CONTINUOUS PROCESS FOR THE PRODUCTION OF POLYETHER POLYOLS

Abstract: A continuous alkoxylation process for the production of polyether polyols is disclosed. The process comprises the use of a plurality of reaction modules each having an outer tube and an inner tube with annular chamber between them. A spiral reaction tube is spaced from the inner tube and winds around the inner tube within the annular chamber. The spiral reaction tube includes an inlet and an outlet, each of which extend through said outer tube. A heat exchange medium flows through the annular chamber and controls the reaction temperature in the spiral reaction tube. The process comprises continuously forming an initial reaction mixture of at least one alkaline oxide and an initiator having at least one reactive hydrogen which is reactive to the alkaline oxide. Continuously flowing the initial reaction mixture through a first spiral reaction tube having an internal diameter and a spiral diameter that promote a pseudo-turbulent flow of the initial reaction mixture through the first spiral reaction tube to form a reaction product. Then flowing the reaction product into a second spiral reaction tube and adding a catalyst and an alkaline oxide to the reaction product, the second spiral reaction tube having an internal diameter and a spiral diameter that promote a pseudo-turbulent flow of the reaction product, the catalyst and the alkaline oxide in the second spiral reaction tube.

Description: CONTINUOUS PROCESS FOR THE PRODUCTION OF POLYETHER POLYOLS Description This invention relates generally to a method for producing poly- ether polyols and, more particularly, to a continuous process for the production of polyether polyols. Polyols are generally defined as compounds that include a plurality of hydroxyl groups. They can be simple polyols or as complex as a 10,000 Dalton polyether polyol comprising a heteric mixture of ethylene oxide and propylene oxide. Polyols, particularly polyether polyols, are useful when combined with isocyanates to form polyurethanes . To produce a high quality polyurethane it is necessary to begin with a high quality polyol. By high quality it is meant a polyol that has a very narrow size distribution and a generally uniform composition. Typically polyols are produced commercially in a batch reactor. A batch reactor is a large reactor chamber that includes and agitator and a thermal jacket. The reactants are added in bulk to the reactor under pressure and the reaction proceeds for hours and sometimes days. One problem with batch reactors is that thermal control can be hard to achieve and the entire reaction must be run at a common temperature. Also the batch reactor needs to be shut down to remove the reaction product, thus slowing production. It would be advantageous to design a continuous reactor assembly to permit the continuous formation of high quality polyether polyols. It would be most advantageous to design the reactor assembly in a manner that promotes turbulent or pseudo-turbulent flow of the reactants and that is modular to permit rapid and easy modification of the assembly to meet the design requirements of a variety of polyols. It would be additionally beneficial to design the reactor assembly to permit different reaction temperatures at different points in the reaction. In general terms, this invention provides a continuous reactor assembly and a method of using the same to form polyether polyols. The reactor assembly is of a modular design that permits rapid and easy modification of the reactor to accommodate different reaction requirements imposed by the chosen product. 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The drawings that accompany the detailed description can be de- scribed as follows. Figure 1 is a sectional view of a reaction module; Figure 2 is a schematic view of a first embodiment of a continu- ous reactor ; Figure 3 is a schematic view of another embodiment of a continuous reactor; and Figure 4 is an alternative embodiment of the continuous reactor shown in Figure 2. Within the several views described below like components are given the same reference numerals. A reactor module is generally indicated at 20 in Figure 1. Reactor module 20 comprises an outer tube 22 which defines an annular chamber 25. In a preferred embodiment, the module 20 further includes an inner tube 24, with the annular chamber 25 defined between the inner tube 22 and the outer tube 24. Reactor module 20 further includes an upper flange 26 opposite a lower flange 28. A heat exchange medium inlet 30 extends through the outer tube 22 into the annular chamber 25 and a heat exchange medium outlet 32 also extends through the outer tube 22 into the annular chamber 25. In one embodiment, support rods 34 are secured to an inner wall 33 of the outer tube 22 and extend toward the inner tube 24. Alternatively, the support rods 34 may be secured to inner tube 24 and extend toward outer tube 22. A spiral reaction tube 36 is spaced apart from and spirals around the inner tube 24. Spiral reaction tube 36 rests on support rods 34 in the annular chamber 25. Spiral reaction tube 36 has a spiral diameter dl that is preferably approximately 1 to 2 inches less than the inner diameter of outer tube 22. Thus, spiral reaction tube 36 closely follows the inner contour of outer tube 22 which can be varied between about two feet and ten feet in diameter. The spiral reaction tube 36 is preferably formed from stainless steel, but as is apparent to one of ordinary skill in the art, tube 36 could be formed of other materials so long as it is compatible with the desired reaction as described below. The internal diameter of the spiral reaction tube 36 can vary between about 0.25 to 3.0 inches depending on the operating parameters, O rt tr φ cn Φ o O a 3 φ o rt μ- O 3 cn ø ) ø μ- h- 1 O ≤ μ- cn Φ cn 0 ) tr μ- cn tr Φ P. Hi o 3 rt tr Φ μ- 3 Φ rt tfa. to to l-» I- 1 U. o Π LΠ o u. o Lπ 0 ) TJ 3 cn Ω rt rt 0 ) TJ TJ LΠ μ- J cn Ω O o <Q μ- rt Φ rt 0 ø φ tr s- W <J rt rt ø ) rt rt tr 3 Φ Φ 0 ) t O 3 Φ Φ ø o 3 β μ- 0 μ- X 0 cn Φ 3 3 rt tr μ- b rt 0 ) h- 1 0 tr μ- 0 ) ø 3 Φ tr o Φ Ω Ω rt Φ 3 Φ 3 . φ Φ 0 3 3 3 μ- 3 < 3 rt 3 Φ tr Φ • cn Ω o H Φ 0 ) 3 tr 3 Φ 0 cn rt O ø ) μ- TJ o cn ø) Φ 3 cn p. rt Φ <Q TJ μ- ø cn Φ x; tr 3 tr 0 3 ^ Φ 3 rt cn cn 3 O O 3 cn μ- cn 3 Φ rt Φ μ- 3 Φ Φ 0 ) O 3 Φ φ tr 3 3 Φ φ cn ι ft ) 0 p. x; ø 3 Ω cn Φ 3 0 ) 3 H3 Φ 3 Ω Φ Φ rt 3 0 ) to 3 rt cn rt 3 rr S > 3 ø Φ Ω 3 3 3 ø μ- o rt 3 σ. rt tn rt ø 3 Φ 0 ) Cn O rt 3 P. Φ tr ø) O tr 0 ) Φ ^ μ- cn o μ- O cn rt h- 1 μ- 0 ) 3 tr cn ø) Φ μ- Φ TJ 0 ) O O 3 rt tr 0 0 Φ 3 3 rt fi ø ) 0 Ω 3 3 0 ) P. o TJ Φ 0 ) 0 ) 3 Φ Ω φ rt 3 rt 3 ø P. ø) ø φ 0 Φ μ- rt cn 0 3 rt O 3 μ- Φ Ω rt rt Φ O O O Ω o 3 X cn ø 3 rt P. 0 ø) 3 Φ ø ) 3 cn Φ ø) ø ) rt cn O 3 ø) 3 3 Ω μ- tr rt ø) h- 1 h- 1 Φ ≤ O X Ω ιQ 3 X φ Ω rt o cn 0 3 l o 3 ø) 3 O Φ 3 3 μ- X β . ø ) O cn 3 Φ x; φ ≤ cn tr rt Φ Φ Ω rt tr 3 rt tr 0 ) Φ P. rt 3 X ø) Φ 3 Φ 3 0 rt to Φ φ tr x; TJ ø ) cn tr LΠ Φ φ 3 tr cn σ rt μ- h- 1 tr Φ Ω ø) Ω rt Ω cn tr TJ 3 ø) to tr cn 3 O 0 ) Φ O 3 Ω ø ) r-o 3 TJ Φ φ Φ o Φ rt LΠ Φ Ω 3 rt rt Ω tr O rt rt 3 Φ h3 3 Φ Φ rt Ω o φ 3 0 3 O rt vq 3 3 3 Ω β 0 3 o rt Φ to tr μ- rt Φ μ- tr Φ Φ fu tr rt . ø) cn rt Φ 3 μ- TJ 3 <Q cn Φ O Φ o 0 rt O o Ω 0 0 ) φ O ø ) cn rt cn 0 ) Φ cn Ω ø ) 0 r 3 tr rt φ cn rt O Φ LΠ ø) cn 3 Φ 0 3 ø) 3 Ω 3 0 TJ rt cn rt rt 3 Φ ø ) φ tr ø ) Φ 3 TJ μ- Ω ø cn 3 o ø ) J rt rt cn 3 t-3 J rt ø) ø ) X ø) 0 h- 1 Φ o 3 Φ Φ 3 Ω rt Ω ø ) Φ rt • O 0 ) O μ- TJ tr 3 O 3 rt rt ø ) Ω 3 μ- O ø ) tr Ω tr TJ 3 rt 3 Φ 0 ) cn rt 3 3 rt ø 1 μ- 3 O 3 3 3 φ Φ 0 ) O Φ I- 1 rt φ 3 3 cn cn rt . φ tr O Φ Φ Φ Φ 3 a « o x. 3 LΠ tr cn 3 x. 3 TJ cn O μ- cn 3 μ- ø Φ cn O ø) φ 3 o 3 3 3 ø ) 0 O φ TJ cn Φ rt Φ rt fi X ø ) cn Φ rt 3 ø ) o rt O Φ rt ø) 3 3 0 ) ø ) O TJ 0 cn rr P. μ- cn rt ø 3 ø rt 0 Φ 3 rt t Φ cn ø TJ g rt rt O X Φ cn 3 LΠ TJ O ø 3 3 tr ø) cn O ø X 3 Φ ø) 3 σi tr Φ Q* tr Φ 3 X ø 3 cn 3 rt tr h- 1 Ω μ- 0 ) TJ φ tr TJ 3 ø ) Φ 0 ) 3 O O J tr Φ 3 Φ X φ a 0 ) 3 P- ø ) Φ o tr ø) Φ Φ tr 3 Φ 3 • μ- Φ Ω X ø X 3 φ TJ ø) x; & Ω X tr ø) Φ Φ rt ø) 3 μ- p. φ Ω cn Φ n 3 o x. 3 p ) μ- O <Q μ- Φ rt 3 ~o tr tr Ω Φ 3 μ- ø Ω a ø Ω z cn 3 0 ) cn μ- 3 3 O cn tr cn ≤ Φ cn Lπ Φ ø ) 0 ) tr 0 ) x; 3 ø ) 3 tr Φ Ω Ω TJ O φ tr • Φ cn Φ Ω h- 1 3 Φ Φ 3 Φ cn Φ cn x; o cn 3 3 ø ) rt Φ TJ cn Φ rt o 3 φ ø ) 0 ) ø) S Φ rt O rt tr 0 ø Φ cn rt μ- O 3 cn 3 3 ø 3 3 J < 3 Ω tr a 3 tr H 0 φ rt μ- 0 rt 3 3 ø tr Ω 3 rt Φ Φ X O Φ r O P. ≤ x; 0 Φ ' P. rr ø ) 0 3 a Φ Φ μ- X rt to ø cn rt O Φ 3 3 o ø Φ a' Φ X X tr o Φ tr o 3 3 H- 1 3 0 Φ 0 ) 3 s- tr ø ) μ- O 3 3 φ 3 Ω Φ Φ ø Cn ø) ø) Φ cn O Φ μ- TJ ø Ω Ω μ- cn φ TJ Φ O rt rt tr 0 3 rt 3 Φ 3 tr P. 3 O 0 ) rt Lπ 3 Φ 3 3 rt rt 3 Φ φ 3 J tr tr cn o Φ ιQ φ tr 3 Φ ø) Φ ø) ø ) 3 Φ 3 ø ) Φ Ω Φ Φ Ω μ- Φ tr Φ μ- 3 Φ Φ φ 0 0 cn tr Ω Φ Φ s; μ- 3 tr t- 1 P. tr rt μ- 3 O rt 3 O rt cn ø ) cn cn 3 cn Ω rt rt 3 ø ) ø ) 0 >Q 3 tr X Φ LΠ tr 3 0 ) rt o 3 0 ) 3 ø Ω ø ) a TJ 3 0 ) n 0 ) Ω tr rt ø ) Φ Ω x 3 ø φ Φ x. ø) X tr Φ ø ) μ- tr rt tr tr tr σ . Ω rt ø) tr 0 rt tr O 3 O tr rt 3 3 rt μ- 0 ) Φ ø ) 3 Φ Φ Φ . O O rt 3 0 3 tr 3 ø ) cn o Φ 3 0 ) tr 3 3 ø ) rt 3 • 3 x; cn rr 3 φ ø 0 ) μ- 0 μ- 3 X rt Φ o Φ Ω O rt 3 π Φ ιQ 3 TJ Lπ rt ιQ o 3 TJ O 3 φ rt tr 3 3 rt O 3 a ø ) φ o 3 tr rt o Φ Φ 0 ) 3 3 ø) rt μ- o Φ P. tr Φ Φ Φ ø Ω 3 rt rt ø Φ tr . ø) 0 ) Φ .. Φ X μ- 0 Ω μ- tr 3 • w ø ) Ω φ ø) 3 rt cn <Q O 0 ø) rt o X rt rt rt Φ 3 n O X Ω 3 s; 3 3 Φ 0 ) o rt Ω Φ o tr 3 O μ- O 0 ) tr Φ Φ tr tr X 0 ) Ω tr μ- cn Φ Ω rt TJ Φ μ- μ- σi rt 0 ) ø) O rt 3 ø 3 φ cn 3 Φ Φ rt t Φ rt 3 tr ø ) 3 0 ) tr cn tr 3 3 3 . Ω rt a * ø) Φ cn tr LΠ 3 TJ ø) Φ Φ O rt p. ø ) 3 ιQ ø ) cn Φ ø ) TJ 3 3 Φ Φ h- 1 O rt O rt Φ Ω rt Φ o 3 Φ μ- ø ) φ rt 3 3 Ω O . Φ a ιQ a Φ cn 3 Φ φ cn n rt Φ 3 3 O rt 3 tr o Φ 3 3 φ TJ 0 ) 3 μ- LΠ ιQ Φ rt • Φ 3 0 ) rt cn O rt O φ Φ Φ φ ø ) cn 0 ) Φ 0 ) Φ ø Φ LΠ rt cn Φ 3 tr rt 0 ) Ω Φ o ø σ. 3 3 3 h- 1 3 Φ 0 ) tr TJ O cn Φ rr rt X Ω 3 cn D o O φ rt < Φ rt 3 Ω 3 cn μ- Φ LΠ μ- Ω 0 ) o o X . rt O ø Ω rt ø) Φ O cn ø ) rt 3 Ω tr μ- H3 3 μ- 0 ) X Φ Φ 3 rt X rt fl ) o rt rt rt < ø μ- Ω 3 tr μ- rt 3 o tr 0 Φ O rt Φ cn tr 3 O tr Φ tr o rt ø Ω o μ- O O X Φ 3 X Φ 0 ) O ø O ø) 3 ø Ω Φ rt Φ 3 t- 1 ø ) O O Ω ø tr rt ø) 3 ø ) P. Φ 3 3 3 3 O < 0 ) tr 3 3 μ- O tr 0 ) ^ h- 1 Ω X 3 Φ J rt 3 rt rt cn ø ) Φ O ø rt Φ 3 ø) 0 φ tr 3 cn ø ) Ω rt Ϊ tr Φ rt O O Φ tr ø ) μ- tr J o 3 Φ rt 3 tr rt < 3 Ω 0 Ω μ- ø ) rt rt ø rt 0 ) tr μ- rt O ø 3 φ cn 3 Φ TJ 3 ø X tr Φ 0 ) ø) ø) Φ rt 3 rt 3 μ- tr tr h- 1 Φ 3 Ω tr Φ cn 3 cn Φ Φ 3 ø ) ø ) 3 Φ 3 ιQ O Φ Φ Φ x; <Q μ- O Φ Φ rt Φ O Φ X α μ- μ- Φ < 3 J rt φ 3 tr Φ ø) ø 3 ft ) Φ cn 3 cn 3 ≤ 3 μ- øJ o cn 3 . 3 O ø ) Φ tr μ- Ω O Φ Z O rt rt cn O 3 Φ Φ , rt 3 3 X TJ Φ σ. φ 3 μ- Φ o tr ø rt φ o 3 Φ σ. cn 3 Φ o Φ 0 3 3 φ cn Φ O cn 3 rt x; 3 3 ' 3 rt ØJ 3 P. O ø rt Φ rt 3 Φ Ω μ- 3 Ω ø ø ) rt Φ cn ø ) tr Φ ø ) rt Φ X Ω tr ø ) a <Q Φ 3 Φ μ- ø 3 rr tr 3 O 0 ιQ tr ø ) rt Pi TJ TJ rt 0 ) O φ tr i rt O 0 ) TJ rt 0 ) Ω Ml TJ rt i φ 3 ø ) H-j ≤ tr 2 Ω μ- Φ 3 I- 1 ø Mi rt Φ Φ O Hi H 3 μ- 3 Φ μ- 3 0 μ- rt ø ) I- 1 μ- μ- Φ o O o 03 Φ ø ) tr 3 tr rt rt X μ- O Pi Φ 03 3 Φ ø ) tr rt X y Q μ Φ ≤ 3 3 μ- Hi Ω φ Φ Φ χι ≤ ø ) Φ χ ι O 3 Pi o 03 Hi 0 3 μ- ø ) ø I- 1 3 rt 03 >α Φ Φ ø ) rt h- 1 Φ OJ fi rt h- i 3 03 μ- - rt φ φ μ- i Ω h- 1 3 rt μ- 3 3 03 -J Ω tr Φ Φ 00 Pi tr Φ 3 o 3 3 3 Φ μ- Φ tr i tr 3 o Φ ø ) n rt χι 3 3 μ- χι 3 rt O μ- μ- 0 ) 3 Φ Φ 3 μ- 3 Φ Φ ø ) ø Hh Pi tr rt μ- Φ o rt Φ O Mi rr rt μ i Φ Φ 3 Φ bO cn rt O tr rt O Φ _o Mi μ- Φ μ- ≤ X i pi μ- P. Ω ø J rt XI Φ O 3 3 O o O 3 O ø ) 0 ) ø ) Φ μ- XI μ- O rt O Z Φ 3 rt cn O O Φ X o Mi 3 Φ X i h- 1 rt μ- cn H rt ø ) S X μ- X ø ) cn μ- tr h- i rt 3 Mi TJ μ- μ- μ- i X 0 <P Φ t 3 tr μ- ø ) μ- 03 Ω tr φ 3 x; TJ tr φ o 3 O Pi 0 ) 3 O O Pi μ- x. 3 tr TJ 3 ø ) μ- Φ Pi rt Pi 3 φ Φ 3 3 Φ ø ) 3 O X Φ 3 03 Mi X Φ 3 h- 1 - rt 3 Φ rt 3 3 φ O Φ 0 μ- P. cn ø ) Φ O Ω 3 Pi μ- i rt μ- <Q φ Φ Φ • 3 cn t ^ rt Ω 3 Pi 03 rt ø Pi μ- Ω P- ø ) 3 rt o\° Mi O 0 ) cn S φ Φ 3 rt μ- ø rt μ- ø ) Ω Φ 3 03 0 ) φ 3 Ω Φ tr Φ X Φ tr ø ) Pi Pi μ- ø O Ω Ω O <! r TJ rr i ø) 0 tr 3 μ- h- i O O ø ) 03 • rt Ω 3 Φ μ- Φ 3 ø ) 0 ) σ μ- ø) tr ft O cn ø ) 3 Pi 3 Mi 3 < rt cn rt ) Ω Φ Pi 3 o 3 h- i Φ rt ø ) X 03 Φ Φ O Φ μ- φ O ø ø) h- i ø ) 3" tr ø ) ø ø ) x; 0 μ- μ- φ i Mi 0 ) Ω 3 rt t-3 ø 3 Cn X μ- ι Ω 3 μ- TJ h- i 03 ø ) H x; Pi rt i TJ Ω ø) Φ ιQ tr Mi tr cn Φ cn ø ) 3 O fi rt μ- rt β 0 rt i ø 03 Φ rt 3 rt μ- rt X χι O Φ φ Φ I- 1 Φ 3 3 μ- 3 O ø ø 3 . Pi Φ rt 3 o tr μ- tr Pi ø) 0 ) 3 3 0 μ- 0 ) Φ O O y Q h- 1 μ- 3 Φ Φ 3 . μ- ø ) 3 0 ) O φ 03 3 Φ Φ 3 Ω rt Ml 3 Ω rt >Q 3 0 Pi Pi 0 ) Pi Φ 3 XI rt 3 x. TJ ø ) 3 o O i Φ rt 3 Φ Hh Φ 03 Ω rt 3 cn N h- i Ω Φ ø ) 3 rt x; μ- XI 3 TJ μ-> 3 cn rt tr rt Pi ≤ 3 tr tr ft rt Φ 0 μ- φ rt rt Mi tr O O 03 3 O φ rt J μ- Φ O μ- tr ø Φ φ tr O ø ) Ω 3 μ- O TJ μ- O Φ i X 3 O O s; ø ) φ O ø ) Φ I- 1 Φ n tr >q O <; X O 3 3 μ- Mi O Pi pi rt 3 3 Φ Φ 3 a rt 3 rt ø ) rt Hi φ μ- h- i ø 3 Ω o Pi TJ 3 ø rt μ- Φ rt ø ) μ- μ- Φ o Mi Pi μ- ø ) μ- Pi XI O o • Φ 3 0 ) Ω tr ø ) . cn rt tr Ω 3 0 TJ Ω rt 3 P. < cn 3 03 tr Φ Φ 0 cn 3 . O I- 1 rt rt 3 3 ø x; tr Φ cn h- i φ ø ) Φ μ- Φ μ- 0 rt cn Φ rt Pi X tr O μ- tr I- 1 μ- φ 03 h- i Φ 3 TJ rt Ω fi 0 ) tr < μ- ø 0 ) φ ≤ ø 3 ø ) φ Φ 3 μ- 3 03 ιp tr tr μ- tr 3 3 φ 3 Φ 3 H Ω μ i tr 1 Φ tr 3 3 0 rt *Q cn 0 ) s: 0 ) x; O ø ) 0 Pi 3 Φ 3 ø 3 rt μ- 0 ) Φ tr Φ Φ - 1 Φ I- 1 TJ 3 0 ) pi cn rt ø ) y 0 ) 0 ) O 3 3 3 cn σ. Φ μ- Φ μ- XI μ- X 3 3 TJ O 3 Φ rt J Ω ø 03 ≤; Φ μ- Φ rt Φ μ- μ- O 03 rt 3 y XI O tr 3 3 tr O rt cn 0 μ- 3 μ- tr i 3 3 ø X o tr ) rt tr h- i y Q O 03 μ- 03 Φ O φ tr rt O Φ 3 φ Mi μ- Ω 3 μ- Mi J ι O rt φ ø) Φ 3 3 x. 3 X 3 03 tr X cn rt tr Pi i 3 3 Pi 3 μ- 0) μ- rt μ- O 0 ) Φ Φ μ- Φ Mi Ω μ- Φ Φ rt Φ Φ 3 ø 0 Φ i 03 Ω 0 rt tr 3 μ i ø ) 3 ø ) r3 < Pi O rt μ- ø ) ø ) n 3 O Hh 3 Φ 03 Hh μ- Ω μ- ø ) μ- 03 TJ Ω φ Φ Mi tr 3 rt o μ- Φ Φ ø ) Φ O rt 0 ) ø) tr ø ) rt rt s: cn h- rt Φ 3 x; cn ø ) ø ) 03 ø 3 Ω rt X μ- 3 Ω rt μ- tr Φ Φ O 3 x; rt rt rt h- 1 3 3 Φ 3 O rt 3 tr μ- O Φ μ- 0 ) O 0 ) ø ) φ g- 3 rt O O Φ x; Φ ø ) TJ Ml 3 Φ X μ- 0 φ Pi 3 Pi 03 3 3 rt 3 TJ 1 h- 1 3 03 N ø ) μ- 3 Φ Φ Pi μ- O i Φ ø ) 3 Φ O Φ I- 1 O ø ) 3 o μ- ø Φ TJ Φ Ω 3 Φ Pi Pi 3 rt ø ) h- i Φ ø ) ø ) μ- 3 μ- x; t- i 03 O z 3 Φ μ- cn rt rt cn Pi rt Φ μ- h- i I- 1 0 ) 3 3 cn 3 3 XI 03 fi μ- 3 O 3 μ- ø ) 03 μ- μ- tr rt TJ X Φ Ω Ω Φ μ- Φ Z φ Φ ø Ω rt Φ X ø ) 0 ) o μ- ø 3 ø ) 0 ) ø ) ø h- i x; < ø ) rt 3 rt ø ) ø ) rt o rt h- 1 O μ- μ- I- 1 3 3 3 3 rr 3 rt cn tr Φ Φ rt Φ ø Φ O Ω cn tr tr Φ 3 ø ) Pi Pi Pi φ O μ- Φ φ h- 1 ø) Pi cn cn rt Φ cn Φ i I- 1 03 Ω rt μ- Φ 3 3 rt 3 it* rr 03 μ- 3 h- 1 Φ - 0 μ- 0 ) tr 3 XI - Φ O ø ) Φ r μ- tr O rt Φ tr 3 Φ 3 XI s; Φ < 3 Hi O 3 3 3 3 ø ) φ X Φ Hi tr 3 Φ l_J. O 03 μ- t- i 3 Φ μ- 3 TJ 0 ) rt μ- φ Ω Ω rt φ J O cn φ O rt ft rt μ- μ- Φ ø) 3 3 o o hh 3 μ- 3 rt 0 ø 3 h- 1 Ω X tr rt X rt 3 03 h- 1 rt ø ) 03 Φ μ- 3 3 μ- μ- Φ μ- Φ Φ O 0 rt μ- XI tr φ • O Φ Φ 3 O 03 Pi X rt μ- 3 O ø ) 3 3 cn 3 Φ tr 03 h- 1 03 Φ 03 ether polyols which are all of approximately the same length, thus reducing heterogeneity in the product. In addition, the design ensures that at any given time the amount of alkaline oxide in the reaction is low compared to a batch reactor and that the stoichiometry is better controlled. This also enhances the quality of the polyether polyol. The multiple addition points permit an operator to form a variety of polyols, for example, a polyether polyol having blocks of ethylene oxide and propylene oxide or a heteric polyol. As will be understood by one of ordi- nary skill in the art the separate heat exchangers 58 permit the reaction temperature to be changed during the reaction. This ability can be useful to increase the yield of the reaction and the reaction temperature will be determined in part by the identity of the alkaline oxide used in a given spiral reaction tube. The continuous reactor assembly shown in Figure 3 will be used when it is not desirable to first replace all of the reactive hydrogens on the initiator with an alkaline oxide prior to beginning the elongation reaction. The reactor assembly 150 is more efficient when it is desired to run the entire reaction at a single reaction temperature. Suitable alkaline oxides for use in the formation of polyether polyols include ethylene oxide, propylene oxide, and butylene oxide. Suitable catalysts include: the alkaline catalysts such as potassium hydroxide, sodium hydroxide, alcoholates of potassium hydroxide, alcoholates of sodium hydroxide, cesium hydroxide, or amines; Lewis acid catalysts such as boron trifluoride; and metal complex catalysts such as double metal cyanide complexes. Preferably the catalyst is added in an amount of 0.1% to 1.0% in a given addition. Suitable initiators include amines and aromatic initiators having hydrogens which are reactive with alkaline oxides. Preferred aromatic initiators include toluene diamine, hydroquinone, and other aromatic initiators. Other initiators include the well known non-aromatic initiators which have hydrogens that are reactive to alkaline oxides such as glycerol. EXAMPLE 1 A continuous reactor similar to that disclosed in Figure 2 was utilized in preparing the following example. Vicinal toluene diamine (a mixture of 2,3-and 3,4-toluene diamine) was loaded into stock initiator tank 68 and kept under nitrogen pressure. Ethylene oxide monomer was loaded into stock alkaline oxide tank 9 62 and also kept under nitrogen pressure (35 lbs. per square inch) . Propylene oxide monomer was loaded into the other alkaline oxide tank 88 and also kept under nitrogen pressure. The vicinal toluene diamine was injected together with the ethylene oxide monomer into a first spiral reaction tube 76. The feed rate ratio of vicinal toluene diamine to ethylene oxide monomer was 7.3:8.6 (w/w) . The pressure upon injection into the first spiral reaction tube 76 was 995 lbs. per square inch and the heat exchange medium was at a temperature of 160°C. The reaction product exiting the first spiral reaction tube was passed into a second spiral reaction tube 78 wherein the heat exchange medium was at a temperature of 210°C. Intermediate removed at this point in the reaction had a hydroxyl number of 758, and an amine number of 216, and a viscosity of 6,200 centipoise at 120°F. The inter - mediate from the second spiral reaction tube 78 was injected together with an aqueous KOH solution (45%) and propylene oxide monomer mixture from the other alkaline oxide tank 88 into a third spiral reaction tube 80. The feed ratio of intermediate to monomer mixture was 7.9:9.0 (w/w). The catalyst concentration of KOH was 0.2%. The heat exchange medium was at a temperature of 180°C. The reaction product from the third spiral reaction tube was passed through a fourth spiral reaction tube 80 wherein the heat exchange medium was at a temperature of 230°C. The product from the fourth spiral reaction tube was placed under high vacuum to remove unreacted alkaline oxide monomer. The obtained product had a hydroxyl number of 395, and an amine number of 103, and a viscosity of 6,600 centipoise at 80°F. EXAMPLE 2 Example 2 was prepared similar to Example 1. Vicinal toluene diamine and ethylene oxide were fed into the first spiral reaction tube at a ratio of initiator to monomer of 7.3:9.0 (w/w) . The pressure at the injection point was 660 lbs. per square inch and the heat exchange medium was at a temperature of 140°C. The product from the first spiral reaction tube was passed through a second spiral reaction tube wherein the heat exchange medium was at a temperature of 200°C. The intermediate from the second spiral reaction tube had a hydroxyl number of 749, and an amine number of 205, and a viscosity of 6,300 centipoise at 120°F. The intermediate from the second spiral reaction tube was injected together with an aqueous KOH solution (45%) and propylene oxide monomer mixture into a third spiral reaction tube. The feed ratio of intermediate to propylene oxide monomer mixture was 7.2:8.9 (w/w). The catalyst concentration of KOH was 0.2% and the heat exchange medium was at a temperature of 180°C. The product from the third spiral reaction tube was passed through a fourth spiral reaction tube wherein the heat exchange medium was at a temperature of 230°C. The product from the fourth spiral reaction tube was placed under high vacuum to remove nreacted alkaline oxide monomer. The product obtained had a hydroxyl num- ber of 366, and an amine number of 94, and a viscosity of 4,000 centipoise at 80°F. EXAMPLE 3 Example 3 was prepared similar to Example 1. The vicinal toluene diamine and ethylene oxide monomer mixture were injected into a first spiral reaction tube at a feed ration of 8.4:8.2 (w/w). The pressure at injection was 650 lbs. per square inch and the heat exchange medium was at a temperature of 140°C. The product from the first spiral reaction tube was passed through a second spiral reaction tube wherein the heat exchange medium was at a temperature of 200°C. The intermediate at this point had a hydroxyl number of 830 and an amine number of 297. The product from the second spiral reaction tube was injected with aqueous KOH solution (45%) and propylene oxide monomer mixture into a third spiral reaction tube. The feed ratio of intermediate to propylene oxide monomer mixture was 8.1:8.8 (w/w). The catalyst concentration of KOH was 0.2% and the heat exchange medium was at a temperature of 180°C. The reaction product from the third spi- ral reaction tube was passed into a fourth spiral reaction tube wherein the heat exchange medium was at a temperature of 230°C. The product from the fourth spiral reaction tube was placed under high vacuum to remove unreacted alkaline oxide monomer and the product obtained had a hydroxyl number of 421 and an amine number of 143. EXAMPLE 4 Example 4 was prepared similar to Example 1. To the first spiral reaction tube vicinal toluene diamine, ethylene oxide monomer, and aqueous KOH catalyst solution (45%) were injected into the first spiral reaction tube. The feed ratio of vicinal toluene diamine to ethylene oxide monomer was 6.6:9.2 (w/w). The catalyst concentration of KOH was 0.4%. The pressure at injection was 840 lbs. per square inch and the heat exchange medium was at a temperature of 170°C. The product from the first spiral reaction tube was passed through a second spiral reaction tube wherein the heat exchange medium was at a temperature of 210°C. The intermediate at this point had a hydroxyl number of 750 and an amine number of 139. The product from the second spiral reaction tube was injected together with propylene oxide monomer mixture into a third spiral reaction tube. The feed ra- tio of intermediate to propylene oxide mixture was 8.7:8.9 (w/w). The heat exchange medium was at 180°C. The product from the third spiral reaction tube was passed into a fourth spiral reaction tube wherein the heat exchange medium was at a temperature of 5 230°C. The product from the fourth spiral reaction tube was placed under high vacuum to remove unreacted alkaline monomer and the product obtained had a hydroxyl number of 388 and an amine number of 69. 0 The present invention has been described in accordance with the relevant legal standards, thus the foregoing description is exemplary rather than limiting in nature. Variations and modifications to the disclosed embodiment may become apparent to those skilled in the art and do come within the scope of this inven- 5 tion. Accordingly, the scope of legal protection afforded this invention can only be determined by studying the following claims . 0 5 0 5

Claims: We claim : 1. A continuous process of forming polyether polyols comprising the steps of: a) continuously forming an initial reaction mixture of at least one alkaline oxide and an initiator having at least one reactive hydrogen which is reactive to said alkaline oxide; b) continuously flowing said initial reaction mixture through a first spiral reaction tube having an internal diameter and a spiral diameter that promote a pseudo-tur- bulent flow of said initial reaction mixture through said first spiral reaction tube to form a reaction product; c) flowing said reaction product into a second spiral reaction tube operably connected to said first spiral reaction tube and adding a catalyst and an alkaline oxide to said reaction product, said second spiral reaction tube having an internal diameter and a spiral diameter that promote a pseudo-turbulent flow of said reaction product, said catalyst and said alkaline oxide in said second spiral reaction tube; and d) continuously flowing a heat exchange medium around said first and said second spiral reaction tubes, said heat exchange medium establishing and maintaining a reaction temperature between 130 G C and 250°C in said first and said second spiral reaction tubes. 2. A continuous process as recited in Claim 1 wherein, step c) comprises adding one of potassium hydroxide, sodium hydro - xide, an alcoholate of potassium hydroxide, an alcoholate of sodium hydroxide, cesium hydroxide, an amine, a Lewis acid catalyst, or a metal complex catalyst as said catalyst. 3. A continuous process as recited in Claim 1 wherein, step a) comprises adding an aromatic compound having at least one reactive hydrogen which is reactive to said alkaline oxide as said initiator. 4. A continuous process as recited in Claim 1 comprising the further step of maintaining a pressure in said first and said second spiral reaction tubes that is above the vapor pressure of said alkaline oxides and that maintains said alkaline oxi- des in a liquid state in said first and said second spiral reaction tubes. 5. A continuous process as recited in Claim 1 wherein, said catalyst is added to both said first and said second spiral reaction tube. 6. A continuous process as recited in Claim 1 wherein said method includes maintaining said reaction temperature between 180°C and 250°C with said heat exchange medium. 7. A continuous process of forming polyether polyols comprising the steps of: e) continuously forming an initial reaction mixture of ethylene oxide and a self catalyzing initiator in the absence of a catalyst, said initiator having at least one reactive hydrogen which is reactive to said ethylene oxide; f) continuously flowing said initial reaction mixture through a first spiral reaction tube having an internal diameter and a spiral diameter that promote a pseudo-turbulent flow of said initial reaction mixture through said first spiral reaction tube to form a reaction product; g) flowing said reaction product into a second spiral reaction tube operably connected to said first spiral reaction tube and adding a catalyst and an alkaline oxide to said reaction product, said second spiral tube having an internal diameter and a spiral diameter that promote a pseudo-turbulent flow of said reaction product, said catalyst and said alkaline oxide in said second spiral tube ; h) surrounding said first and said second spiral reaction tube with a heat exchange medium, said heat exchange medium establishing and maintaining a reaction temperature between 130°C and 250°C in said first and said second spiral reaction tubes; and i) pressurizing said first and said second spiral reaction tube at a pressure between 200 to 1500 pounds per square inch, thereby maintaining said ethylene oxide and said alkaline oxide in a liσuid state. 8. A continuous process as recited in Claim 7 wherein steps a) and b) are repeated a plurality of times until said ethylene oxide completely reacts with each of said reactive hydrogens prior to step c) . 5 9. A continuous process as recited in Claim 7 wherein step c) comprises adding one of potassium hydroxide, sodium hydroxide, an alcoholate of potassium hydroxide, an alcoholate of sodium hydroxide, cesium hydroxide, an amine, a Lewis acid 10 catalyst, or a metal complex catalyst as said catalyst. 10. A continuous process as recited in Claim 7 wherein step a) comprises adding toluene diamine as said initiator. 15 11. A continuous process as recited in Claim 7 wherein said method includes maintaining said reaction temperature at a temperature between 160°C to 210°C. 12. A continuous process as recited in Claim 7 comprising the 20 further steps of flowing an output from said second spiral reaction tube through an additional spiral reaction tube, said additional spiral reaction tube surrounded with said heat exchange medium and at a pressure between 200 to 1500 pounds per square inch; and adding additional alkaline oxide 25 to said additional spiral reaction tube. 13. A continuous process as recited in Claim 12 wherein the step of adding additional alkaline oxide to said additional spiral reaction tube comprises adding propylene oxide to said addi- 30 tional spiral reaction tube. 14. A continuous process of forming polyether polyols comprising the steps of: 5 j) continuously forming an initial reaction mixture of at least one alkaline oxide and an initiator having at least one reactive hydrogen which is reactive to said alkaline oxide; 0 k) forming a plurality of spiral reaction tubes operably connected to each other in series and each having an internal diameter between 0.25 and 3.0 inches, a spiral diameter of between 2 feet and 10 feet, said spiral reaction tubes promoting a pseudo-turbulent flow of said 5 initial reaction mixture; 1) continuously flowing said initial reaction mixture through said first of said spiral reaction tubes to form a reaction product; m) flowing said reaction product into a second of said spiral reaction tubes adjacent to said first of said spiral reaction tubes and adding a catalyst and an alkaline oxide to said reaction product; n) surrounding said plurality of spiral reaction tubes with a heat exchange medium, said heat exchange medium establishing and maintaining a reaction temperature within said plurality of spiral reaction tubes of between 130°C and 250°C; and maintaining a pressure in said spiral reaction tubes of between 200 to 1500 pounds per square inch. 15. A continuous process as recited in Claim 14 wherein, step a) comprises forming said initial reaction mixture by combining ethylene oxide with toluene diamine. 16. A continuous process as recited in Claim 15 wherein, step e) comprises maintaining said reaction temperature at between 160°C and 210°C. 17. A continuous process as recited in Claim 14 wherein, step d) comprises adding one of potassium hydroxide, sodium hydroxide, an alcoholate of potassium hydroxide, an alcoholate of sodium hydroxide, cesium hydroxide, an amine, a Lewis acid catalyst, or a metal complex catalyst as said catalyst. 18. A continuous process as recited in Claim 14 wherein, step c) further comprises adding said catalyst to said initial reaction mixture in said first of said spiral reaction tubes. 19. A continuous process as recited in Claim 14 further comprising the steps of adding additional amounts of said catalyst and said alkaline oxide to others of said spiral reaction tu- bes. 20. A continuous process as recited in Claim 14 wherein step e) further comprises the additional steps of establishing and maintaining a first reaction temperature in a first plurality of spiral reaction tubes and establishing and maintaining a second reaction temperature in a second plurality of spiral reaction tubes, said second reaction temperature being greater than said first reaction temperature.

Inventors: DEXHEIMER EDWARD MICHAEL, HINZ WERNER, DEXHEIMER, EDWARD, MICHAEL, HINZ, WERNER
Applicants: BASF CORP, DEXHEIMER EDWARD MICHAEL, HINZ WERNER, BASF CORPORATION, DEXHEIMER, EDWARD, MICHAEL, HINZ, WERNER
Application year: 2000
Main classification: C08G65
IPC codes: B01J19, C08G59, C08G65