PREPARATION OF PHOSPHONIC ACID DERIVATIVES

Abstract: The method provides for the preparation of alkene phosphonic acids and salts thereof, such as VDPA (vinylidene diphosphonic acid). The products can be produced in a stable, substantially pure form and in high yield. The method includes the azeotropic removal of water from salts of alpha -hydroxy-alkane disphosphonic acid dimer or corresponding acids thereof, and the pyrolysis of the dehydrated reactant at a temperature of from 170 DEG C to 300 DEG C. There may be included a step to convert anhydrides which have been formed during the pyrolysis. The method may include the use of heat transfer agents and/or bases, and may be carried out at elevated or reduced pressure.

Description: PREPARATION OF PHOSPHONIC ACID DERIVATIVES The present invention provides a novel method for the preparation of phosphonic acid derivatives, especially alkene diphosphonic acids e.g. vinylidene diphosphonic acid (VDPA) and salts thereof. Said phosphonic acids and salts are produced in a purer form than has hitherto been achieved and in a high yield. VDPA exhibits greater chelancy than VPA. VDPA is known for use as a chelant for metals and for use in pharmaceutical applications. VDPA and VPA may be used in combination with each other according to the required properties of the mixture, depending upon the application in question. Because of its ability to polymerise, VDPA may be used as a copolymer with other polymerisable compounds. VDPA is conventionally prepared from either methylene bis phosphonates, or from diphosphonic acid derivatives. US 3-686-290 describes the preparation of VDPA salts from the tetra- sodium salt of 1-hydroxy, 1-ethylidene diphosphonic acid, at a pyrolysis temperature of from 300°C to 500°C, preferably 350°C to 425°C. However the product is typically obtained in low yields. EP-0-252-244 describes the preparation of VDPA salts from the sodium salt of l -(O-acyl) ethane-l , l-diphosphonic acid, at a temperature of between 200°C to 250°C. However the product is typically obtained in a maximum yield of 75%. The preparation of VDPA from his phosphonates, using a two step procedure involving the base catalysed reaction of an ethylene b_is (phosphonate) ester with paraformaldehyde followed by acid catalysed elimination of methanol and conversion to the free acid by reaction with bromotrimethylsilane is described in J. Org. Chem 1986, 51,3488-3490. It has been found that alkene diphosphonic acids and their derivatives produced by this method typically exhibit a purity of less than 80mol%, and were produced in low yield. The multistage production of VDPA and its derivatives from methylene diphosphonate and bi≤(diethylamino) methane using temperatures of 170 -180°C is described by Prishchenko et al in Zhurnal Obshchei Khimii. Vol 61 . No.4.p, 1018. It has been found that this method produces low yields (58%) , and products of low purity. There are several disadvantages associated with the known methods of preparation of alkene diphosphonic acids, although not all disadvantages may be associated with each known method. Some require high dehydration temperatures, typically above 400°C, to produce the alkene diphosphonic acids. This is above the decomposition temperature of approximately 285°C of tetra-sodium VDPA and hence products are obtained in a low yield and are of low purity due to the presence of high amounts of esters of the aforementioned acids. The methods of preparation of the prior art typically provide products of, for example, 50mol% to 80mol% purity. This may be unacceptably low for some uses, for example pharmaceutical applications. Furthermore due to the impure products typically obtained by said known methods of preparation longwinded and cumbersome purification methods are frequently required. There is therefore a requirement to provide a method of preparation of alkene phosphonic acids , such as VDPA which produces the reaction product in a stable, purer form than has hitherto been possible, whilst being obtained in a high yield. Furthermore the method of preparation should preferably require the products to undergo minimal purification. We have now discovered that alkene phosphonic acids e.g. VDPA may be prepared from the salts of α-hydroxy-alkane diphosphonic acid dimers or the corresponding acids thereof, by the dehydration of the reactant followed by the low temperature pyrolysis thereof. The dehydration and pyrolysis may be carried out in the presence of a heat transfer agent. The alkene phosphonic acids prepared by the method of the invention are obtained in high yield and in a substantially pure form. According to one embodiment, the present invention provides a method of preparation of alkene phosphonic acids or salts thereof of general formula (I):- wherein each R is independently H, an alkyl group, an alkali metal, an alkaline earth metal, or a nitrogen-containing group; R and R are independently H, or an alkyl group; wherein said method comprises the steps: - (a) the azeotropic removal of water from the reactant of general wherein R 1 is CHR 3 R 4 ; R 2 , R 3 , R 4 and R 5 are as hereinabove defined; and X is a number between 0 and 20, (b) the pyrolysis of the dehydrated reactant (II) at a temperature of from 170°C to 300°C, and (c) optionally, conversion of any anhydrides formed during stage (b) to the corresponding acid or salt having the general formula (I) . According to a second embodiment, the present invention provides a method for the preparation of alkene phosphonic acids or salts thereof of general formula (I) as hereinabove defined, wherein (a) said azeotropic removal of water from said reactant (II) is carried out by dehydrating a reactant of general formula (II) in the presence of at least one inert liquid heat transfer agent which exhibits effective azeotropic properties with water and which is liquid at the reaction temperature; and (b) said pyrolysis of dehydrated reactant (II) is carried out by adding at least one inert heat transfer agent which is liquid at the reaction temperature to the reaction mixture from (a) , and the reaction mixture is maintained at 170°C to 300°C until pyrolysis of the dehydrated reactant (II) is complete According to a third embodiment, the present invention provides a method of preparation of the alkene phosphonic acids or salts thereof of general formula (I) as defined hereinabove, wherein pyrolysis of the dehydrated reactant (II) at a temperature of from 170°C to 300°C is in the presence of at least one base, and optionally at least one inert heat transfer agent. Reactants and products The alkene phosphonic acids are produced from a cyclic reactant of general formula (II) as given hereinabove, which may be present either as a salt or as the acid. Suitable salts of the acid include amongst others the alkali metal, alkaline earth metal, or nitrogen-containing salts. The alkyl groups R " , R ' and R 5 are preferably each C C 6 alkyl groups. The or each nitrogen-containing group R is preferably an a ine salt. Particularly preferred as a reactant is the hexa-sodium salt of ADPA dimer [Formula (II) wherein R is CH 3 , and R is Na] Said reactant (II) may be produced in situ without being isolated and said reactant may be subsequently converted to a compound having the general formula (I) i.e. by means of a multistage preparation incorporating the process of the present invention. An example of such a multistage reaction is the conversion of phosphorous acid and acetic anhydride to the sodium salt of ADPA dimer, followed by the conversion of said dimer to VDPA by the process of the present invention. Alternatively the process of the present invention may be used to convert the isolated cyclic reactant e.g. ADPA dimer or the sodium salt thereof, to the alkene phosphonic acid (I) . The reactant may be added to the reaction vessel as a solid or as a solution e.g. an aqueous solution. The present invention provides a particularly advantageous method for the preparation of alkene diphosphonic acids of general formula (I). Reaction conditions Any one or more of steps (a) , (b) and (c) of the method of the invention may be carried out under reduced pressure. Alternatively any one or more of steps (a) , (b) and (c) of the method may, if required, be carried out at pressures greater than atmospheric pressure. According to the present invention, stage (a) and/or stage (b) may be carried out in the absence of heat transfer agents, for example by heating the reactant (II) under vacuum to dehydrate and/or pyrolyse said reactant (ID . Heat transfer agents Preferably, both of stages (a) and (b) of the reaction are carried out in the presence of heat transfer agents. However stage (a) and/or stage (b) may be carried out in the absence of said agents. At least one heat transfer agent is preferably used in the method of the present invention, in either stage (a) , or in stage (b) , or in both stage (a) i.e. azeotropic removal of water from the reactant (II) , and stage (b) , i.e. the pyrolysis of the dehydrated reactant (II) . Mixtures of heat transfer agents, wherein each agent has the requisite properties may be used in each stage, or alternatively mixtures of heat transfer agents chosen so that the mixture has the requisite properties may be used. The reactant and/or reaction product is preferably insoluble or sparingly soluble even when heated in the heat transfer agent or mixture thereof used in each stage. Any inert solvent for example aliphatic or aromatic hydrocarbons, or other polar aprotic solvents, having the properties here described are suitable for use as heat transfer agents. Suitable heat transfer agents for use in the azeotropic removal of water in stage (a) include inert liquids which exhibit effective azeotropic properties with water and which are liquid at the reaction temperature. In particular aromatic hydrocarbons including for example toluene, xylene and cumene are suitable. Alternatively, straight or branched chained alkanes or cycloalkanes with the aforementioned boiling points and properties, such as octane, cycloheptane and cycloctane may be used. A different heat transfer agent may be used in stage (a) from the heat transfer agent used in stage (b) . Suitable heat transfer agents for use in stage (b) include inert materials which are liquid at the reaction temperature. Preferably these heat transfer agents are at least substantially water immiscible, although water miscible heat transfer agents may work under certain conditions, for example some water miscible glycols. Straight or branched chain alkanes, for example decane, dodecane and tetradecane have been found to be particularly effective. Furthermore, aromatic compounds such as phenyl ethers (for example diphenyl ether and propyl phenyl ether) having the above identified properties are also suitable for use. Oily compounds, such as vegetable, hydrocarbon or silicone oils, or alternatively polyoxylene glycols and mixed polyoxylene glycols having the above properties may also be used. The method may be carried out in the absence of heat transfer agents, in a suitable manner, e.g. in a fluidised bed reactor or oven. Stage (a) of method - dehydration of reactant The reactant (II) and the heat transfer agent for use in the azeotropic removal of water may be charged to a suitable reaction vessel in any appropriate manner. The heat transfer agent for use in this stage is chosen in accordance with the properties required for said agent as described hereinabove. The weight to volume ratio for the amount of reactant (II) to the amount of heat transfer agent is preferably within the range of 1 : 100 to 10: 1 , preferably 1 : 10 to 1 : 1. The reaction mixture is typically heated to a temperature (dependent upon the heat transfer agent, employed, if any) sufficient to effect the azeotropic removal of water from the reaction (II) . This temperature will usually be within the range of from 50°C to 175°C, preferably 75° C to 130°C. The azeotropic distillation is typically stopped when the temperature of the reaction mixture reaches a constant boiling point. For example, when using toluene as the heat transfer agent the reaction is stopped at a temperature within the range 108°C to 113°C, most preferably within the range 110°C to 112°C. The azeotropic distillation is continued until substantially all the water of dehydration of the reactant (II) is removed. This is typically complete within 0.1 to 20 hours, for example 0.25 hours to 10 hours, such as 0.3 hours to 3 hours. The reaction mixture resulting from the completion of stage (a) is allowed to cool to between 25°C to 60°C prior to the second stage of the process of the invention. It may however, if circumstances permit, be possible to continue with said second stage before the reaction mixture has so cooled. Stage (b) of method - pyrolysis of dehydrated reactant Optionally, either before, during or after stage (b) at least one drying agent may be added to the reaction mixture. This addition of at least one drying agent aids the removal of any residual water from the reaction mixture. Preferably a relatively small amount of drying agent is added. Particularly preferred is the addition of at least one anhydride to the reaction mixture, preferably during the heating thereof in stage (b) . Preferably the anhydride is acetic anhydride. It is preferred that the amount of said drying agents used is less than 70% by weight, based on the total amount of reactant (II) , most preferably less than 60%, e.g. less than 55%. Stage (b) involves the removal of the first heat transfer agent and the pyrolysis of the dehydrated reactant (II) . The second heat transfer agent, chosen in accordance with the requisite properties mentioned hereinabove may be added by any suitable means and in any suitable manner to the reaction mixture obtained from the above first stage. It is particularly preferred that the second heat transfer agent, e.g. dodecane, or diphenyl ether is added to the reaction mixture at a temperature lower than the flash point of the second heat transfer agent. Typically the total amount of the second heat transfer agent is simply added to said reaction mixture in one addition. However, it is possible to add aliquots of said heat transfer agent if so required. The weight to volume ratio for the amount of reactant (II) to the amount of heat transfer agent should be sufficient to maintain a stirrable slurry at the reaction temperature, with said ratio typically being within the range of 1 : 100 to 10: 1 , preferably 1 : 10 to 1 : 1. The reaction mixture during stage (b) is preferably heated to a temperature within the range given below dependent upon the boiling point of the second heat transfer agent employed. However, in order to provide an alkene phosphonic acid product of high purity it is important to maintain the temperature below the decomposition temperature of said reactant or product. Preferably the reaction mixture is maintained at a temperature of from 170°C to 300°C, most preferably 180°C to 250°C, especially 190°C to 240°C. The reaction time during stage (b) is obviously dependent upon the temperature used, but is usually in the range of from 1 hour to 15 hours, preferably 2 hours to 14 hours, most preferably 2.5 hours to 13 hours, after which time the reaction mixture is allowed to cool to between 25°C and 60°C. At this stage the reaction mixture may comprise the alkene phosphonic acid or salt product and anhydrides thereof. Water may be added to the reaction mixture, preferably in a quantity sufficient to dissolve the product and thus produce a discrete aqueous solution thereof. The aqueous product-containing layer and the second stage heat transfer agent may be separated by means of one or more steps, preferably by any suitable technique, for example by using a separating funnel. Several separations may be required in order to remove as much of said heat transfer agent as possible from said aqueous layer. Stage (c) of method: conversion of anhydrides to corresponding acid or salt Stage (c) , which is optional, involves the conversion of any anhydrides produced during stage (b) to their corresponding alkene phosphonic acids (I) . This stage may optionally be effected concurrently with the second stage (b) , i.e. the conversion of anhydrides to the corresponding acid or salt may be effected in a simultaneous stage with the pyrolysis of the dehydrated reactant. This method of conversion is particularly preferred as products of very high purity may be obtained. The aforementioned conversion may be achieved by the addition of at least one base to the reaction mixture of stage (b) , either before or during that stage. Suitable bases include inorganic bases such as alkali and alkaline earth metal hydroxides, carbonates, bicarbonates and hydrides e.g. sodium hydroxide, sodium carbonate, sodium bicarbonate and sodium hydride. Also suitable are organic bases such as alkali metal and alkaline earth metal acetates, and alkoxides, for example sodium acetate, sodium methoxide and sodium ethoxide. Nitrogen-containing bases may also be used, for example trialkylamines. The base may be added as a solution, for example sodium methoxide in methanol. It is preferred that the mole ratio of the base to the reactant (II) is in the range 6: 1 to 1 :6, such as 4: 1 to 1 :4, preferably 3: 1 to 1 : 1 , most preferably 3: 1 to 2: 1 . In addition to, or instead of, the above method involving the addition of a base, the conversion of the reaction mixture may be effected by heating an acidic or alkaline solution of the anhydride to convert any anhydrides to the corresponding acids or salts. This may be achieved, for example by heating said solution at a temperature of from 30°C to 80°C, for 0.5 to 5 hours, e.g. 60°C for 3 hours. A product of high purity is thus obtained. The above conversion methods are preferred as they have been found to be particularly effective and to yield a product of very high purity. The method of conversion involving the addition of the base is particularly preferred. Alternatively, any other process which facilitates the conversion of any anhydrides into alkene diphosphonic acids may be employed, for example the use of one or more catalysts e.g. diazabicycloundecane (DBU) in the base hydrolysis of said anhydrides. Isolation and purification Where it is required to remove cations e.g. sodium or calcium, from the product the aqueous product containing solution may be subjected to an ion-exchange process, for example column chromatography using ion exchange resins. Any other suitable, conventional purification process may alternatively be used. The product may be isolated by any conventional technique, for example recrystallisation from a suitable solvent such as aqueous industrial methylated spirits (IMS) . This may be achieved by adding IMS to a warmed aqueous solution of the product followed by cooling, and filtration to remove the product crystals. Alternatively the product may for example be isolated from the aqueous solution by rotary evaporation under reduced pressure for a suitable period of time. The acid product may also for example, be isolated by the addition of a suitable mineral acid, e.g. H 2 SO 4 , in the presence of a suitable solvent, e.g. methanol and/or ethanol to the salt of the acid product followed by recrystallisation of the mineral acid salt from the solvent to yield said acid product. The tetra sodium salt of the product is typically obtained as a white or off white crystalline solid. Yields of at least 80% are usually obtained with the process of the invention. The purity of said products is typically found to be at least 81 mol%, often at least 90mol%. Uses The alkene phosphonic acids produced according to the method of the present invention, find particular use as chelants for metals e.g. calcium, and as intermediates for medically active components such as anti inflammatory and arthritic agents and other pharmaceutical uses. They also find use in heterocyclic synthesis. Because of the polymerisable nature of the alkene diphosphonic acids they also find application as co- monomers for polymeric compositions. In particular, the products find use as co-monomers in polymeric compositions comprising unsaturated co-monomers including polymeric flame retardant compositions (see our co-pending published application EP-A-0780406) . Also, said acids find use as ion exchangers for transuranics because of their chelancy effect. The invention will be further described with reference to the following examples. 8. EXAMPLES Example 1 - the single stage preparation of the tetra-sodium salt of VDPA from the hexa-sodium salt of ADPA dimer [Formula (II) wherein To toluene (400ml) , the hexa-sodium salt of aceto diphosphonic acid dimer (ADPA) (lOOg, 0.13 moles) was added, and the reaction mixture heated to 106°C to remove water azeotropically. The azeotropic distillation was stopped when the temperature reached 110.6°C, and the reaction mixture allowed to cool to ambient temperature. Solid sodium methoxide (20g, 0.37 moles) and diphenylether (400ml) were then added to the cooled reaction mixture, which was subsequently heated to, and maintained at, 216°C for 3 hours. During heating, toluene was distilled out from the reaction mixture. After the heating, the mixture was allowed to cool. Water (675 ml) was added to the cooled reaction mixture, and then the aqueous product containing solution separated from the diphenylether and then heated to 50°C. Industrial methylated spirits (180g) was added to the aqueous solution which was then allowed to cool. The crystalline white solid reaction product was isolated by filtration. The tetra-sodium salt of VDPA was produced in a yield of 79%. Analysis ooff tthhee pprroodduucctt bbyy P nmr determined the product to be of a very high purity (96 mol%) . Example 2 - multistage preparation of the tetra-sodium salt of VDPA from phosphorous acid (i) First stage: preparation of the hexa-sodium salt of the ADPA dimer (intermediate) Phosphorous acid (656g, 8 moles) was added to acetic acid (1200ml) in a reactor at room temperature. The reaction mixture was heated to 121 °C over 100 minutes, during which time acetic anhydride (900g, 8.8 moles) was slowly added. After approximately 16 hours of a total time of 30 hours at 121°C, a white precipitate appeared in the reaction mixture. After this time the reaction mixture was cooled to 40°C and then filtered. Next, the filtered solid (900g, 2.4 moles; which was still wet with acetic acid) and 50% w/w aqueous sodium hydroxide (1150g) were added with stirring to water (2000g) , at a rate which maintained the temperature of the reaction mixture below 60°C and the pH in the range 7-11. The ADPA dimer product was precipitated from the reaction mixture, filtered, washed with cold alkaline water having a pH of approximately 1 1 .5 and dried to constant weight in vacuo (1500g, 65% yield) . 2 P nmr showed no observable phosphorus containing impurities in the product. The product contained 14 H 2 0 molecules as water of crystallisation. (ii) Second stage: preparation of tetra-sodium salt of VDPA from the hexa-sodium salt of ADPA dimer To toluene (800ml) , the hexa-sodium salt of ADPA dimer from the first stage (400g, 0.53 moles) was added to the mixture heated to, and maintained at, a temperature of 106°C for 3 hours during which time water (130ml) was removed azeotropically. The reaction mixture was cooled to 60°C and dodecane (800 ml) added, after which the temperature was raised to, and maintained at, 200°C to 206°C for I I V2 hours. Toluene (350 ml) was removed from the reaction mixture during the heating of the reaction mixture up to the final temperature. The reaction mixture was then cooled and water (800 ml) added. The solid reaction product dissolved, and the product-containing aqueous layer was separated from the dodecane in a separating funnel. The separated aqueous layer (approximately 300 ml) was passed over an ion-exchange resin, and reduced on a rotatory evaporator at 40°C for approximately 4 hours. The VDPA was produced in a yield of 64%. Analysis of the final ssoolluuttiioonn by P nmr determined the product to be of high purity (81 mol%) . Example 3 - preparation of the tetra-sodium salt of VDPA from the hexa-sodium salt of ADPA dimer To a sample of the recrystallised hexa-sodium salt of ADPA dimer of Example 2 Stage (i) (lOg, 0.013 moles) , toluene (150ml) was added. The mixture was brought to, and maintained at 106°C for approximately 30 minutes. At the end of this time approximately 2ml of water had been removed azeotropically from the reaction mixture, which was then cooled to 60°C. Dodecane (150 ml,) was added to the cooled reaction mixture, and the temperature then raised to 214°C in order to remove the toluene. The reaction mixture was maintained at approximately 214°C for a further 8 hours, after which time the mixture was cooled and water (50 ml) added. The solid product dissolved upon addition of the water, and the aqueous product-containing layer was separated from the dodecane. Purification of the tetra-sodium salt of VDPA was undertaken as described in Example 2. Analysis of the tetra-sodium VDPA product by 31 P nmr determined the product to be of high purity (87.5 mol%). Example 4 - Preparation of tetra-sodium VDPA from the hexa-sodium salt of ADPA dimer To toluene (150ml) , the hexa-sodium salt of ADPA dimer (20g, 0.026 moles) was added and the reaction mixture subsequently heated to, and maintained at 106°C for 1 hour during which time water (6ml) was removed. The reaction mixture was cooled to 60°C and dodecane (150 ml) added. Acetic anhydride (lOg) was added shortly after heating of the reaction mixture had commenced, to remove further traces of water with the temperature being raised to 214°C to remove the toluene and acetic acid. The heating was continued for approximately 8 hours, after which time the mixture was cooled to 60°C and water (150 mis) added. The solid reaction product then dissolved, and the aqueous product-containing layer was separated from the dodecane. Purification of the reaction product was undertaken as described in Example 2. Analysis of the final solution of tetra-sodium salt of VDPA by P nmr determined the product to be of high purity (84mol%) . Example 5 - preparation of tetra-sodium VDPA from hexa-sodium salt of ADPA dimer To toluene (800ml) , the hexa-sodium salt of ADPA dimer (200g, 0.26 moles) was added and the reaction mixture heated to 106°C, at which it was maintained for 3 hours to allow for the azeotropic removal of water (approximately 125 ml) . The reaction mixture was then cooled, and dodecane (80ml) added, after which the temperature was raised to, and maintained at, 214°C for 8 hours to remove toluene. After this time the mixture was cooled to 60°C and water added (80 ml) . The solid reaction product dissolved and the aqueous product-containing layer was separated from the dodecane. Purification of the reaction product was undertaken as described in Example 2. Analysis of the product by P nmr determined the product to be of high purity (81mol%) . Example 6 - multistage preparation of the tetra-sodium salt VDPA from ADPA dimer precursor (i) First stage: preparation of the hexa-sodium salt of the ADPA dimer (intermediate) ADPA precursor (621g, 1.6 moles; the precursor containing some acetic acid) and acetic acid (503g 8.4 moles) were added to a flask, heated to, and maintained at approximately 120°C for 35 hours. Diphenylether (400 ml) was then added, and the reaction mixture heated to 120°C - 130°C, with acetic acid being removed by distillation. The reaction mixture was then added to water (500 ml) concurrently with a 50% w/w aqueous solution of sodium hydroxide (700g) , at a rate so as to maintain the temperature at below 60°C and the pH between 7 and 11. The hexa- sodium salt of ADPA dimer was precipitated, filtered, washed with alkaline water (approximately 2000g, pH 11.5) and dried to constant weight in a vacuum oven. The sodium salt of ADPA dimer was obtained in an amount of 436g (yield 73%) . (ii) Second stage: preparation of the tetra-sodium salt of VDPA from the hexa-sodium salt of ADPA dimer To toluene (800 mis) was added the hexa-sodium salt of ADPA dimer from the first stage (400g, 0.525 moles) , and the reaction mixture heated to 106°C. Water was removed azeotropically until the temperature reached 110.6°C. The reaction mixture was cooled to 60°C and a solution of 25% w/w sodium methoxide in methanol (384g) was added. The temperature of the reaction mixture was increased gently to allow for the removal of methanol by distillation and when all the methanol had been removed the reaction mixture was allowed to cool to 60°C. Diphenylether (800ml) was then added. The temperature was increased to, and maintained at 216°C for 3 hours, with toluene being removed from the reaction mixture as the temperature was increased. The reaction mixture was then again allowed to cool. To the cooled reaction mixture, water (2500 ml) was added and the diphenylether separated off. The aqueous product-containing solution was heated to 50°C and industrial methylated spirits (640g) added. The solution was allowed to cool to 60° C to recrystallise the product which was filtered and dried to constant weight in a vacuum oven. The tetra-sodium salt of VDPA was produced in an amount of 316g (62% yyiieelldd)) .. AAnnaallyyssiiss ooff tthhee pprroodduucctt by P nmr determined the product to be of very high purity 95.5 mol%. Example 7 - preparation of vinylidene diphosphonic acid, tetra-sodium salt (VDPANa 4 ) by thermolysis of ADPA dimer, hexa-sodium salt (dodecahydrate). lOOOg of hydrated ADPA dimer (1.38 moles) was heated at 200°C in a fan assisted oven for 20 hours, to leave 700g of a colourless, hygroscopic solid which was then cooled and dissolved in 2000g water. To this solution was added 234g of 47% w/w sodium hydroxide. This mixture was heated to reflux (103 °C) for 5 hours. After this time, 300g of IMS was added to the refluxing solution over a period of 45 minutes, during which time the reflux temperature dropped to 83°C. Cooling of the solution was continued to 30°C over a period of 3 hours, during which time solids crystallised from solution. Filtration and air drying gave 945g of a colourless solid which had a purity of 91 .5% VDPANa 4 by 3I P-NMR spectroscopy. Thermogravimetric analysis of the hydrated solid showed a total water content of 42% by weight, indicating a chemical yield of 72% VDPANa 4 (548g = 1.99 moles) based on the starting ADPA dimer used.

Claims: CLAIMS 1. A method of preparing a compound of general formula (I): (I) wherein each R is independently H, an alkyl group, an alkali metal, an alkaline earth metal, or a nitrogen-containing group; R and R 4 are independently H, or an alkyl group; and R is H, an alkyl group or characterised in that said method comprises the steps :- (a) the azeotropic removal of water from the reactant of general formula (II) wherein R 1 is CHR 3 R 4 , R " , R J , R and R are as hereinabove defined; and X is a number between 0 and 20. (b) the pyrolysis of the dehydrated reactant (II) at a temperature of from 1 70°C to 300° C, and (c) optionally, conversion of any anhydrides formed during stage (b) to the corresponding acid or salt having the general formula (I) 2. A method according to Claim 1 wherein (a) said azeotropic removal of water from said reactant (II) is carried out by dehydrating a reactant of general formula (II) in the presence of at least one inert liquid heat transfer agent which exhibits effective azeotropic properties with water and which is liquid at the reaction temperature; and (b) said pyrolysis of dehydrated reactant (II) is carried out by adding at least one inert heat transfer agent which is liquid at the reaction temperature to the reaction mixture from (a) , and the reaction mixture is maintained at 170°C to 300°C until pyrolysis of the dehydrated reactant (II) is complete. 3. A method according to Claim 1 wherein pyrolysis of the dehydrated reactant (II) at a temperature of from 170°C to 300°C is in the presence of at least one base, and optionally at least one inert heat transfer agent. 4. A method according to any one of Claims 1 to 3 wherein the alkyl groups R " , R and R are each Cι -C 6 alkyl groups. 5. A method according to any preceding claim wherein the or each nitrogen-containing group R 2 is an amine salt. 6. A method according to any preceding claim wherein a reactant having the general formula (II) has been produced in situ without being isolated and said reactant is subsequently converted to a compound having the general formula (I) . 7. A method according to any preceding claim wherein any one or more of stages (a) , (b) and (c) is carried out under reduced pressure. 8. A method according to any one of Claims 1 to 6 wherein any one or more of stages (a) , (b) and (c) is carried out at pressures greater than atmospheric pressure. 9. A method according to Claim 1 wherein at least one heat transfer agent is used in either stage a) , or stage b), or both stages a) and b) . 10. A method according to Claim 2, 3, or 9 wherein in any one stage mixtures of heat transfer agents are used. 11. A method according to Claim 2, 3, 9 or 10 wherein an inert liquid is used as a heat transfer agent. 12. A method according to Claim 11 wherein aliphatic or aromatic hydrocarbons, or other polar aprotic solvents are used as heat transfer agents . 13. A method according to Claim 2, or 3, or any one of Claims 9 to 12, wherein a different heat transfer agent is used in stage a) from the heat transfer agent used in stage b) . 14. A method according to Claim 2, or 3, or any of Claims 9 to 13, wherein the weight to volume ratio for the amount of reactant (II) to the amount of heat transfer agent is within the range 1 : 100 to 10: 1. 15. A method according to Claim 2, or 3, or any one of Claims 9 to 13, wherein the weight to volume ratio for the amount of reactant II to the amount of heat transfer agent is within the range 1 : 10 to 1 : 1. 16. A method according to any preceding claim wherein stage a) occurs within the range 50°C to 175°C. 17. A method according to Claim 16 wherein stage a) occurs within the range 75 °C to 130°C. 18. A method according to Claim 2, or 3, or any one of Claims 9 to 15, wherein toluene is used as the heat transfer agent and the reaction is stopped at a temperature within the range 108°C to 113°C. 19. A method according to Claim 18 wherein the temperature range is 110°C to 112°C. 20. A method according to any preceding claim wherein in stage a) substantially all the water of hydration of the reactant (II) is removed within a period of 0.1 to 20 hours. 21 . A method according to Claim 20 wherein said period is within 0.25 to 10 hours. 22. A method according to Claim 20 or 21 wherein said period is within 0.3 hours to 3 hours. 23. A method according to any preceding claim wherein the reaction mixture resulting from completion of stage a) is allowed to cool to between 25°C to 60°C prior to stage b) . 24. A method according to any preceding claim wherein at least one drying agent is added to the reaction mixture. 25. A method according to Claim 24, wherein said drying agent comprises at least one carboxylic acid anhydride. 26. A method according to Claim 24 or 25, wherein the drying agent is added either: i) before stage b) ; ii) during stage b) ; or iii) after stage b) . 27. A method according to Claim 24, 25 or 26, wherein the amount of drying agent used is less than 70% by weight based on the total amount of reactant (II) . 28. A method according to any preceding claim wherein the reaction mixture during stage b) is maintained at a temperature from 170°C to 300°C. 29. A method according to Claim 28 wherein the reaction mixture during stage b) is maintained at a temperature from 180°C to 250°C. 30. A method according to Claim 28 or 29 wherein the reaction mixture during stage b) is maintained at a temperature from 190°C to 240°C. 31 . A method according to any preceding claim wherein the reaction time of stage b) is in the range from 1 hour to 15 hours. 32. A method according to Claim 31 wherein the reaction time of stage b) is in the range from 2 hours to 14 hours. 33. A method according to Claim 31 or 32 wherein the reaction time of stage b) is in the range from 2.5 hours to 13 hours. 34. A method according to any preceding claim wherein after the completion of stage b) the reaction mixture is allowed to cool to between 25°C and 60°C. 35. A method according to any preceding claim wherein water is added to the reaction mixture after the completion of stage b) . 36. A method according to Claim 35 wherein sufficient water is added to produce a discrete aqueous product-containing layer, said layer being separable from the second stage heat transfer agent. 37. A method according to Claim 1 wherein stage c) is effected concurrently with stage b) . 38. A method according to any preceding claim wherein at least one base is added to the reaction mixture of stage b) , either before or during stage b) . 39. A method according to Claim 38 wherein the base is an inorganic base. 40. A method according to Claim 38 or 39 wherein the base is sodium hydroxide, sodium carbonate, sodium bicarbonate or sodium hydride. 41 . A method according to Claim 38 wherein the base is an organic base. 42. A method according to Claim 38 or 41 wherein the base is an alkali metal acetate, alkaline earth metal acetate or alkali metal alkoxide 43. A method according to any one of Claims 38 to 42, wherein the mole ratio of base to the reactant (II) is in the range 6: 1 to 1 :6. 44. A method according to Claim 43 wherein the mole ratio of base to the reactant (II) is in the range 4: 1 to 1 :4. 45. A method according to Claim 43 or 44 wherein the mole ratio of the base to the reactant (II) is in the range 3: 1 to 1 : 1. 46. A method according to any one of Claims 43 to 45 wherein the mole ratio of the base to the reactant (II) is in the range 3: 1 to 2: 1. 47. A method according to Claim 1 wherein conversion of the reaction mixture from anhydride to a product having the general formula (I) is effected by heating an acidic or alkaline solution of the anhydride at a temperature from 30°C to 80°C for 0.5 hours to 5 hours. 48. A method according to Claim 47 wherein the acidic or alkaline solution is heated at 60°C for 3 hours. 49. A method according to Claim 1 , 47 or 48 wherein the conversion of the anhydride to an alkene diphosphonic acid is accelerated by means of one or more catalysts. 50. A method according to Claim 49 wherein diazab/cyc/oundecane (DBU) is used as a catalyst. 51. A method according to Claim 37 wherein the solution containing the aqueous product-containing layer is subjected to an ion-exchange process. 52. A method according to any preceding claim wherein the product is isolated by recrystallisation from a suitable solvent. 53. A method, substantially as hereinbefore described, with reference to any one or more of the Examples.

Inventors: BRIERLEY TIMOTHY KEVIN, HARRIS JOHN CHRISTOPHER, HAYES AIDAN MICHAEL, PADDA RANBIR SINGH, WOODWARD GARY, BRIERLEY, TIMOTHY, KEVIN, HARRIS, JOHN, CHRISTOPHER, HAYES, AIDAN, MICHAEL, PADDA, RANBIR, SINGH, WOODWARD, GARY
Applicants: ALBRIGHT & WILSON UK LTD, BRIERLEY TIMOTHY KEVIN, HARRIS JOHN CHRISTOPHER, HAYES AIDAN MICHAEL, PADDA RANBIR SINGH, WOODWARD GARY, ALBRIGHT & WILSON UK LIMITED, BRIERLEY, TIMOTHY, KEVIN, HARRIS, JOHN, CHRISTOPHER, HAYES, AIDAN, MICHAEL, PADDA, RANBIR, SINGH, WOODWARD, GARY
Application year: 1998
Main classification: C07F9
IPC codes: C07F9