilst the process disclosed in WO 94/18154 provides the desired product m better yield and with greater selectivity than m EP-A-0, 495, 547, further improvement remains desirable. Indeed, there still remain instances where reaction is slow to proceed if at all. The present invention aims at providing a process with increased reaction rate, without impeding other factors such as selectivity or catalyst stability. Surprisingly, it has now been found that by inclusion into the catalyst system of substoichiometric amounts of halide anions, and/or -m case of a coreactant other than an aromatic alcohol- by the presence of a phenolic com¬ pound, the catalyst activity is substantially increased. Accordingly, the invention provides a process for the carbonylation of ethylenically unsaturated compounds by reaction thereof with carbon monoxide and a coreactant in the presence of a catalyst system obtainable by combining (a) a source of a Group VIII metal cation (b) a phosphine, arsme or stibine compound acting as a ligand; and (c) a source of anions, other than halide anions, carried out m the presence of substoichiometric amounts of a halide anion and/or -m case of a coreactant other than an aromatic alcohol- m the presence of a phenolic promoter. It is believed that the carbonylation reactions proceed under the influence of an active catalyst system containing one or more Group VIII metal cations, in complex coordination with the ligand, the ethylenically unsaturated compound and the halide anion and/or the phenolic promoter. The halide anion can be a chloride, bromide, iodide, or fluoride anion. From a commercial point of view, based on price and availability, the chloride is preferred. From a technical point of view, based on its greater promoting effect and the linearity of the carbonylation products, the iodide anion is preferred. Substoichiometric in this specification means that less halide anions are present than required to neutralise the Group VIII metal cations. Preferably, the molar ratio of dissociated halide anions versus Group VIII metal cations is less than 2:1, for instance from 0.02:1 to 1:1, per mole of cation. The ideal ratio depends on the liquid medium and may be easily found by those skilled m the art. Suitable sources of the halide anion include both hydrogen halides, e.g., HCl, HBr and HI, quaternary ammonium or phosphonium halides, e.g., triphenylmethylphosphomum chloride and metal halides, e.g., NaCl, MgBr 2 / ZnCl 2 , Znl 2 , LiBr, RbCl, CsCl, Csl, Mgl 2 and CuCl, m particular alkali or earth alkaline metal halides. The pnenolic promoter is an aromatic compound having one or more hydroxyl groups attached to the aromatic backbone of the compound. Typically, the aromatic backbone is a 6-membered ring, which may be part of a larger fused (aromatic) ring system. Examples of such aromatic compounds include 3-hydroxypyrιdme, 3- or 6- qumolmol, 1- or 2-hydroxynaphthalene (α- or β- naphthol), o,o'-, m,m'- or p,p'-biphenol, 2,2-dι(p- phenylol) propane (DPP), etc. Suitably, it is a 6-membered ring composed of carbon atoms only. More suitably, the aromatic backbone is a benzene ring, optionally having one or more inert groups, such as alkyl groups of up to 20 carbon atoms, attached thereon. For instance, the phenolic promoter may be 3, 5-dιmethoxyphenol, hydroqui- none, or phenol, etc. Preferably, the phenolic promoter is DPP or phenol. The use of the phenolic promoter has been found particularly beneficial in an amount of up to 40% by weight, based on the total weight of reactants, optional solvent and the catalyst system. Preferably, it is used in an amount of 10 to 20 %wt. It will be understood that the phenolic promoter cannot at the same time partake in the carbonylation reaction as coreactant. Therefore, in order for the phenolic promoter to function as promoter, another compound must be present to act as coreactant. Preferably, the carbonylation process is carried out in the presence both of the phenolic promoter and the halide anion. The carbonylation reaction is conveniently carried out at moderate temperatures. Accordingly, the process is suitably carried out at a temperature in the range of from 30 to 200 °C, eg from 100 to 2U0°C. Preferred temperatures are in the range of from 50 to 180 °C. The reaction pressures may also vary widely. For instance, the reaction can be carried out at a pressure in the range of from 1 to 200 bar gauge, pressures m the range of from 5 to 60 bar g being preferred. Carbon monoxide is preferably supplied m molar excess over the ethylenically unsaturated compound and the coreactant. In addition, the ethylenically unsaturated compound and the coreactant are suitably supplied in a molar ratio in the range of from 10:1 to 1:10, preferably m the range of from 5:1 to 1:5, more preferably in the range of from 2:1 to 1:2. In the present specification, Group VIII metals (referring to the Periodic Table of the Elements as disclosed in the 61st ed. of the Handbook of Chemistry and Physics) comprise the elements Fe, Co, Ni, Ru, Rh, Pd, Os, lr and Pt. Preferably the Group VIII metal is a platinum group metal, i.e., Ni, Pd or Pt. Of these, palladium is most preferred. Examples of suitable sources of the cation are salts, such as salts of the Group VIII metal and nitric acid, sulphuric acid, carboxylic acids having up to 12 carbon atoms in the carboxylate group or sulphonic acid; and metal complexes, e.g., with carbon monoxide or acetyl¬ acetonate. Palladium(II) acetate is an example of a suitable source of the preferred cation. Regarding the phosphine, arsine or stibine compound acting as ligand, monodentate ligands such as triphenyl¬ phosphine, etc., may be used. However, preference is given to bidentate ligands containing a second atom that coordinates with the cation, selected from trivalent N, P, As or Sb atoms. Suitably, these bidentate ligands have an organic bridging group that contains from 1 to 5 atoms in the bridge between the two coordinating atoms. One example of such a bidentate ligand is diphenyl- (2-pyridyl) arsine. Preferred bidentate ligands are compounds of the formula R 1 R 2 M 1 -R-M 2 R 3 R 4 , wherein M 1 and M 2 independently are P, As or Sb, R represents a bivalent substituted or non-substituted bridging group containing from 1 to 5 atoms in the bridge, Rl and R 2 together are a substituted or non-substituted bivalent group whereby the two free valencies are linked to M 1 , and R 3 and R 4 together are a substituted or non-substituted bivalent group whereby the two free valencies are linked to M 2 or R 3 and R 4 inde¬ pendently represent a substituted or unsubstituted hydrocarbyl group. Regarding the preferred bidentate ligands, M^ and M 2 preferably both represent phosphorus atoms. The bivalent bridging group R typically is an organic group, inclusive of organometallic groups such as ferrocylene as in WO 95/06027 or ortho-anellated annular systems as in WO 95/30680, connecting the atoms M^ and M 2 through carbon atoms. Usually all bridging atoms are carbon atoms, optionally with hetero-atoms (other than H or C) attached thereto. Preferably, R represents an alkylene group containing from 1 to 3 carbon atoms in the bridge, suitably 2 or 3, in particular an ethylene group or a propylene group. In the preparation of alkylphenol esters, R ideally represents a propylene group. The bivalent substituted or non-substituted group, represented by R 1 together with R 2 , preferably contains from 5 to 9 atoms, preferably 8 atoms. Examples of suitable bivalent groups include 1, 6-hexylene, 1,6- heptylene, and 1, 5-octylene. Together with M 1 , this group forms a phosphacycloalkyl group. Preferably, R 1 together with R 2 represent a bivalent substituted or non- substituted cyclic group. Together with M 1 , this preferred group forms a phosphabicycloalkyl group. Examples of suitable bivalent cyclic groups are 1, 4-cyclohexylene, 1, 4-cycloheptylene, 1, 2-cyclooctylene, 1, 4-cyclooctylene, 1, 5-cyclooctylene and 2-methyl-l, 5- cyclooctylene groups. / - 6 - R 3 and R 4 may independently represent any substituted or unsubstituted hydrocarbyl group, such as alkyl, aryl, alkaryl or aralkyl groups. Preferably, R 3 and R 4 together have the same meaning as R 1 together with R 2 . Suitable substituents in the case that any of R, or R 1 to R^ is substituted may be selected from the group consisting of halogen atoms, and cyano, alkoxy, ammo and alkylamino groups. The alkyl groups in the alkoxy and alkylamino groups preferably each contain from 1 to 4 carbon atoms. Particularly preferred bidentate ligands are the [3,3,1] and [4,2,1] isomers of 1, 2-P, P' -bis (9-phospha- bicyclononyl) ethane, 1, 2-P, P'-bis (dimethyl-9-phospha- bicyclononyl) ethane, 1, 3-P, P' -bis (9-phosphabicyclo- nonyl)propane, 1, 3-P, P'-bis (dimethyl-9-phosphabicyclo- nonyl)propane. For the preparation of the bidentate ligands, reference is made to known techniques, for example the method disclosed in British patent specification No. 1,127,965 and Canadian patent specification No. 2,086,285. The catalyst systems used in the process of the invention are further based on a source of anions other than halide anions, i.e., component (c) . It is believed that the size of the anion and the distribution of electric charge in the anion significantly contribute to the stability of the catalyst system. Suitably, acids are used as the source of anions, or the salts thereof. Preferably, anions are used that are the conjugated base of acids having a pKa (measured at 18 °C in water) of less than 3, preferably less than 2. The anions derived from these acids are non-coordinating or weakly coordinating with the Group VIII metal cation, by which is meant that little or no covalent interaction occurs between the anion and the cation. Catalysts based on these anions exhibit a substantially improved activity. Suitable anions include anions derived from Bronsted acids, such as from phosphoric acid and sulphuric acid, and m particular from sulphonic acids and (halogenated) carboxylic acids, such as trifluoroacetic acid, 2, 6-dιchlorobenzoιc acid, and 2, 6-bιs (trifluoromethyl) - benzoic acid or trifluoroacetic acid. Anions derived from sulphonic acids are particularly preferred, for example methanesulphonic acid, trifluoromethanesulphonic acid, tert-butanesulphonic acid, p-toluenesulphonic acid and 2, 4, 6-trιmethylbenzenesulphonιc acid. Also, complex anions are suitable, such as the anions generated by a combination of a Lewis acid such as BF3, B(CgF5)3, A1C13, SnF 2 , Sn(CF3Sθ3) 2 , SnCl 2 or GeCl 2 , with a protic acid, preferably having a pKa of less than 5, such as a sulphonic acid, e.g. CF3SO3H or CH3SO3H or a hydrohalogenic acid such as HF or HCl, or a combination of a Lewis acid with an alcohol. Examples of such complex anions are BF 4 ~ , SnCl3 ~ , [SnCl 2 .CF3SO3] ~ and PFg ~ . When an organic or inorganic base is present, e.g., as further catalyst promoter, anions derived from acids having a pKa in the range of 6 to 3 may also be used. Examples thereof include carboxylic acids. The quantity m which the catalyst system is used, is not critical and may vary withm wide limits. Usually amounts in the range of from 10 ~ ^ to 10 ~ 1, preferably in the range of from 10-^ to 10 ~2 mole atom of component (a) per mole of ethylenically unsaturated compound are used. For the preparation of the catalyst systems of the invention, the amount of ligand is generally applied m some excess of the amount of the Group VIII metal cation, expressed as moles of ligand per mole atom of the cation. Typically the amount of ligand is selected such that per mole atom of the cation, in the range of from 0.5 to 10 moles of ligand are present. However, for the preferred C E 7 19 5 catalyst system the active species is believed to be based on an equimolar amount of bidentate ligand per mole cation. Thus, the molar amount of bidentate ligand per mole of cation is preferably m the range of from 1 to 3, more preferably in the range of from 1 to 2. In the presence of oxygen, slightly higher amounts may be beneficial. The amount of the anion source may range from 0.5 to 15, preferably from 1 to 8 moles per mole of cation. If desired, the reaction may be performed in the presence of a further catalyst promoter, such as an organic or inorganic base. Suitably, an amme is used. The amme is typically a cyclic amme or a tertiary amine, for example a tπalkylamme. A preferred further catalyst promoter is triethylamine. The amine may be used in large amounts. Suitable amounts include up to 1000, e.g., from 1 to 20 moles per mole of cation. In particular in the carbonylation of (cyclo) alkadienes, and or the carbonylation with (substituted) phenols as coreactant, the presence of a further catalyst promoter has been found very beneficial. In the process of the invention, the starting materials and the formed carbonylation products may act as reaction diluent. Hence, the use of a separate solvent is not necessary. Conveniently, however, the carbonyla¬ tion reaction may be carried out in the additional presence of a solvent. As such, saturated hydrocarbons, e.g. paraffins and isoalkanes are recommended and furthermore ethers such as 2, 5, 8-trιoxanonane (diglyme), diethylether and anisole, sulphones such as sulpholane, and aromatic hydrocarbons such as toluene. The ethylenically unsaturated compound may have one or more double bonds and is preferably an olefin having from 2 to 30 carbon atoms per molecule. The unsaturated bond(s) may be internal or, preferably, terminal. Particularly preferred are olefins having from 2 to 22 carbon atoms per molecule, such as ethene, propene, 1-butene, 1-hexene, 1-octene, 1-dodecene and 1-octadecene . In the ethylenically unsaturated compound one or more hydrogen atoms may have been substituted by other atoms, such as halogen atoms or by groups of atoms, such as hydroxyl groups, cyano groups, such as methoxy or ethoxy groups, or amino groups such as dimethyl- and diethyl- amino groups. Another preferred category of ethylenically unsatu¬ rated compounds, consists of unsaturated esters of carboxylic acids and esters of unsaturated carboxylic acids. For example, the starting material may be a vinyl ester of a carboxylic acid such as acetic acid or propanoic acid, or it may be an alkyl ester of an unsaturated acid, such as the methyl or ethyl ester of acrylic acid or methacrylic acid. A further preferred category of ethylenically unsaturated compounds, consists of cycloalkadienes, which will ordinarily refuse carbonylation. For example, the starting material may be dicyclopentadiene or norborna- diene, to give diesters, diamides or diacids, etc., which may find use as monomer in polymerization reactions. Suitable coreactants in the process of the invention include compounds comprising a nucleophilic moiety and a mobile hydrogen atom. Preferred nucleophilic compounds include: water and alcohols, e.g., monohydric alcohols, such as methanol, ethanol, isopropanol and 1-butanol, and polyhydric alco¬ hols, such as ethyleneglycol, 1,4-butanediol and glycerol; thiols; primary or secondary (poly) amines or amides, such as diethylamine, N,N-dimethyl ethylene¬ diamine; aromatic alcohols and carboxylic acids, for example acetic acid, pivalic acid and propanoic acid. Monohydric alcohols having from 1 to 6 carbon atoms per molecule and dihydπc alcohols having from 2 to 6 carbon atoms per molecule are preferred. 1-Butanol, methanol and 1, 4-bαtanedιol are especially preferred. The use of these compounds as coreactants enables the production of valuable carbonylation prod¬ ucts, such as methyl propanoate, butyl propanoate and 1, 4-dιacyloxy butanes. These compounds are of commercial interest and may be used as solvents and in flavouring compositions and perfumes. Another preferred class of coreactants is composed of alkylphenols, wherem one or more alkyl groups of up to 30, typically 4 or 6 to 22 carbon atoms are attached to the phenol molecule. Carbonylation of these coreactants produces alkylphenyl esters. Certain of these alkylphenyl esters may find use as synthetic lubricants in industrial application, but in particular in automotive engines, as they exhibit a very low volatility combined with a low viscosity and a high oxidation stability. These characteristics give the alkylphenyl esters a significant advantage over existing lubricants when considering two important requirements for future lubricants: increasing fuel economy and lowering emissions. Besides, they exhibit excellent hydrolytic stability, good cleanliness performance and good elastomer compatibility. From Japanese patent specification no. 2-292395A, esters of alkyphenols and monobasic acids are proposed as component base oils for lubricant compositions. The alkyl phenol ester proposed have the formula m which m is 0 to 2, R^ is nydrocarbon eg alkyl, and R 2 is alkyl of 1 to 8 carbon atoms. No specific example of such an ester is disclosed, nor are any lubricant properties for such compounds specified. It has now been found that C -g alkylphenol esters have unsuitable properties as lubricants whereas similar alkyl phenol esters but with a higher carbon-containmg alkyl substituent surprisingly show significantly better volatility, VI and pour point properties. Thus, the invention also provides novel alkylphenyl esters of the general formula R' n C 6 H (5 _ n) OC(=0)R" (I) wherem R' is an alkyl group of from 10 to 30 carbon atoms, suitably of from 10 or 12 to 22, preferably from 10 to 20, more preferably from 12 to 20, especially from 14 to 18, carbon atoms, n is an integer of 1 to 5, typically 1 or 2, and R" is an alkyl group of from 1 to 30 carbon atoms, suitably of from 4 to 22, preferably 6 to 20, more preferably 6 to 15, especially 8 to 12, carbon atoms. Preferably, n is 1, and R' together with R" preferably have from 20 to 40 carbon atoms. More preferably, the number of carbon atoms in R' is equal to or preferably larger than to the number of carbon atoms m R". An alkyl group R' or R" may be a straight chain or branched chain alkyl group. The starting alkylphenol is suitably prepared by alkylation of the phenol. For instance, they may be prepared by alkylation of a phenol with an alpha or internal olefm, e.g., such as an alpha olefin having from 14 to 18 carbon atoms. The novel alkylphenol esters may also be prepared through esterification, e.g., by reaction of the alkylphenol with the carboxylic acid or corresponding acid chloride by conventional procedures, eg preferably at reflux, in an organic solvent, if necessary, and using an acid catalyst, for example methane sulphonic acid. The invention further provides the use of the alkylphenyl esters of formula I as synthetic lubricants, for instance in automotive applications. In particular the alkylphenyl esters wherein R' together with R" have from 20 to 40 carbon atoms exhibit attractive properties regarding viscosity, oxidative stability and volatility. Those wherein the number of carbon atoms in R' is equal to or preferably larger than the number of carbon atoms in R" can exhibit an attractive, low pour point. Oxidative stability and pour point may be further improved by the presence of branched alkyl groups in either R" (resulting from alkylation with an internal or branched olefin) or R" (resulting from carbonylation of an internal or branched olefin) . Finally, in accordance with the present invention there is also provided a lubricating oil composition comprising as a base fluid an alkylphenol ester as mentioned above. In the lubricating oil composition, the alkylphenol ester may be present in an amount of at least 2% by weight, preferably at least 10% w/w, more prefer- ably at least 40% w/w of the total base fluid. It may be present in an amount up to 100% w/w, preferably up to 90% w/w, more preferably up to 75% w/w on the same basis. It should be understood, however, that the amount of alkyl¬ phenol ester may vary with the price-performance aimed at. Furthermore, in the lubricating oil composition according to the present invention, the balance of the total base fluid is preferably a base oil of mineral or synthetic origin. Suitable additives with which the compounds of the present invention may be used for engine oil application may include one or more extreme pressure/anti-wear agents, for example zinc salts such as zinc dialkyl or diaryl phosphorodithioates (at a concentration giving from 0 to 0.15% w/w phosphorus in the lubricating oil composition) ; one or more overbased metal-containing detergents such as calcium or magnesium alkyl salicylates or alkylarylsulphonates (present at total detergent concentration m the lubricating oil composition from 0 to 20% w/w) ; one or more detergents such as phenates and phenate/sulphonate mixtures (present at total detergent concentration m the lubricating oil composition from 0 to 20% w/w) ; one or more ashless dispersant additives such as reaction products of polyisobutenyl succinic anhydride and an amme or ester (present at total dispersant active matter concentration in the lubricating oil composition from 0 to 20% w/w) ; optionally one or more primary antioxidants, for example hindered phenols or ammes (present at concentrations in the lubricating oil composition from 0 to 5% w/w) . Other supplementary additives, for example anti-rust or friction-modifying additives may optionally be present. Viscosity Index improving polymers may optionally be present at polymer concentrations from 0 to 20% w/w. Pour point depressing additives may optionally be present at concentrations from 0 to 5% w/w. The balance of base oil m the lubricating oil composition may be a base oil of mineral or synthetic origin. Base oils of mineral origin may be mineral oils, for example produced by solvent refining or hydro- processing. Base oils of synthetic origin may typically be mixtures of Cm-50 hydrocarbon polymers, for example liquid polymers of alpha-olefms . They may also be conventional esters, for example polyol esters. The base oil may also be a mixture of these oils. Preferably the base oil is that of mineral origin sold by the Royal Dutch/Shell Group of Companies under the designations "HVI" (trade mark) or, most preferably, the synthetic hydrocarbon base oils sold by the Royal Dutch/Shell Group of Companies under the designation "XHVI" (trade mark) . The invention will now be further described in the following examples, however, without restricting its scope. All experiments were carried out in a magnetically stirred 250 ml autoclave unless otherwise indicated. The abbreviations used m the Tables have the following meanings: BCPE = l,2-P,P'-bιs(9-phosphabιcyclo[3,3,l or 4,2,1] nonyl) ethane; BCPP = 1, 3-P,P'-bιs (9-phosphabιcyclo [3, 3, 1 or 4,2,1]nonyl)propane; MSA = methanesulphonic acid; DPP = 2, 2-dι (p-phenylol)propane. Example 1 (Comparative) The autoclave was charged with 20 ml of butanol, 40 ml of butyl propanoate (solvent), 0.25 mmol of palla- dιum(II) acetate, 0.6 mmol of BCPE, 0.5 mmol of MSA and 5 ml of triethylamine. After being flushed, the autoclave was pressurised with carbon monoxide and ethene to a partial pressure of 15 bar and 10 bar respectively. Next, the reactor was sealed. The contents of the autoclave were heated to a temperature of 125 °C and maintained at that temperature for 2 hours. After cooling, a sample was taken from the contents of the autoclave and analysed by Gas Liquid Chromatography. Ethene was fully converted with 100% selectivity into butyl propanoate at an average rate of 300 mol per mole Pd per hour (mol/mol.hr) . Similar results were found m the presence of 1 ml triethylamine. Example 2 The experiment of Example 1 was repeated, however, in the presence of 0.25 mmol HCl. Ethene was now fully converted with 100% selectivity into butyl propanoate at an average rate of 1200 mol/mol.hr. Example 3 The experiment of Example 1 was repeated, however, m the presence of 2 mmol propanoic acid instead of MSA and in the presence of 10 g DPP. Ethene was now fully converted with 100'ϊ selectivity into butyl propanoate at an average rate of 1200 mol/mol.hr. When phenol is used instead of DPP, an average rate was found of 1200 mol/mol.hr. Example 4 The experiment of Example 1 was repeated, however, in the presence of 0.25 mmol HCl and 5 g phenol. Ethene was now fully converted with 100% selectivity into butyl propanoate at an average rate of 4000 mol/mol.hr. When 10 g of phenol were used, the average rate increased to 8000 mol/mol.hr. An average rate of 8000 mol/mol.hr was also found when 10 g of DPP instead of phenol, and triphenylmethylphosphonium chloride instead of HCl were used. Example 5 The experiment of Example 1 was repeated, however, without triethylamine and 1 mmol of propanoic acid instead of MSA, and in the presence of 0.25 mmol HCl and 10 g phenol. Ethene was now fully converted with 100% selectivity into butyl propanoate at an average rate of 7000 mol/mol.hr. When 2 ml of triethylamine were added, the average rate increased to 8000 mol/mol.hr. Example 6 The autoclave was charged with 20 ml 1-octene, 15 ml N,N-dimethyl-1, 3-propanediamine, 40 ml toluene, 0.25 mmol of palladium(II) acetate, 0.6 mmol BCPE, 0.5 mmol MSA, 0.25 mmol NaCl and 10 g of α-naphthol. After being flushed, the autoclave was pressurised with 20 bar carbon monoxide. Next, the reactor was sealed. The contents of the autoclave were heated to 145°C and maintained at that temperature for 5 hours. After cooling, a sample was taken from the contents of the autoclave and analysed by GLC. The product, (N,N-dιmethyl-3-amιnopropyl)nonanamide, was formed with a linearity of 92%. An olefm conversion of 50% was reached, corresponding to an average rate of 300 mol/mol.hr. Example 7 Example 6 was repeated, however, with Nal instead of NaCl. Besides, the contents of the autoclave were now heated for 1 hour. The product was formed with a linearity of 97%, whereas an olefin conversion of 60% was reached. This corresponds to an average rate of 1500 mol/mol.hr. Example 8 Example 7 was repeated, however, at 125 °C instead of 145 °C. The contents of the autoclave were now heated for 1.5 hours. The product was now formed with a linearity of 98.5%, whereas an olefm conversion of 80% was reached. This corresponds to an average rate of 1000 mol/mol.hr. Example 9 The autoclave was charged with 20 ml 1-octene, 15 ml 2-ammoethanol, 40 ml diglyme, 0.25 mmol of palladιum(II) acetate, 0.6 mmol BCPE, 0.5 mmol MSA, 0.25 mmol Nal and 5 g of phenol. After being flushed, the autoclave was pressurised with 20 bar carbon monoxide. Next, the reactor was sealed. The contents of the autoclave were heated to 175 °C and maintained at that temperature for 1 hour. After cooling, a sample was taken from the contents of the autoclave and analysed by GLC. The product, (2-ethylol) nonanamide, was formed with a linearity of 97%. An olefm conversion of 60% was reached, corresponding to an average rate of 1500 mol/mol.hr. Example 10 Using the same catalyst as in Example 9, 10 ml 1, 7-octadιene was carbonylated at 150 °C and 15 bar CO with 40 ml methanol. The contents of the autoclave were heated for 10 hours. The product was analysed to find it composed for 90% of diesters (48% linear) , produced at an average rate of 40 mol/mol.hr and an octadiene conversion of 95%. Example 11 The autoclave was charged with 20 ml 1-octene, 20 g phenol, 40 ml toluene, 0.25 mmol of palladium(II) acetate, 0.6 mmol BCPP, 0.5 mmol MSA, 0.25 mmol NaCl and 0.2 ml triethylamine. After being flushed, the autoclave was pressurised with 20 bar carbon monoxide. Next, the reactor was sealed. The contents of the autoclave were heated to 150 °C and maintained at that temperature for 1.5 hours. After cooling, a sample was taken from the contents of the autoclave and analysed by GLC. The product, phenyl nonanoate, was formed with a linearity of 70%. An olefm conversion of 80% was reached, corresponding to an average rate of 1200 mol/mol.hr. Example 12 Example 11 was repeated, however, using LiBr instead of NaCl, at a temperature of 125 °C. Besides, the contents of the autoclave were heated for 1 hour. Phenyl nonanoate was now formed with a linearity of 83%. An olefin conversion of 50% was reached, correspond¬ ing to an average rate of 1500 mol/mol.hr. Example 13 Example 11 was repeated, however, using Nal instead of NaCl, at a temperature of 125 °C. Phenyl nonanoate was now formed with a linearity of 86%. An olefm conversion of 90% was reached, cor¬ responding to an average rate of 1200 mol/mol.hr. Example 14 The autoclave was charged with 5 ml dicyclopentadiene (DCPD) , 40 ml methanol, 0.25 mmol of palladium(II) acetate, 0.6 mmol BCPE, 0.5 mmol MSA, 0.25 mmol Nal, 2 ml triethylamine and 5 g of phenol. After being flushed, the autoclave was pressurised with 20 bar carbon monoxide. Next, the reactor was sealed. The contents of the autoclave were heated to 155 °C and maintained at that temperature for 10 hours. After cooling, a sample was taken from the contents of the autoclave and analysed by GLC. The product was analysed to be composed for 64% of diesters and 36% of monoesters (by mole) . The product was formed at 100% DCPD conversion and an average rate of 30 mol/mol.hr. At a temperature of 165 °C, the diester content increased to 70%, and the average rate to 100 mol/mol.hr. Example 15 Example 14 was repeated, however, using 10 g phenol (155 °C) . The diester content increased to 80%, and the average rate to 150 mol/mol.hr. Example 16 Example 14 was repeated, however, using 10 g β-naphthol or 3, 5-dιmethoxyphenol (155 °C) . The diester content in each experiment increased to 84%, and the average rate to 200 mol/mol.hr. Example 17 A hexadecylphenol was prepared by alkylating phenol with 1-hexadecene in the presence of 2% by weight of an acidic zeolite as catalyst. The autoclave was charged with 11 ml 1-octene, 41.75 g of the hexadecylphenol, 26 g sulpholane, 0.25 mmol of palladium(II) acetate, 0.6 mmol BCPP, 0.5 mmol MSA, 0.10 mmol HCl and 1.65 ml triethylamine. After being flushed, the autoclave was pressurised with 17.7 bar carbon monoxide. Next, the reactor was sealed. The contents of the autoclave were heated to 140 °C and maintained at that temperature for 6 hours. After cooling, a sample was taken from the contents of the autoclave and analysed by GLC. Hexadecylphenyl nonanoate was formed at 61.5% hexadecylphenol conversion with 100% selectivity at an average rate of 187 mol/mol.hr. Example 18 A Ci4_χ8-alkylphenol was prepared by alkylating phenol with a mixture of Ci4_i8~l -a lkenes in the presence of 2% by weight of an acidic zeolite as catalyst. The autoclave was charged with 18.3 ml 1-dodecene, 39.7 g (122 mmol) of the Ci^-ig-alkylphenol, 25 g sulpholane, 0.26 mmol of palladιum(II) acetate, 0.66 mmol BCPP, 0.10 mmol HCl and 1 ml triethylamine. After being flushed, the autoclave was pressurised with 16.4 bar carbon monoxide. Next, the reactor was sealed. The contents of the autoclave were heated to 125 °C and maintained at that temperature for 6 hours. After cooling, a sample was taken from the contents of the autoclave and analysed by GLC. The C ] _4_ig-alkylphenyl tridecanoate was formed at 76.2% alkylphenol conversion with 100% selectivity at an average rate of 188 mol/mol.hr. Example 19 - hexadecylphenyl dodecanoate In a 0.5 litre 3-necked flask equipped with a Dean and Stark apparatus were placed 120 g (0.6 mol) dodecanoic acid, 63.6 g (0.2 mol) hexadecyl phenol and 80 g of xylene. The mixture was heated gently until the dodecanoic acid had melted. Next 1 g of methanesulphonic aicd was added and the mixture was neated to reflux (170°C) while water was removed continuously. After 5 hours a 99% conversion of alkylphenol was reached. Xylene was removed on a rotary evaporator at 100°C/10 mbar. The excess dodecanoic acid was removed on a wiped film evaporator at 120°C/0.02 mbar, while the remaining alkylphenol ester was purified by a final wiped film evaporator distillation at 220°C/0.01 mbar, yielding 89% of isolated ester. Example 20 - C14/16/18-alkylphenyl octanoate In a 10 1 round-bottomed glass reactor connected to a vacuum pump and equipped with a nitrogen gas inlet (50 1/h) , a mechanical stirrer, a temperature sensor, a pressure sensor and a Dean and Stark apparatus were placed 3996 g (27.75 mol) of octanoic acid and 3010 g(0.26 mol) of mixed C14/16/18 alkylphenol. The mixture was stirred and purged with nitrogen and subsequently 44.31 g (0.46 mol) of methanesulphonic acid was added. The pressure in the reactor was lowered to 85-73 mbar and the contents of the flask were heated to 164-168 C C. After about 6 hours 134 g of water were collected in the Dean and Stark trap. The nitrogen pressure was raised to 1 bar and the mixture was continuously purged with nitrogen and allowed to cool to room temperature. The excess of octanoic acid was removed by passing the product twice through a wiped film evaporator at 150°C, 0.1 mbar. Subsequently, the product was filtered to give 3914 g (94% yield) of mixed C14/16/18-alkylphenyl octanoate. Example 21 - C14/16/18-alkylphenylnonanoate In a 10 1 round-bottomed glass reactor connected to a vacuum pump and equipped with a nitrogen gas inlet (50 1/hr) , a mechanical stirrer, a temperature sensor, a pressure sensor and a Dean and Stark apparatus were placed 4134.7 g (26.13 mol) of nonanoic acid and 3061.0 g (9.42 mol) of mixed C14/16/18 alkylphenol. The mixture was stirred and purged with nitrogen and subsequently 46.27 g (0.48 mol) of methanesulphonic acid was added. The pressure in the reactor was lowered to 82-77 mbar and the contents of the flask were heated to 166-170°C. After 3 hours 150 g of water was collected in the Dean and Stark trap. After about 8 hours the nitrogen pressure was raised to 1 bar and the mixture was continuously purged with nitrogen and allowed to cool to room temperature overnight. The excess of nonanoic acid was removed by passing the product twice through a wiped film evaporator at 150°C, 0.1 mbar. Subsequently, the product was rolled for 1.5 hr with 92 g of basic alumina and filtered to give 4300 g (95% yield) of mixed C14/16/18 alkyphenyl nonanoate. Example 22 - Cl4/16/18-alkylphenyldodecanoate This was prepared using a procedure analogous to that of Example 19, from the appropriate starting materials. Example 23 The properties of the products of Examples 17, 18 and 20 to 22 were analysed in respect of I) the kinematic viscosity at 100 °C (VklOO) ; n) viscosity index (VI) ; m) pour point (PP) ; iv) volatility (as measured by ThermoGravimetric Analysis) ; v) oxidation stability (as measured by Differential Scanning Calorimetry) ; seal swell; and deposit formation (as measured by the Wolf Strip Test method) . Besides, the products have been compared with two commercial esters: BISOFLEX TOT, tradename for a 2-ethylhexyl trimellitate; and PRIOLUBE 3939, a tradename for an ester of pentaerythritol and C5_ 9 linear acid. Table 1 shows the physical properties of the alkylphenol esters of the present invention as compared to the commercially available products. The VklOO of an oil is measured under low shear conditions (gravity) . The viscosity index (VI) is a number indicating the effect of change of temperature on the Vk of an oil. A high VI signifies relatively small change of Vk with temperature, which is desirable. The VklOO was determined according to ASTM D 445-94; the VI was calculated accordmg to ASTM D 2270-86. The pour point is defined at the lowest temperature at which an oil will flow when cooled at a specific rate. In crankcase use, a low pour point is desirable. Pour point has been determined according to ASTM D 97-87. The oxidation stability of the alkylphenol esters was evaluated by DSC. DSC measures the differential heat flow when a sample of oil in a small pan and an empty pan (reference) are heated under an oxygen or air atmosphere in a closed cell. Typically, a 2 mg sample of oil is used in an open aluminium pan. The measurements were designed to mimic oil conditions encountered m automotive engine lubrication. In temperature programmed (dynamic) experi¬ ments, the test temperature was increased linearly from 40 to 350 °C at 20 °C/mιn. The cell atmosphere was 205 kPa 0 2 , and the gas flow rate 60 ± 10 ml/mm. The onset of rapid oxidation is marked by a rapidly increasing exotherm. The extrapolated onset temperature is defined by the intersection of the tangent at the steepest part of the increasing exotherm and the baseline extrapolated from lower temperatures, on a plot of power versus temperature. For neat fluids, a DSC onset temperature value above about 220 °C is considered good. Weight loss up to 262 °C was determined according to method IP 393/91 from the record of mass loss as a function of temperature m a suitable ThermoGravimetric instrument, run at a constant heating rate of 10 °C/mm from 40 to 550 °C under flowing nitrogen. This measure¬ ment has been shown (based on a limited correlation exercise) to provide an indication of the evaporative loss (= volatility) from an oil held at 250 °C (the "Noack method") . A low volatility (low volatile loss at high temperature) is desirable. Seal swell was evaluated according to test method IP 278/72. A value of 9, as found for a 80:20 w/w blend of a commercially available synthetic base oil (referred to hereinafter as the reference oil) and PRIOLUBE 3939, is acceptable, but a lower seal swell is most desired to reduce wear. The Wolf Strip Test (based on method DIN 51392) is an inclined hot plate test, where the lubricant under test is circulated at 50 ml/mm. for a number of hours over a hot metal test strip, that is 8° declined against the horizontal. The ester was tested either neat or at 20% w/w in a hydrogen base oil. The weight of deposit remaining on the test strip is recorded at the end of the test. A low deposit is desirable. Table 1 I IN3 n.d. not determined It WJ.11 be apparent ro tne ε*:_iiec reader mat t:ιe alkyipnenol esters net only exhmit tne αesiraoie combination of low viscosity witr. low volatility, out also exhibit a low seal swell ana perfcr.τ well m the Wolf Strip Test. Example 24 A Cχ4_i8-alkylphenyl dodecanoate, tne compounα cf Example 22, was tested in a fully formulated oil for diesel applications. The alkylphenol ester, at either 30 or 60% w/w concentration, was blended with the reference oil used previously and detergent and ash levels in the mid range of current commercially available diesel engine Oxidation stability of the blend containing the alkylphenol ester was tested by comparing the induction periods during isothermal Differential Scanning Calori¬ metry with blends containing a commercial polyol ester. The IP was measured at 200 and 210 °C. Long IP's are preferable. The test results are set out in Table 2. These test results show that the alkyipnenol ester at 30 " concentration shows an oxidation stability benefit over similarly formulated synthetic base fluids, containing either polyol esters (PRIOLUBE 3939 and 3970, ex UNICHEMA), a trimellitate ester (REOLUBΞ OTM, ex FMC) or a carbonate ester (AGIP MX2201, ex AGIP Petroli/ENICHEM AUGUSTA JV) at equivalent concentrations at both 200 and 210 °C. The alkylphenol ester at 60% concentration shows a twofold increase m induction period compared with tne blend of reference oil containing the same detergent and ash levels and an appreciable benefit compared with the commercial carbonate ester. Table 2, induction periods by Isothermal DS( Example 25 The 60% w/w lubricating oil composition of Example 24 was subjected to a caterpillar micro oxidation test, which is a laboratory bench text used to predict the lubricant deposit-forming tendencies under thin film conditions. Accordingly, samples are subjected to 230 °C under air with a set flow rate to oxidize oil and cause deposit-formation on a pre-weighed metal coupon. Deposits are then weighed and the accumulation of deposits determines the induction time. An induction period of 275 minutes was found, as compared to 115 minutes for the reference oil. Example 26 An MWM-B Diesel Engine test (pursuant test method CEC L-12-A-76) was conducted to evaluate the 60% w/w lubri¬ cating oil composition of Example 24 as crankcase oil in respect of piston deposits and ring sticking. The higher the piston rating, the better the composition's perform ¬ ance. As may be learned from Table 3, the alkylphenol ester at this concentration dramatically improves the cleanliness ratings in many piston regions and in particular the top groove (i.e., groove 1) , land 1 and undercrown as compared with the reference oil. Table 3 Example 27 Use of high concentrations of polar esters m lubricants may cause problems of compatibility with elastomer sealing materials. The acrylate seal compatibility of the phenolic ester of Example 21 was tested according to test method CEC-L-39-T-87. The ester was tested at a concentration of 35% w/w in a polyalphaolefin-based engine oil containing a typical additive package, m comparison with corresponding oils where the base fluids was polyalphaolefin alone, or polyalphaolefm containing 35% w/w of an alternative commercially available aliphatic ester or diester. Results are shown m Table la. Table la Acrylate seal compatibility of engine lubricants containing esters at 35% w/w Ester Poperty Required Polyol Polyol cpd of Limits None ester X ester Y diester Z Example 21 Tensile strength (%) -15 to +10 -11 • 15 -23 -21 Elongation -35 to +10 -37 -25 -22 -33 -19 Volume change -5 to +5 +1.9 +7.6 +14 +5.5 +4.8 Hardness (pts -5 to +5 +4 -3 -4 INJ 00 Only the oil containing phenolic ester Example 21 passes all specification limits Example 28 Alkyl pheno-L esters iiπiiiar to those of formula I but with a smaller alkyl substituent of the phenyl ring, were prepared by a caroonylation process analogous to tnat αescribed in Examples 17 and 18, and their kinematic viscosity at 100°C (Vk 100) viscosity index (VI), pour point (PP) and volatility (TGA) were investigated. Details and results are given m Table 4, below, m which Rx and R2 in the formula II are alkyl groups having the specified number of carbon atoms. Table 4 It can be seen that unsuitable viscosity, VI, and volatility are given where Rx and R 2 each have 8 carbon atoms. Increasing the number of carbon atoms m alkyl group R 2 improves the viscosity, VI and volatility favourably but increases the pour point to an unsatisfactory level. From Table 1 hereinbefore, it can be seen that all the compounds of the formula I exemplified show m comparison a very desirable combination of low volatility, low viscosity, and low pour point with a high VI.

Claims: - 3 C - C L t I M S 1. A process for the carbonylation of ethylenically unsaturated compounds by reaction thereof with carbon monoxide and a coreactant m the presence of a catalyst system obtainable by combining (a) a source of a Group VIII metal cation (b) a phosphine, arsine or stibme compound acting as a ligand; and (c) a source of anions, other than halide anions, carried out m the presence of substoichiometric amounts of a halide anion and/or -in case of a coreactant other than an aromatic alcohol- m the presence of a phenolic promoter. 2. A process as claimed m claim 1, carried out m the presence of a chloride or iodide anion. 3. A process as claimed in claim 1 or 2, carried out in the presence of a halide anion in a molar ratio versus the Group VIII metal cation that is less than 3:1, preferably less than 1:1. 4. A process as claimed in any one of claims 1 to 3, carried out m the presence of the phenolic promoter in an amount up to 40% by weight, preferably of 10 to 20% by weight, based on the total weight of reactants. 5. A process as claimed in any one of claims 1 to 4, wherein the Group VIII metal is palladium. 6. A process as claimed in any one of claims 1 to 5, wherem the phosphine, arsine or stibme compound is a bidentate ligand, containing a second atom that coordinates with the cation, selected from trivalent N, P, As or Sb atoms. 7. A process as claimed in claim 6, wherein the bidentate ligand is a compound of the formula R 1 R 2 M 1 -R-M 2 R 3 R 4 , wherem M 1 and M 2 independently are P, As or Sb, R represents a bivalent substituted or unsubstituted bridging group containing from 1 to 5 atoms in the oridge, R^ and R 2 together are a substituted or unsubstituted bivalent group whereby the two free valencies are linked to M-*-, and R 3 and R 4 together are a substituted or unsubstituted bivalent group whereoy the two free valencies are linked to M 2 or R 3 and R 4 independently are substituted or unsubstituted hydrocarbyl groups . 8. A process as claimed m claim 7, wherem the bivalent (substituted) group, represented by R 1 together with R 2 is a bivalent cyclic group selected from 1,4-cyclo- hexylene, 1, 4-cycloheptylene, 1, 3-cycloheptylene, 1, 2-cyclooctylene, 1, 3-cyclooctylene, 1, 4-cyclooctylene, 1, 5-cyclooctylene, 2-methyl-l, 5-cyclooctylene, 2, 6-dιmethyl-l, 4-cyclooctylene and 2, 6-dιmethyl-i, 5- cyclooctylene groups. 9. A process as claimed in claim 6, wherem compo¬ nent (b) of the catalyst system is selected from the [3,3,1] and [4,2,1] isomers of 1, 2-P, P' -bis (9-phospha- bicyclononyl) ethane, 1, 2-P, P' -bis (dιmethyl-9-phospha- bicyclononyl) ethane 1, 3-P, P' -bis (9-phospha- bicyclononyl) propane, and 1, 3-P, P'-bis (dιmethyl-9- phosphabicyclononyl)propane. 10. A process as claimed in any one of claims 1 to 9, wherem the coreactant is an alkylphenol having one or more alkyl groups of up to 30 carbon atoms attached to the phenol molecule. 11. An alkylphenol ester of the general formula R' n C 6 H (5 _ n) OC(=0)R" (I) wherem R' is an alkyl group of from 10 to 30 carbon atoms, n is an integer of 1 to 5, and R" is an alkyl group of from 1 to 30 carbon atoms. 12. An alkylphenol ester as claimed in claim 11, wherem R' is an alkyl group of from 12 to 20 carbon atoms. 13. An alkyl phenol ester as claimed in claim 11 or claim 12, wherem R' is an alkyl group having at least 14 carbon atoms . 14. An alkyl phenol ester as claimed m any one of claims 11 to 13, wherem R" is an alkyl group of from 4 to 22 carbon atoms. 15. An alkylphenol ester as claimed in any one of claims 11 to 14, wherein n is 1. 16. An alkylphenol ester as claimed in any one of claims 11 to 15, wherem R' together with R" have from 20 to 40 carbon atoms. 17. An alkylphenol ester as claimed in any one of claims 11 to 16, wherem the number of carbon atoms m R 1 is larger than or equal to the number of carbon atoms in R". 18. Use of the alkylphenol ester as claimed in any one of claims 11 to 17 as synthetic lubricant. 19. A lubricating oil composition comprising as base fluid an alkyl phenol ester as claimed in any one of claims 11 to 17. 20. A lubricating oil composition as claimed in claim 19, wherem the balance of the total base fluid is a base oil of mineral or synthetic origin.

Inventors: DE CASTRO LOUREIRO BARRETO ROS, DRENT EIT, GIILESPIE HAROLD MONCRIEFF, MCKENNA EUGENE GERARD, SAVAGE PAUL DAVID, VAN HELDEN AREND KUINDERT, DE CASTRO LOUREIRO BARRETO ROSA, MARIA, MANUEL, DRENT, EIT, GIILESPIE, HAROLD, MONCRIEFF, MCKENNA, EUGENE, GERARD, SAVAGE, PAUL, DAVID, VAN HELDEN, AREND, KUINDERT
Applicants: SHELL INT RESEARCH, SHELL INTERNATIONALE RESEARCH MAATSCHAPPIJ B.V.
Application year: 1997
Main classification: C07C67
IPC codes: B01J31, C07B61, C07C67, C07C69, C10M105, C10M111