Patent EA-001482-B1 (EA)
Title: Hydroformulation process for production aldehyde in the presence of a metal-organophosphite complex catalyst
Inventor: BRYANT ROBERT DAVID
IPC: F04D29/28
Filed: 1996-12-05
Abstract: 1. A hydroformylation process which comprises reacting one or more reactants in the presence of a metal-organophosphite ligand complex catalyst and dissolved water and optionally free organophosphite ligand to produce a reaction product fluid comprising one or more products, wherein said process is conducted in the presence of carbon dioxide in an amount sufficient not to effect substantial degradation of any said organophosphite ligand and/or substantial deactivation of said metal-organophosphite ligand complex catalyst. 2. A hydroformylation process of claim 1, which comprises reacting one or more olefinic unsaturated compounds with carbon monoxide and hydrogen in the presence of a metal-organophosphite ligand complex catalyst and dissolved water and optionally free organophosphite ligand to produce a reaction product fluid comprising one or more aldehydes. 3. An improved hydroformylation process of claims 1 or 2, which comprises (i) reacting in at least one reaction zone one or more olefinic unsaturated compounds with carbon monoxide and hydrogen in the presence of a metal-organophosphite ligand complex catalyst and dissolved water and optionally free organophosphite ligand to produce a reaction product fluid comprising one or more aldehydes and (ii) separating in at least one separation zone or in said at least one reaction zone the one or more aldehydes from said reaction product fluid, the improvement comprising eliminating the need for carbon dioxide removal from a mixture of carbon monoxide and hydrogen prior to it being introduced into said at least one reaction zone. 4. The process of any preceding claims wherein said catalyst is a rhodium organophosphite ligand complex catalyst. 5. The process of any preceding claims wherein said hydroformylation is conducted in the presence of carbon dioxide in an amount of from about 0.1 mole percent to about 70 mole percent, based on the total gas mixture. 6. The process of claim 5 wherein the carbon dioxide partial pressure is greater than about 5 mole percent, based on the total gas mixture and changes depending on the amount of carbon dioxide. 7. The processes of any preceding claims wherein said dissolved water is present in an amount from about 0.01 to about 10 weight percent based on the total weight of the hydroformylation reaction product fluid. 8. The process of claims 2 or 3 wherein said hydroformylation process comprises a continuous liquid recycle process. 9. The process of any preceding claim wherein said metal-organophosphite ligand complex catalyst is homogeneous or heterogeneous. 10. The process of claims 1 to 8 wherein said reaction product fluid contains a homogeneous or heterogeneous metalorganophosphite ligand complex catalyst or at least a portion of said reaction product fluid contacts a fixed heterogeneous metalorganophosphite ligand complex catalyst. 11. The process of any preceding claim wherein said metal-organophosphite ligand complex catalyst comprises a rhodium complexed with an organophosphite ligand selected from: (i) a monoorganophosphite represented by the formula:   wherein R<1> represents a substituted or unsubstituted trivalent hydrocarbon radical containing from 4 to 40 carbon atoms or greater; (ii) a diorganophosphite represented by the formula:   wherein R<2> represents a substituted or unsubstituted divalent hydrocarbon radical containing from 4 to 40 carbon atoms or greater and W represents a substituted or unsubstituted monovalent hydrocarbon radical containing from 1 to 18 carbon atoms or greater; (iii) a triorganophosphite represented by the formula:   wherein each R<6> is the same or different and represents a substituted or unsubstituted monovalent hydrocarbon radical; and  (iv) an organopolyphosphite containing two or more tertiary (trivalent) phosphorus atoms represented by the formula:   wherein X represents a substituted or unsubstituted n-valent hydrocarbon bridging radical containing from 2 to 40 carbon atoms, each R<7> is the same or different and represents a divalent hydrocarbon radical containing from 4 to 40 carbon atoms, each R<8> is the same or different and represents a substituted or unsubstituted monovalent hydrocarbon radical containing from 1 to 24 carbon atoms, a and b can be the same or different and each have a value of0 to 6, with the proviso that the sum of a + b is 2 to 6 and n equals a + b. 12. The process of any preceding claim wherein the reaction product fluid contains a phosphorus acidic compound. 13. The process of claim 12 wherein the phosphorus acidic compound present in the reaction product fluid is treated with an aqueous buffer solution. 14. The process of claim 13 wherein the aqueous buffer solution comprises a mixture of salts of oxyacids having a pH of 3 to 9. 15. The processes of claim 14 wherein the aqueous buffer solution comprises a mixture of an anion selected from the group consisting of phosphate, carbonate, citrate and borate compounds and a cation selected from the group consisting of ammonium and alkali metals. 16. The process of claim 12 wherein phosphorus acidic compounds present in the reaction product fluid are scavenged by an organic nitrogen compound that is also present in said reaction product fluid and wherein at least some amount of the phosphorus acidic compound of the conversion products of the reaction between said phosphorus acidic compound and said organic nitrogen compound are also removed by the aqueous buffer solution treatment. 17. The process of claim 16 wherein the organic nitrogen compound is selected from the group consisting of diazoles, triazoles, diazines and triazines. 18. The processes of claim 17 wherein the organic nitrogen compound is benzimidazole or benzotriazole.