Patent Publication Number: US-4319056-A

Title: Process for the hydrocarbonylation of methanol to ethanol in the presence of an inert liquid

Description:
This is a continuation of application Ser. No. 957,700, filed Nov. 6, 1978, now abandoned. 
    
    
     The present invention relates to the production of ethanol from methanol and synthesis gas (mixtures of carbon monoxide and hydrogen) in the presence of a cobalt-containing catalyst. 
     Ethanol is a valuable industrial product which is generally manufactured either by fermentation of natural products eg molasses or by hydration of ethylene in the presence of an acid catalyst, such as phosphoric acid. The rapidly dwindling reserves of crude oil from which ethylene is derived and the associated need to utilise fully the remaining natural resources such as coal and the vast amounts of gases eg methane potentially available from the exploitation of North Sea oilfields has stimulated researchers to investigate other routes to ethanol utilising these materials as feedstocks. Both coal and methane gas can be converted into synthesis gas (CO+H 2 ), which in turn can be reacted to form methanol, which methanol can be further reacted with carbon monoxide and hydrogen under appropriate conditions to form ethanol. 
     It has long been known that methanol can be hydrocarbonylated with hydrogen and carbon monoxide to ethanol in the presence of a water soluble cobalt catalyst at high temperatures and pressures. The course of this reaction can be represented by the following equation: 
     
         CH.sub.3 OH+CO+2H.sub.2 →C.sub.2 H.sub.5 OH+H.sub.2 O 
    
     The problem with the majority of prior art processes is that they produce large amounts of by-products such as esters, and acids in addition to ethanol. Our copending application Ser. No. 908,060 filed May 22, 1978 which was abandoned in favor of continuation application Ser. No. 52,006 filed on June 25, 1979, now abandoned, describes one method of suppressing or inhibiting undesirable by-product formation and thereby increasing the total realisable yield and selectivity to ethanol, which method involves the addition of acids and/or acid derivatives to the reaction catalysed by cobalt optionally in the presence of either a halide or an organo-phosphorus compound as a promoter. Another method whereby ethanol is produced in higher yield and greater selectivity by reacting methanol, carbon monoxide and hydrogen in the presence of a nonpolar solvent and a catalyst comprising a tertiary phosphine, cobalt and iodine or bromine is described in U.S. patent application Ser. No. 585,276 (Shell, now abandoned). Two elements are said to be essential in the process of the invention; (a) a nonpolar solvent and (b) a catalyst comprising a tertiary phosphine, cobalt and an iodine or bromide. The nonpolar solvent is selected from the group consisting of alkanes, benzene and alkyl-substituted benzenes. None of the solvents listed in the specification contains bonds other than carbon/carbon and carbon/hydrogen in their molecular structure, ie they are all hydrocarbons. 
     We have found that, in the hydrocarbonylation of methanol with hydrogen and carbon monoxide to ethanol in the presence of a catalyst comprising both an iodide or a bromide and either an organo-phosphorus or organo-nitrogen compound at high temperatures and pressures, the total realisable yield and selectivity to ethanol may be increased by the addition of an inert liquid. 
     The term, inert liquid, as used in this specification means a compound which does not poison or otherwise adversely affect the catalyst, is mainly in liquid form under the conditions of the reaction, is capable of forming a separate phase in the presence of methanol containing up to 20% w/w water under normal conditions of temperature and pressure and is further characterised by having in its molecular structure one or more atoms other than carbon and hydrogen. The inert liquid typically contains such bonds as carbon/oxygen, carbon/sulphur, carbon/halogen, carbon/nitrogen, or carbon/silicon as well as normal carbon/carbon and carbon/hydrogen bonds. 
     By total realisable yield of ethanol within the context of the specification is meant the yield of free ethanol plus the yield of ethanol realisable by the hydrolysis of ethanol-yielding esters (eg ethyl acetate). In the same way, by realisable methanol is meant the free methanol plus the methanol realisable by the hydrolysis of methanol-yielding esters (eg methyl acetate). Thus, ##EQU1## By the yield of realisable acetic acid is meant the yield of free acetic acid plus the yield of acetic acid realisable by the hydrolysis of acetic acid-yielding esters (eg methyl acetate). In calculating the yield it is assumed that all the acetic acid is derived from methanol and synthesis gas and no account is taken of acetic acid derived from cobalt acetate, when this is added as catalyst. Thus, ##EQU2## 
     Thus according to the present invention there is provided a process for the production of ethanol which process comprises reacting at elevated temperature and pressure methanol with hydrogen and carbon monoxide in the presence of an inert liquid, as hereinbefore defined, and a catalyst comprising cobalt, an iodide or a bromide and a compound having the formula: ##STR1## wherein X is nitrogen or phosphorus and A, B and C are individually monovalent organic radicals, or X is phosphorus and any two of A, B and C together form an organic divalent cyclic ring system bonded to the X atom, or X is nitrogen and all of A, B and C together form an organic trivalent cyclic ring system bonded to the X atom. 
     Methanol is a readily available industrial product. It is generally manufactured on an industrial scale from synthesis gas. Whilst it is preferred that the methanol be substantially pure the presence of small amounts of certain impurities can be tolerated. The methanol may however contain up to 50% by weight of water. 
     Mixtures of the gases hydrogen and carbon monoxide are abundantly available in the form of synthesis gas. Methods for preparing synthesis gas are well-known in the art and usually involve the partial oxidation of a carbonaceous substance, eg coal. Alternatively synthesis gas may be prepared, for example, by thermal steam reforming of methane. For the purpose of the present invention the molar ratio of carbon monoxide to hydrogen may suitably be in the range 2:1 to 1:3, preferably 1:1 to 1:2. Methods for adjusting the molar ratio of carbon monoxide to hydrogen are well-known to those versed in the art. Although it is preferred to use substantially pure synthesis gas the presence of such impurities as carbon dioxide and nitrogen can be tolerated. On the other hand impurities having a deleterious effect on the reaction should be avoided. Thus it may be necessary in a continuously operated process to employ a gas purge to prevent the build-up of deleterious impurities. 
     Compounds capable of forming, under normal conditions of temperature and pressure, a separate phase in the presence of methanol containing up to 20% w/w water fall into a class characterised by the presence of bonds other than carbon/carbon and carbon/hydrogen, eg carbon/oxygen, carbon/sulphur, carbon/halogen, carbon/nitrogen or carbon/silicon. Thus the compound may be, for example, an aryl halide, an ether, a thiophene, a long chain acid, an aromatic acid or a silicone oil. An example of a suitable aryl halide is chlorobenzene. A suitable example of a long chain acid is decanoic acid. Typical of the silicone oils which may be used are polydimethylsiloxane fluids and methyl phenyl silicone fluids. Specific fluids which have been found useful in the process are the DC 200 series of fluids supplied by Dow Corning. Those compounds that are capable of forming, under normal conditions of temperature and pressure, a separate phase in the presence of methanol containing up to 20% w/w water but otherwise poison or adversely affect the catalyst (ie, non-inert compounds) are not included within the scope of the present invention. 
     The catalyst comprises cobalt, an iodide or bromide and a compound having the formula (I). Any source of cobalt which will react with carbon monoxide to yield a cobalt carbonyl or hydro carbonyl cobalt complex can be used in the process of the present invention. Cobalt is preferably employed in the ionic form, but the use of cobalt metal to react in situ to form ionic cobalt which then further reacts to form the desired cobalt complex is within the scope of the present invention. Typical sources of cobalt are, for example, compounds such as cobalt acetate, cobalt formate, cobalt propionate and the like, which under the reaction conditions form carbonyl or carbonyl/hydride complexes. The iodide or bromide can be added either in ionic form, eg as cobalt iodide or cobalt bromide, or as molecular iodine (I 2 ) or bromine (Br 2 ). Furthermore the iodide may be added as an alkyl or aryl iodide or bromide, preferably methyl iodide. However, the iodide or bromide may also be added in ionic form utilising cations which are inert with regard to the hydrocarbonylation reaction. Typical of the inert form is potassium iodide or bromide, sodium iodide or bromide and lithium iodide or bromide. 
     Compounds having the formula (I) are tertiary phosphines, amines, and nitrogen-containing heterocyclic systems, of which phosphines are preferred. A class of phosphines found to be particularly useful in the process of the present invention are those disclosed by Dewhirst in U.S. Pat. No. 3,759,838. These compounds are phosphines having the general formula: 
     
         R.sub.3 P                                                  (II) 
    
     wherein R independently is an organo group containing from 1 to 20 carbon atoms, is preferably free from aliphatic carbon-carbon unsaturation, and is bonded to the phosphorus atom by a carbon/phosphorus bond. The organo group R in the phosphine of formula (II) is preferably a hydrocarbyl group which may be a saturated aliphatic, a saturated cycloaliphatic, an aromatic, a substituted saturated aliphatic, a substituted saturated cycloaliphatic or a substituted aromatic group of which the unsubstituted saturated and aromatic groups are preferred. The substituents are preferably free from aliphatic carbon-carbon unsaturation and may contain, besides atoms of carbon and hydrogen, other atoms, such as oxygen, sulphur and halogen, in particular halogen of atomic number from 9 to 35, provided that such atoms are not directly bonded to phosphorus. Illustrative of suitable saturated aliphatic R groups are hydrocarbyl R groups such as methyl, ethyl, propyl, isopropyl, butyl, isoctyl, decyl, dodecyl, octadecyl, cyclohexyl, cyclopentyl, 3,4-dimethyl cyclopentyl, cyclooctyl, benzyl and β-phenylethyl. Aromatic R groups include hydrocarbyl aromatic groups such as phenyl, tolyl, xylyl, p-ethylphenyl, p-tert-butylphenyl, m-octylphenyl, 2,4-diethylphenyl, p-phenylphenyl, m-benzylphenyl and 2,4,6-trimethylphenyl. In the compound of formula (II) the R moieties may be the same or different, although for economic reasons they are preferably identical. Exemplary compounds of formula (II) are triethyl phosphine, tributylphosphine, tricyclohexylphosphine, triphenylphosphine, tris(4-tolyl)phosphine, tris(3-chlorophenyl)phosphine, diphenylhexylphosphine, dibutyloctadecylphosphine, tribenzylphosphine, cyclohexyldibutylphosphine and the like. Preferred compounds are triethylphosphine, tri-n-butylphosphine, tricyclohexylphosphine, tri-t-butylphosphine and triphenylphosphine. 
     Another type of phosphine which may be used in the operation of the invention is that disclosed by Mason et al in U.S. Pat. No. 3,400,163. These compounds are bicyclic heterocyclic tertiary phosphines, and are generally hydrocarbyl-substituted or unsubstituted monophosphabicyclo-alkanes of 8 to 9 atoms in which the smallest phosphorus-containing ring contains at least 5 atoms and the phosphorus atom therein is a member of a bridge linkage but is not a bridgehead atom. 
     Exemplary compounds of formula (I) wherein X is nitrogen are pyridine, diphenylamine and triphenylamine. 
     The term &#34;hydrocarbyl&#34; has been used throughout the foregoing in its accepted meaning as representing a radical formed from a hydrocarbon by removal of a hydrogen atom. 
     The exact nature of the catalysts of this invention under the reaction conditions is not known but they are thought to be phosphine or nitrogen-containing ligand/cobalt carbonyl/hydride/halide complexes. The cobalt is thought to be in a reduced state but its exact valency is not known. The catalyst may be prepared by first reacting the individual components together and then adding the mixture to the reaction vessel, or by adding the individual components to the reaction vessel and allowing the catalyst to form under the reaction conditions. 
     In addition to the inert liquid essential to the invention there may also be added nonpolar solvents such as alkanes, benzene and alkyl-substituted benzenes. 
     Methanol may suitably be reacted with carbon monoxide and hydrogen at any temperature in the range 150 to 250, preferably 180° to 230° C. and at a pressure greater than 100 bars, preferably in the range 140 to 300 bars. 
     The process may be carried out batchwise or continuously, operation in a continuous manner being preferred. The process may be carried out continuously for example by continuously feeding methanol and synthesis gas to a reactor containing the catalyst and the inert liquid, removing from the reactor a liquid product containing ethanol, by-products, unchanged methanol, catalyst and unreacted synthesis gas, separating the synthesis gas which may be recycled to the reactor, removing light ends including ethers, separating the product containing ethanol and by-products from the catalyst and thereafter recovering ethanol from the by-products, there being recycled to the reactor the catalyst, methanol and inert liquid. Other reaction by-products particularly those which can act as precursors for the formation of ethanol such as acetaldehyde and 1,1-dimethoxyethane may also be recycled to the reactor with advantage. It may be necessary to feed from time to time further catalyst. 
     The residence time may suitably be up to 8 hours, but is preferably in the range of from 10 to 180 minutes. Within the context of the specification the residence time for batchwise operation is that time during which the reactor is at the specified reaction temperature. When the process is operated continuously the residence time is calculated as follows: ##EQU3## 
     With regard to the various ratios of reactants to be employed in the process of the invention it has already been stated that the methanol may contain up to 50% by weight of water. In certain circumstances the addition of water may be beneficial to the reaction, ie the ratio of methanol to water in the feed can be adjusted so that two phases are present either at the start or at the end of the reaction or both. The molar ratio of methanol to inert liquid can be varied within wide limits, eg from 30:1 to 1:10, preferably from 25:1 to 1:2. In the case of silicone oils for which the molecular weight is not known with any degree of certainty the volume added/volume of methanol may be in the range of 0.05:50, preferably from 0.1 to 5 v/v. In both continuous and batch operations the molar ratio of methanol to synthesis gas fed may be in the range of from 10:1 to 1:20, preferably from 2:1 to 1:5. 
     In the catalyst the molar ratio of cobalt to iodine or bromine, may be in the range from 1:3 to 10:1, preferably from 1:1 to 5:1.  The molar ratio of cobalt to compound of formula (I) may be in the range of from 2:1 to 1:10, preferably from 1:1 to 1:5. The molar ratio of iodine or bromine to compound of formula (I) may be in the range of from 2:1 to 1:10 preferably from 1:1 to 1:8. The molar ratio of cobalt to methanol may be in the range of from 1:10 to 1:1,000, preferably from 1:40 to 1:800. 
     When the inert liquid is not itself a long-chain acid or an aromatic acid there may be added to the reaction mixture an acid and/or an acid derivative thereof having the formula: ##STR2## wherein the substituent R is a hydrocarbyl group or an oxygen-containing hydrocarbyl group and the substitutent X is the group --OR 1  in which R 1  is independently a hydrogen atom, a hydrocarbyl group or an oxygen-containing hydrocarbyl group or X is the group --O--CO--R 2  wherein R 2  is independently a hydrocarbyl group or an oxygen-containing hydrocarbyl group, as described in our copending application No. 22490/77. Preferred compounds having the structural formula (III) are acetic acid and methyl acetate. The acid and/or acid derivative of structural formula (III) may be added in an amount such that the molar ratio of acid and/or acid derivative to free methanol can be as high as 1.5:1, more usually in the range of from 0.1:1 to 0.7:1. 
    
    
     The invention will now be illustrated by reference to the following Examples. 
     EFFECT OF DIFFERENT TYPES OF INERT LIQUID 
     Example 1 
     A stainless steel, magnetically-stirred autoclave equipped for pressurised reactions was charged under nitrogen with methanol (0.68 mole) containing cobalt acetate tetrahydrate (0.0084 mole), iodine (0.0042 mole) and tri-n-butylphosphine (0.0147 mole). To this mixture was further added 55 mls silicone oil (Silicone Fluid Type DC 200/100 cS supplied by Dow-Corning Ltd). The system was purged with nitrogen, then pressurised to 200 bars with a mixture of carbon monoxide and hydrogen (1:1 molar). The reactor temperature was then raised to 205° C. and maintained at this temperature for 2 hours. When heating was started the pressure in the reactor rose above 200 bars and then began to decrease as the reaction commenced. During the course of the reaction, whenever the pressure in the autoclave fell to 140 bars a fresh charge of carbon monoxide and hydrogen (1:1 molar mixture) was added thereby increasing the reactor pressure to 200 bars. After two hours at 205° C. the autoclave was allowed to cool and the reaction product was analysed. Two liquid phases were noted at STP both before and after the reaction. The feed composition is given in Table 1A and the results are given in the following Table 1B. 
     Comparison Test A 
     The procedure described in Example 1 was followed using the reactants in the concentrations shown in Table 1A and with the results shown in Table 1B. 
     This is not an example according to the present invention because no inert liquid capable of forming, under normal conditions of temperature and pressure, a separate phase in the presence of methanol containing up to 20% w/w water was added. A single liquid phase at STP was noted both before and after the reaction. 
     Example 2 
     The procedure of Example 1 was repeated except that chlorobenzene was added to the methanol, cobalt acetate tetrahydrate, iodine, tri-n-butylphosphine mixture in place of silicone oil. A single phase at STP was noted before the reaction and two phases at STP were observed after the reaction. 
     The feed composition is given in Table 1A and the results are given in Table 1B. 
     Example 3 
     The procedure of Example 1 was followed except that the silicone oil in the reaction mixture was replaced by tetrahydrothiophen. A single phase was observed before and two phases were observed at STP after the reaction. 
     The feed composition is given in Table 1A and the results are given in Table 1B. 
     Example 4 
     The procedure of Example 1 was followed except that the silicone oil in the reaction mixture was replaced by diphenyl ether. Two phases were observed at STP both before and after the reaction. 
     The feed composition is given in Table 1A and the results are given in Table 1B. 
     Example 5 
     The procedure of Example 1 was repeated except that chlorobenzene (0.63 moles) and deionised water (0.47 moles) were added to the methanol, cobalt acetate tetrahydrate, iodine, tri-n-butylphosphine mixture in place of silicone oil. Two phases were noted at STP both before and after the reaction. 
     The feed composition is given in Table 1A and the results are given in Table 1B. 
     Comparison Test B 
     The procedure described in Example 1 was followed except that tributyl phosphine in the reaction mixture was replaced by tricyclohexylphosphine and no inert liquid was added. A single phase was observed at STP both before and after the reaction. The feed composition is given in Table 1A and the results are given in Table 1B. 
     This is not an example according to the present invention because no inert liquid capable of forming, under normal conditions of temperature and pressure, a separate phase in the presence of methanol containing up to 20% w/w water was added. 
     Example 6 
     The procedure of Example 1 was repeated except that the silicone oil in the reaction mixture was replaced by decanoic acid and the tri-n-butylphosphine was replaced by tricyclohexylphosphine. Furthermore the experiment was carried out on a larger scale. Two phases were noted at STP both before and after the reaction. 
     The feed composition is given in Table 1A and the results are given in Table 1B. 
     EFFECT OF VARYING THE AMOUNT OF INERT LIQUID ADDED 
     Example 7 
     The procedure of Example 1 was repeated except that chlorobenzene was added to the methanol, cobalt acetate tetrahydrate, iodine, tri-n-butylphosphine mixture in place of silicone oil. A smaller amount of chlorobenzene (0.13 moles) was added in this Example than in Example 2 (0.63 moles). A single phase was noted at STP both before and after the reaction. 
     The feed composition is given in Table 2A and the results are given in Table 2B. 
     Example 8 
     Example 7 was repeated except that the amount of chlorobenzene was reduced from 0.13 moles to 0.072 moles. A single phase was observed at STP both before and after the reaction. 
     The feed composition is given in Table 2A and the results are given in Table 2B. 
     Example 9 
     Example 1 was repeated except that the volume of silicone oil added was reduced from 55 mls to 7.3 mls. The feed composition is given in Table 2A and the results are given in Table 2B. 
     EFFECT OF VARYING THE AMOUNT OF TRI-ALKYLPHOSPHINE 
     Example 10 
     The procedure of Example 1 was repeated except that chlorobenzene was added to a methanol, cobalt acetate tetrahydrate, iodine, tri-n-butylphosphine mixture. A smaller amount of tri-n-butylphosphine (0.009 moles) was added in this Example than in Example 2 (0.0175 moles). A single phase was observed before and two phases were observed at STP after the reaction. 
     The feed composition is given in Table 3A and the results are given in Table 3B. 
     Example 11 
     Example 10 was repeated on a larger scale. The molar ratio of cobalt acetate tetrahydrate to tri-n-butylphosphine was reduced from 1:0.89 to 1:0.5. The feed composition shown in Table 3A and the results obtained are shown in Table 3B. A single phase was observed before reaction and two phases were observed at STP after reaction. 
     Comparison Test C 
     The procedure of Example 1 was followed except that chlorobenzene was added to a methanol, cobalt acetate, tetrahydrate, iodine mixture. There was observed a single phase before reaction and two phases at STP after the reaction. The feed composition is given in Table 3A and the results are given in Table 3B. 
     This is not an example according to the present invention because no compound of formula I was present in the reaction mixture. 
     EFFECT OF VARYING THE NATURE OF THE COMPOUND OF FORMULA I 
     Example 12 
     The procedure of Example 8 was followed except tributylphosphine was replaced by triphenylphosphine. A single phase was observed at STP both before and after the reaction. 
     The feed composition is given in Table 4A and the results are given in Table 4B. 
     Example 13 
     Example 8 was repeated except tributylphosphine was replaced by triphenylamine. A single phase was observed before and two phases at STP after, the reaction. The feed composition is given in Table 4A and the results are given in Table 4B. 
     Example 14 
     The procedure of Example 2 was followed except that tributylphosphine was replaced by triphenylphosphine. Before reaction a single phase was observed at STP and after reaction two phases were noted at STP. The feed composition is given in Table 4A and the results are given in Table 4B. 
     Example 15 
     Example 14 was repeated except that the triphenylphosphine was replaced by tricyclohexylphosphine. A single phase was observed before, and two phases at STP after, the reaction. The feed composition is given in Table 4A and the results obtained are given in Table 4B. 
     EFFECT OF ADDING COMPOUNDS ADDITIONAL TO THE INERT LIQUID 
     Example 16 
     The procedure of Example 1 was followed except that the silicone oil in the reaction mixture was replaced by a small amount of chlorobenzene. In addition methyl acetate was added to the reactor feed. A single phase was observed at STP both before and after the reaction. 
     The feed composition is given in Table 5A and the results are given in Table 5B. 
     EFFECT OF VARYING THE MOLAR RATIO OF CARBON MONOXIDE TO HYDROGEN 
     Example 17 
     A stainless steel, magnetically-stirred autoclave equipped for pressurised reactions was charged under nitrogen with methanol (1.80 mole) containing cobalt acetate tetrahydrate (0.0225 mole), iodine (0.0113 mole) and triphenyl phosphine (0.0393 mole). To this mixture was further added chlorobenzene (0.072 mole). The system was purged with nitrogen, then pressurised to 120 bars (roughly equivalent to a pressure of 200 bars at 195° C.) with a mixture of carbon monoxide and hydrogen (1:1 molar). The reactor temperature was then raised to 195° C. and maintained at this temperature for two hours. When heating was started the pressure in the reactor rose above 120 bars. As soon as the reaction commenced the rate of increase in the pressure began to decrease. It was therefore necessary to make periodic injections of carbon monoxide and hydrogen (1:1 molar mixture) to compensate for the gas consumed by the reaction and maintain the rate of pressure increase in accord with achieving a pressure of 200 bars at 195° C. When the pressure reached 200 bars it was maintained at that value throughout the reaction by continually feeding fresh carbon monoxide and hydrogen (1:1 molar mixture) to the autoclave. After two hours at 195° C. the autoclave was allowed to cool and the reaction product was analysed. A single phase was observed at STP both before and after the reaction. The feed composition is given in Table 5A and the results are given in Table 6B. 
     Example 18 
     The procedure of Example 17 was followed except that a 1:2 molar carbon monoxide and hydrogen mixture was used instead of the 1:1 molar mixture. A single phase was observed at STP both before and after the reaction. The feed composition is given in Table 6A and the results are given in Table 6B. 
     It can be seen from Table 1B that the addition of an inert liquid (decanoic acid, silicone oil, chlorobenzene, tetrahydrothiophen or diphenylether) improves the realisable ethanol yield, decreases the yield of realisable acetic acid and improves the selectivity to realisable ethanol. Example 5 shows that the additional addition of water can further increase the realisable ethanol yield and selectivity. 
     Table 2B illustrates the effect of adding different quantities of inert liquid. Even small amounts of added inert liquid (eg molar ratio methanol:chlorobenzene=25:1) can improve the ethanol yield (Example 8), whilst larger quantities reduce the formation of realisable acetic acid (Example 2). 
     Table 3B shows the effect of varying the molar ratio of cobalt to tri-n-butylphosphine. The addition of tri-n-butylphosphine, even at the lowest concentration, leads to a marked improvement in realisable ethanol yield and selectivity. 
     Table 4B shows the effect of adding different compounds of formula I. It can be seen that the phosphorus-containing compounds are more effective than the nitrogen-containing compound. 
     Table 5B shows the additional advantage achievable by the addition of methyl acetate to the reactor feed ie the yield of the unwanted by product, realisable acetic acid is reduced. 
     Table 6B shows the additional advantage of using a 1:2 molar mixture of carbon monoxide and hydrogen instead of a 1:1 mixture. By so doing the yield of realisable acetic acid decreases giving an improved selectivity to ethanol. 
     
                                           TABLE 1A                                
__________________________________________________________________________
EFFECT OF ADDING DIFFERENT TYPES OF INERT LIQUID                          
Reactor Feed                                                              
          Inert Liquid                                                    
                     Catalyst Components                                  
     CH.sub.3 OH No of                                                    
                     Cobalt     I.sub.2 X(A)(B)(C)                        
Example                                                                   
     (moles) Nature                                                       
          moles  (moles × 10.sup.-3)                                
                     (moles × 10.sup.-3)                            
                                (moles × 10.sup.-3)                 
(a)  (b)  (c)    (d) (e)        (f)     (g)                               
__________________________________________________________________________
Comp.                                                                     
     2.0  None   None                                                     
                     Co(OAc).sub.2 4H.sub.2 O(25.0)                       
                                I.sub.2 (12.5)                            
                                        P(C.sub.4 H.sub.9).sub.3 (43.7)   
1    0.68 Silicone*                                                       
                 (55mls)                                                  
                     Co(OAc).sub.2 4H.sub.2 O(8.4)                        
                                I.sub.2 (4.2)                             
                                        P(C.sub.4 H.sub.9).sub.3 (14.8)   
          Oil DC 200/                                                     
          100 cS                                                          
2    0.80 Chloro-                                                         
                 0.63                                                     
                     Co(OAc).sub.2 4H.sub.2 O(10.0)                       
                                I.sub.2 (5.0)                             
                                        P(C.sub.4 H.sub.9).sub.3 (17.5)   
          benzene                                                         
3    0.72 Tetrahydro-                                                     
                 0.64                                                     
                     Co(OAc).sub.2 4H.sub.2 O(9.0)                        
                                I.sub.2 (4.5)                             
                                        P(C.sub.4 H.sub.9).sub.3 (15.8)   
          thiophen                                                        
4    0.77 Diphenyl                                                        
                 0.39                                                     
                     Co(OAc).sub.2 4H.sub.2 O(9.6)                        
                                I.sub.2 (4.8)                             
                                        P(C.sub.4 H.sub.9).sub.3 (16.8)   
          ether                                                           
5    0.80 +                                                               
          Chloro-                                                         
                 0.63                                                     
                     Co(OAc).sub.2 4H.sub.2 O(10.0)                       
                                I.sub.2 (5.0)                             
                                        P(C.sub.4 H.sub.9).sub.3 (17.3)   
     H.sub.2 O                                                            
          benzene                                                         
     0.47                                                                 
Comp 2.0  None   None                                                     
                     Co(OAc).sub.2 4H.sub.2 O(24.9)                       
                                I.sub.2 (12.5)                            
                                        P(C.sub.6 H.sub.11).sub.3 (46.8)  
Test B                                                                    
6    4.41 Decanoic                                                        
                 0.66                                                     
                     Co(OAc).sub.2 4H.sub.2 O(55.1)                       
                                I.sub.2 (27.4)                            
                                        P(C.sub.6 H.sub.11).sub.3 (96.1)  
          acid                                                            
__________________________________________________________________________
 
    
     
                                           TABLE 2A                                
__________________________________________________________________________
EFFECT OF VARYING THE AMOUNT OF ADDED INERT LIQUID                        
(a)                                                                       
  (b)                                                                     
     (c)    (d)  (e)        (f)  (g)                                      
__________________________________________________________________________
1 0.68                                                                    
     Silicone*                                                            
            (55mls)                                                       
                 Co(OAc).sub.2 4H.sub.2 O(8.4)                            
                            I.sub.2 (4.2)                                 
                                 P(C.sub.4 H.sub.9).sub.3 (14.8)          
     Oil DC 200/                                                          
     100 cS                                                               
2 0.80                                                                    
     Chloro-                                                              
            0.63 Co(OAc).sub.2 4H.sub.2 O(10.0)                           
                            I.sub.2 (5.0)                                 
                                 P(C.sub.4 H.sub.9).sub.3 (17.5)          
     benzene                                                              
7 1.66                                                                    
     Chloro-                                                              
            0.13 Co(OAc).sub.2 4H.sub.2 O(20.9)                           
                            I.sub.2 (10.4)                                
                                 P(C.sub.4 H.sub.9).sub.3 (36.6)          
     benzene                                                              
8 1.80                                                                    
     Chloro-                                                              
            0.072                                                         
                 Co(OAc).sub.2 4H.sub.2 O(22.5)                           
                            I.sub.2 (11.3)                                
                                 P(C.sub.4 H.sub.9).sub.3 (39.3)          
     benzene                                                              
9 1.80                                                                    
     Silicone*                                                            
            (7.3mls)                                                      
                 Co(OAc).sub.2 4H.sub.2 O(22.5)                           
                            I.sub.2 (11.3)                                
                                 P(C.sub.4 H.sub.9).sub.3 (39.3)          
     Oil DC 200/                                                          
     100 cS                                                               
__________________________________________________________________________
 *The amount of silicone oil added is quoted in mls because its molecular 
 weight is not known.                                                     
 
    
     
                                           TABLE 3A                                
__________________________________________________________________________
EFFECT OF VARYING THE AMOUNT OF TRI-ALKYL PHOSPHINE                       
(a) (b)                                                                   
       (c)  (d)                                                           
               (e)        (f)  (g)                                        
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 2  0.80                                                                  
       Chloro-                                                            
            0.63                                                          
               Co(OAc).sub.2 4H.sub.2 O(10.0)                             
                          I.sub.2 (5.0)                                   
                               P(C.sub.4 H.sub.9).sub.3 (17.5)            
       benzene                                                            
10  0.80                                                                  
       Chloro-                                                            
            0.63                                                          
               Co(OAc).sub.2 4H.sub.2 O(10.0)                             
                          I.sub.2 (5.0)                                   
                               P(C.sub.4 H.sub.9).sub.3 (0.9)             
       benzene                                                            
11  3.2                                                                   
       Chloro-                                                            
            2.52                                                          
               Co(OAc).sub.2 4H.sub.2 O(40.0)                             
                          I.sub.2 (20.0)                                  
                               P(C.sub.4 H.sub.9).sub.3 (20.0)            
       benzene                                                            
Comp                                                                      
    3.2                                                                   
       Chloro-                                                            
            2.52                                                          
               Co(OAc).sub.2 4H.sub.2 O(40.0)                             
                          I.sub.2 (20.0)                                  
                               None                                       
Test C benzene                                                            
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                                           TABLE 4A                                
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EFFECT OF VARYING THE NATURE OF THE COMPOUND X(A)(B)(C)                   
(a)                                                                       
  (b)                                                                     
     (c)  (d) (e)        (f)  (g)                                         
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 2                                                                        
  0.80                                                                    
     Chloro-                                                              
          0.63                                                            
              Co(OAc).sub.2 4H.sub.2 O(10.0)                              
                         I.sub.2 (5.0)                                    
                              P(C.sub.4 H.sub.9).sub.3 (17.5)             
     benzene                                                              
 8                                                                        
  1.80                                                                    
     Chloro-                                                              
          0.072                                                           
              Co(OAc).sub.2 4H.sub.2 O(22.5)                              
                         I.sub.2 (11.3)                                   
                              P(C.sub.4 H.sub.9).sub.3 (39.3)             
     benzene                                                              
12                                                                        
  1.78                                                                    
     Chloro-                                                              
          0.071                                                           
              Co(OAc).sub.2 4H.sub.2 O(22.5)                              
                         I.sub.2 (11.3)                                   
                              P(C.sub.6 H.sub.5).sub.3 (39.4)             
     benzene                                                              
13                                                                        
  1.80                                                                    
     Chloro-                                                              
          0.072                                                           
              Co(OAc).sub.2 4H.sub. 2 O(22.5)                             
                         I.sub.2 (11.3)                                   
                              N(C.sub.6 H.sub.5).sub.3 (39.4)             
     benzene                                                              
14                                                                        
  0.80                                                                    
     Chloro-                                                              
          0.63                                                            
              Co(OAc).sub.2 4H.sub.2 O(10.0)                              
                         I.sub.2 (5.0)                                    
                              P(C.sub.6 H.sub.5).sub.3 (17.5)             
     benzene                                                              
15                                                                        
  0.80                                                                    
     Chloro-                                                              
          0.63                                                            
              Co(OAc).sub.2 4H.sub.2 O(10.0)                              
                         I.sub.2 (5.0)                                    
                              P(C.sub.6 H.sub.11).sub.3 (17.5)            
     benzene                                                              
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                                           TABLE 5A                                
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EFFECT OF                                                                 
ADDING COMPOUNDS ADDITIONAL TO THE INERT LIQUID                           
(a)                                                                       
  (b) (c)  (d)                                                            
              (e)        (f) (g)                                          
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16                                                                        
  1.20 +                                                                  
      Chloro-                                                             
           0.060                                                          
              Co(OAc).sub.2 4H.sub.2 O(18.8)                              
                         I.sub.2 (9.4)                                    
                             P(C.sub.4 H.sub.9).sub.3 (32.8)              
  methyl                                                                  
      benzene                                                             
  acetate                                                                 
  0.30                                                                    
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                                           TABLE 6A                                
__________________________________________________________________________
EFFECT OF VARYING                                                         
THE MOLAR RATIO OF CARBON MONOXIDE TO HYDROGEN                            
(a)                                                                       
  (b) (c)  (d)                                                            
              (e)        (f) (g)                                          
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17                                                                        
  1.80                                                                    
      Chloro-                                                             
           0.072                                                          
              Co(OAc).sub.2 4H.sub.2 O(22.5)                              
                         I.sub.2 (11.3)                                   
                             P(C.sub.6 H.sub.5).sub.3 (39.3)              
      benzene                                                             
18                                                                        
  1.80                                                                    
      Chloro-                                                             
           0.072                                                          
              Co(OAc).sub.2 4H.sub.2 O(22.5)                              
                         I.sub.2 (11.3)                                   
                             P(C.sub.6 H.sub.5).sub.3 (39.3)              
      benzene                                                             
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                                           TABLE 1B                                
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EFFECT OF ADDING DIFFERENT TYPES OF INERT LIQUID                          
                                           % Molar                        
% Molar yields on methanol fuel      % Molar                              
                                           selectivity                    
     Realis-                                                              
          Realis-                                                         
                Dimethyl       n-C.sub.3 H.sub.7 OH                       
                                     yield CH.sub.4                       
                                           to realis-                     
     able able  acetal     Ethers                                         
                               +     +CO.sub.2                            
                                           able  % CH.sub.3 OH            
Example                                                                   
     C.sub.2 H.sub.5 OH                                                   
          CH.sub.3 COOH                                                   
                *    CH.sub.3 CHO                                         
                           **  n-C.sub.4 H.sub.9 OH                       
                                     ***   C.sub.2 H.sub.5 OH             
                                                 conversion               
(h)  (i)  (j)   (k)  (l)   (m) (n)   (o)   (p)   (q)                      
__________________________________________________________________________
Comp 22.0 7.3   6.6  &lt;1    1.9 1.7   27.0  41.7  52.8                     
Test A                                                                    
1    32.8 3.2   1.2  1.2   &lt;1  &lt;1    12.0  69.8  47.0                     
2    26.3 3.4   4.3  &lt;1    1.1 &lt;1    5.5   50.7  51.9                     
3    27.5 5.2   6.2  &lt;1    &lt;1  &lt;1    4.6   61.9  44.4                     
4    32.2 6.0   8.6  1.9   1.6 1.0   5.8   55.8  57.7                     
5    31.6 4.4   3.5  &lt;1    &lt;1  &lt;1    10.4  56.6  55.8                     
Comp 12.9 10.9  3.9  &lt;1    &lt;1  1.0   10.7  34.5  37.4                     
Test B                                                                    
6    26.5 6.6   2.9  1.5   &lt;1  1.7   9.9   53.0  50.0                     
__________________________________________________________________________
 * Dimethyl acetal is 1,1dimethyoxy ethane                                
 ** Ethers are dimethyl ether + ethyl methyl ether                        
 *** The % molar yield of methane plus carbon dioxide (ie CH.sub.4 +      
 CO.sub.2) is calculated on the carbon monoxide fed to the reaction       
 
    
     
                       TABLE 2B                                                    
______________________________________                                    
EFFECT OF VARYING                                                         
THE AMOUNT OF ADDED INERT LIQUID                                          
(h)  (i)     (j)    (k)  (l)  (m)  (n)  (o)  (p)  (q)                     
______________________________________                                    
1    32.8    3.2    1.2  1.2  &lt;1   &lt;1   12.0 69.8 47.0                    
2    26.3    3.4    4.3  &lt;1   1.1  &lt;1    5.5 50.7 51.9                    
7    29.0    6.6    5.3  &lt;1   1.1  1.6  16.0 48.3 60.0                    
8    28.8    6.9    6.4  &lt;1   &lt;1   2.2  19.6 47.8 60.3                    
9    25.8    7.8    4.8  &lt;1   1.1  1.7  20.7 53.9 47.9                    
______________________________________                                    
 
    
     
                       TABLE 3B                                                    
______________________________________                                    
EFFECT OF VARYING                                                         
THE AMOUNT OF TRI-ALKYL PHOSPHINE                                         
(h)   (i)    (j)    (k)  (l)   (m) (n)  (o)  (p)  (q)                     
______________________________________                                    
 2    26.3   3.4    4.3  &lt;1   1.1  &lt;1   5.5  50.7 51.9                    
10    25.9   4.0    4.9  &lt;1   &lt;1   1.1  6.4  54.8 47.3                    
11    24.6   5.8    8.1  &lt;1   1.2  &lt;1   7.9  40.9 60.1                    
Comp                                                                      
Test C                                                                    
      14.4   7.2    19.9 1.9  7.2  &lt;1   7.5  20.8 69.2                    
______________________________________                                    
 
    
     
                       TABLE 4B                                                    
______________________________________                                    
EFFECT OF VARYING                                                         
THE NATURE OF THE COMPOUND X(A)(B)(C)                                     
(h)  (i)    (j)    (k)  (l)  (m)   (n)  (o)  (p)  (q)                     
______________________________________                                    
 2   26.3   3.4    4.3  &lt;1   1.1   &lt;1   5.5  50.7 51.9                    
 8   28.8   6.9    6.4  &lt;1   &lt;1    2.2  19.6 47.8 60.3                    
12   29.0   10.1   3.5  1.3  &lt;1    2.5  9.3  44.8 64.8                    
13   19.8   12.7   2.8  1.1  &lt;1    2.1  16.3 36.7 53.9                    
14   28.2   5.7    9.4  &lt;1   1.2   1.0  6.9  44.4 63.5                    
15   20.5   3.6    6.5  &lt;1   &lt;1    &lt;1   4.7  53.1 38.6                    
______________________________________                                    
 
    
     
                       TABLE 5B                                                    
______________________________________                                    
EFFECT OF ADDING                                                          
COMPOUNDS ADDITIONAL TO THE INERT LIQUID                                  
(h)  (i)     (j)    (k)  (l)  (m)  (n)  (o)  (p)  (q)                     
______________________________________                                    
16   28.0    3.4    3.8  2.0  1.3  1.1  10.5 55.3 50.6                    
______________________________________                                    
 
    
     
                       TABLE 6B                                                    
______________________________________                                    
EFFECT OF VARYING THE                                                     
MOLAR RATIO OF CARBON MONOXIDE TO HYDROGEN                                
(h)  (i)    (j)     (k) (l)  (m)  (n)  (o)  (p)   (q)                     
______________________________________                                    
17   31.2   11.7    6.7 3.2  &lt;1   3.0  10.0 42.1  74.1                    
18   28.1   3.1     6.8 1.7  &lt;1   1.9  6.7  58.4  48.1                    
______________________________________