Patent Abstract:
Disclosed is a process for purifying 2,6-naphthalene dicarboxylic acid produced by disproportionation and more efficiently recycling byproduct dipotassium salts which includes the steps of:  
     a) Contacting an aqueous solution containing the disalt of 2,6-NDA(2,6-K2NDA) with carbon dioxide to form as a precipitate the monopotassium salt of 2,6-NDA (KHNDA) and an aqueous solution containing 2,3-KHNDA, K2NDA, and potassium bicarbonate;  
     b) Disproportionating said monopotassium salt (KHNDA) to form 2,6-NDA and an aqueous solution containing K2NDA, and potassium bicarbonate;  
     c) Separating said 2,6-NDA and concentrating said aqueous solution containing K2NDA and potassium bicarbonate by reverse osmosis.

Full Description:
CROSS REFERENCE  
       [0001]    This application is a continuation of U.S. Ser. No. 09/643,354 filed on Aug. 22, 2000, which claims the benefit of U.S. Serial Nos. 60/151,577, 60/151,607, 60/151,498, 60/151,602, 60/151,603, 60/151,529, 60/151,489, 60/151,604, 60/151,606, 60/151,589, 60/151,497, 60/151,590 and 60/151,578 all filed on Aug. 30, 1999. 
     
    
     
       FIELD OF INVENTION  
         [0002]    This invention is related to a process for the production of purified 2,6-naphthalene dicarboxylic acid (hereafter referred to as 2,6-NDA) from a crude 2,6-NDA disproportionation product. More particularly, this invention is related to a novel method of separating and recycling byproducts in a process for producing 2,6-NDA from a disproportionation product that utilizes reverse osmosis and is industrially advantageous.  
         BACKGROUND OF THE INVENTION  
         [0003]    Aromatic carboxylic acids are highly useful organic compounds. They are useful as intermediates for the preparation of other organic compounds, and as monomers for the preparation of polymeric materials. In particular, the naphthalene carboxylic acids are used for preparing photographic chemicals and dyestuffs. Naphthalene dicarboxylic acids can also be used to prepare a variety of polyester and polyamide compositions. 2,6-NDA is a particularly useful aromatic carboxylic acid which can be reacted with ethylene glycol to prepare poly(ethylene-2,6-naphthalate). Polyesters prepared from 2,6-NDA have excellent heat resistance, gas barrier, and mechanical properties. Therefore, much research in the art has focused on methods of preparing 2,6-NDA. The production of 2,6-NDA from disproportionation product is described, for example, in U.S. Pat. Nos. 2,823,231 and 2,849,482.  
           [0004]    Production of high purity 2,6-NDA from disproportionation product requires many process steps to separate impurities from the dipotassium salt of 2,6-NDA hereafter referred to as 2,6-K2NDA, which is the 2,6-NDA precursor. The impurities include naphthalene, zinc oxide, and several naphthalene mono- and dicarboxylic acid salts. This complexity results in numerous byproduct streams that must be recycled to make the process less costly.  
           [0005]    There have been different approaches to the separation of the dialkali metal salt products of disproportionation reactions and conversion of them into 2,6-NDA.  
           [0006]    In U.S. Pat. No. 2,823,231, the method used to separate the dialkali metal salts of 2,6-naphthalene dicarboxylic acid comprises dissolving the disproportionation conversion product mixture in water, filtering off insoluble impurities from the resulting solution, acidifying the filtrate with mineral or organic acid, such as sulfuric or hydrochloric acid, and separating the precipitated naphthalene-2,6-dicarboxylic acid from the acid solution. In U.S. Pat. No. 2,823,231 the dialkali metal salt of naphthalene 2,6-dicarboxylic acid formed is converted into free naphthalene 2,6-dicarboxylic acid by acidification of said dialkali metal salt with a strong mineral acid.  
           [0007]    U.S. Pat. No. 2,849,482 teaches acidifying an aqueous solution of the crude reaction product of the disproportionation or converting the crude alkali metal salt directly into the dichloride or into esters of naphthalene-2,6-naphthalene dicarboxylic acid in accordance with known methods.  
           [0008]    In U.S. Pat. No. 3,631,096, to Phillips, salts formed by the reaction can be transformed into the corresponding free acids by acidifying the solution with organic or inorganic acids or by introducing carbon dioxide into the solution at atmospheric or elevated pressure, and then separating the free acids from the acidified solution. The individual reaction products may be separated from each other and isolated in pure form by methods that are based upon their different solubilities or volatilities and may thereafter, if desired, be transformed into their derivatives. The salt mixture produced by the reaction may also be transformed directly into derivatives of the acids, for example, into their esters or halides, and these derivatives may be purified, if desired, by fractional distillation.  
           [0009]    U.S. Pat. No. 3,671,578, to Teijin, discloses that the monoalkali salt of 2,6-naphthalene dicarboxylic acid is easily disproportionated when heated in water or water-containing organic solvent, to form free dicarboxylic acid and by-product dialkali salt, and the former acid is precipitated.  
           [0010]    In U.S. Pat. No. 3,952,052, to Phillips, there is disclosed a process for separating a disproportionation reaction product by forming a slurry comprising alkali metal salts of aromatic polycarboxylic acid and dispersant and a gaseous effluent, and then lowering the pressure, flashing the dispersant, and recovering said alkali metal salts of said polycarboxylic acids as solids from said separation zone.  
           [0011]    U.S. Pat. No. 3,888,921, to Teijin Ltd., discloses a method for purifying a dialkali salt of crude 2,6-naphthalene dicarboxylic acid comprising precipitating 40 to 97 mol percent of the dialkali 2,6-naphthalene dicarboxylate dissolved in an aqueous solution substantially as monoalkali salt of 2,6-naphthalenedicarboxylic acid while maintaining the pH of said aqueous solution at a value not lower than 6.3, and separating the precipitate, and converting the separated precipitate to 2,6-naphthalene dicarboxylic acid.  
           [0012]    Canadian Patent 864587 discloses a process for the preparation of 2,6-NDA which comprises heating a monoalkali salt of 2,6-NDA in water or water-containing organic solvent causing disproportionation thereof into 2,6-NDA and a dialkali salt and separating the 2,6-NDA by a method that includes dissolving a rearrangement reaction product containing dialkali salt of 2,6-naphthalene dicarboxylic acid in warm water, filtering off the insoluble matter therefrom, concentrating the remaining solution, whereby the filtrate is concentrated to such a degree that the precipitation yield of the dialkali salt precipitated when the concentrated liquid is cooled to room temperature reaches at least 70% and the purity of said precipitate exceeds 99%, passing gaseous carbon dioxide through the aqueous solution of the precipitate recovered from the concentrated liquid, and recovering the resulting precipitate, and the mother liquour containing the side product dialkali salt of 2,6-naphthalene dicarboxylic acid is recycled into the carbon dioxide reaction step.  
           [0013]    U.S. Pat. No. 5,175,354 discloses a reaction step wherein 2,6-naphthalene dicarboxylic acid potassium salts are allowed to react with benzene-carboxylic acids in the presence of water to yield 2,6-NDA and benzene-carboxylic acid potassium salts and a separation step wherein the crystallized 2,6-NDA is separated from the benzene-carboxylic acid potassium salts dissolved in the aqueous solution and provides 2,6-NDA.  
           [0014]    None of these references suggest the idea of incorporating reverse osmosis membranes into a process for purifying 2,6-NDA.  
           [0015]    There is a need in the art for alternative methods of separating the desired product and efficiently recycling byproducts. The purification process of the present invention provides an efficient way of separating and recycling byproducts which is advantageous.  
         SUMMARY OF THE INVENTION  
         [0016]    In accordance with the foregoing the present invention comprises a process for purifying 2,6-naphthalene dicarboxylic acid produced by disproportionation and more efficiently recycling byproduct dipotassium salts which comprises:  
           [0017]    a) Dissolving the disproportionation product of potassium naphthoate comprising the dipotassium salt of 2,6-NDA (K2NDA) in water, removing any residual disproportionation reaction medium, centrifuging the solution to remove the disproportionation catalyst, and removing acid salts other than 2,6-NDA by crystallization and/or carbon adsorption;  
           [0018]    b) Contacting said aqueous solution of 2,6-K2NDA with carbon dioxide to form as a precipitate the monopotassium salt of 2,6-NDA (KHNDA) and an aqueous solution containing 2,3-KHNDA, K2NDA, and potassium bicarbonate;  
           [0019]    c) Separating said monopotassium salt as a solid from said stream containing 2,3-KHNDA, K2NDA and potassium bicarbonate;  
           [0020]    d) Disproportionating said monopotassium salt (KHNDA) to form solid 2,6-NDA and an aqueous solution containing K2NDA and potassium bicarbonate;  
           [0021]    e) Separating said 2,6-NDA;  
           [0022]    f) Concentrating said aqueous solution containing K2NDA and potassium bicarbonate from step (d) by reverse osmosis; and  
           [0023]    e) Recycling concentrated K2NDA to step (b) and pure water to step (d). 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWING  
       [0024]    The drawing is a process flow diagram illustrating the use of the process of the present invention as part of an integrated process for producing 2,6-naphthalene dicarboxylic acid. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0025]    The novel process of the present invention for producing high purity 2,6-NDA begins with a disproportionation reaction product. This type reaction is described, for example, in U.S. Pat. Nos. 2,823,231 and 2,849,482.  
         [0026]    The present invention is advantageously used in conjunction with a process for the production of 2,6-NDA by disproportionation of potassium naphthoate as described in copending U.S. Patent Application Ser. No. 60/151,577 (Attorney&#39;s Docket #TH1432), incorporated by reference herein in the entirety. In that application the disproportionation effluent solids (in naphthalene) consist primarily of 2,6 K2NDA, 2,3 K2NDA (isomer intermediate), unreacted KNA, catalyst, and trace coke. After leaving the disproportionation reactor the solvent is flashed.  
         [0027]    Next, the solid product comprising dipotassium salts of 2,6-NDA, K2NDA (2,6-and 2,3-isomers), unreacted KNA, catalyst, heavy by-products, any residual solvent, and trace coke enter a water wash. The organic salts are dissolved and the liquid is directed to a decanter and centrifuge to remove residual solvent, catalyst and coke particles. The ZnO catalyst is regenerated and recycled.  
         [0028]    The next step in the process is crystallization of the dipotassium salt. The dipotassium salt of naphthalene dicarboxylic acid resulting from the disproportionation reaction contains at least 15% unconverted feed and intermediates. The liquid carrying the dipotassium salts of NDA, K2NDA (2,6-and 2,3-isomers), KHCO 3 , and unreacted KNA, flows to a two-stage evaporative crystallization section, where the disalt of 2,6 NDA (2,6 K2NDA) is selectively precipitated.  
         [0029]    The crystallization section rejects a mother liquor stream containing KHCO3, unreacted KNA, and 2,3 K2NDA. Recovery of 2,6 K2NDA is approximately 90%, and the purity of the K2NDA leaving the second crystallizer is 99.9%+.  
         [0030]    The purified K2NDA slurry is then redissolved with additional clean water and optionally treated with a solid adsorbing agent. Examples of solid adsorbing agents include activated carbon, alumina, magnesia or ion exchange resins. The use of activated carbon is especially preferred. The amount of the solid adsorbent to be used depends upon the amounts of impurities contained therein. A suitable amount of adsorbent would be in the range of 0.1 to 10 percent by weight, preferably 0.5 to 5 percent by weight, based on the K2NDA. By subjecting an aqueous solution of the dipotassium salt to a solid adsorbent, most residual trace impurities that could affect the color of the final product can be removed.  
         [0031]    Next, the monopotassium salt of 2,6-NDA (KHNDA) is selectively precipitated from an aqueous solution of K2NDA (about 20%) by reacting said aqueous solution at 0-200 psi CO 2  pressure, and 0-50° C. for about 30 minutes. The reaction produces the solid mono-potassium salt of 2,6-NDA, 2,6-KHNDA, and also 2,3-KHNDA and potassium bicarbonate. 2,3-KHNDA is rejected from the 2,6-KHNDA crystals.  
         [0032]    The CO 2  precipitation step effectively separates 2,6-KHNDA from 2,3-KHNDA, which remains in solution due to its higher solubility. Examples 1-8 demonstrate this separation. The rejection of the 2,3-KHNDA is beneficial because, as a result, 2,3-KHNDA does not interfere with the separation of the 2,6-NDA from the K2NDA and the reverse osmosis of the present invention that takes place after the disproportionation of the 2,6-KHNDA.  
         [0033]    Yields of 2,6-KHNDA better than 80% have been demonstrated at only 1 atm CO 2  pressure. The fact that the precipitation can be done effectively at modest pressure allows for centrifugation of the product without releasing pressure. The centrate also contains dissolved potassium bicarbonate and 2,3-KHNDA.  
         [0034]    KHNDA solids are then diluted to 5-10% and disproportionated by reacting for less than an hour, preferably about 20 to 30 minutes at 150° C., under about 50 Psi CO 2  pressure. The reactor effluent from this step is separated to give a 2, 6-NDA solid, and a centrate containing predominantly 2,6-K2NDA and KHCO 3 .  
         [0035]    This centrate stream from the disproportionation of the monosalt, KHNDA, is the primary focus of the present invention. According to the present invention the K2NDA in the centrate stream would be very useful if recycled to the CO 2  precipitation step, however it has to be concentrated because the optimal salt concentration in the CO2 precipitation step is about 20 wt %, whereas it is less than 10 wt % in the KHNDA disproportionation step. Concentrating this solution by evaporating off water is very energy intensive and costly.  
         [0036]    It has been discovered in the present invention that when the solid 2,6-NDA produced in the disproportionation of KHNDA is separated out, the remaining solution containing K2NDA and potassium bicarbonate can be concentrated via reverse osmosis and recycled to the CO 2  precipitation step very efficiently and economically. The reverse osmosis step produces a pure water stream that can be recycled to the disproportionation step, and a concentrated K2NDA solution that can be recycled to the CO 2  precipitation step. Any potassium present in forms such as potassium carbonate or potassium bicarbonate is also separated by the membrane for recycle.  
         [0037]    The dipotassium salt should be concentrated to a wt % in the range of 10-30 wt % salt. In the examples of the present invention the target was 20 wt % salt.  
         [0038]    The reverse osmosis membranes that are suitable for use in the process are those characterized by high flux and high salt rejection, hydrolytic stability, resistance to compaction under pressure, and resistance to chemical attack.  
         [0039]    The membranes employed in the examples were thin film composite membranes. These membranes consist of three layers: a support web, a microporous polysulfone layer with controlled pore diameters, and an ultrathin polyamide coating which is the selective layer. The support web provides the major structural support; the interlayer provides a smooth surface for the selective layer. The selective layer is on the order of 0.2 microns and can withstand high pressures due to the support provided by the interlayer. Examples of suitable membranes are FT-30 and HP-31, commercially available from Rochem Environmental, Inc.  
         [0040]    In the present invention it is necessary to increase pressure in conjunction with the use of the membranes to achieve the desired concentration of the K2NDA. Suitable pressure is a pressure higher than the osmotic pressure of the solution. Good results were observed where a pressure in the range of 800 to 2000 psig was used. In some cases it is advantageous to use a pressure on the lower end of the range until most of the water is recovered, say 60-80%, and then employ a higher pressure. Examples 9-13 and 14-19 set forth data obtained for tests at low pressure and two-stage (low to high) pressure, respectively.  
         [0041]    It has been found that the 2,6-NDA produced by this process is of high purity and contains only low levels of potassium. It has also been found that potassium can be removed to even lower levels by washing the 2,6-NDA with water.  
       DETAILED DESCRIPTION OF THE DRAWING  
       [0042]    The drawing is a flow diagram showing one embodiment of the process of the present invention as part of a purification section for producing 2,6-NDA. It is understood the drawing is only intended as an illustration and not intended to limit the scope of the invention.  
         [0043]    Referring to the Figure, solid product comprising dipotassium salts of NDA, K2NDA (2,6 and 2,3 isomers), unreacted KNA, catalyst, heavy by-products, and trace coke from which most of the reaction medium from the disproportionation reaction has been removed, represented by  1  enters water wash  2  where the organic salts are dissolved. Steam and 25% naphthalene can enter the water wash via  3  from another section of the process. The entire integrated process is discussed in detail in copending Ser. No. 60/151,577 (Attorney&#39;s Docket #TH1432), incorporated by reference herein in its entirety. The liquid is then directed to a decanter  4  to remove any residual solvent, catalyst and coke particles. Naphthalene and some solids exit the process at  5 , while an aqueous solution of crude K2NDA also containing solid ZnO catalyst is directed to a centrifuge  6 . ZnO catalyst exits the centrifuge through  7  and is recycled. The liquid carrying the mixed organic salts, including the crude K2NDA is directed through  8  to a two-stage evaporative crystallization section,  9  and  10 .  
         [0044]    In the evaporative crystallization section  2 , 6  -K2NDA is selectively precipitated from crude K2NDA product, rejecting KNA, 2,3-K2NDA, and KHCO 3 . First, the crude K2NDA stream  8  and a recycle stream  11  containing KHCO 3  are added to evaporative crystallizer  9 . In evaporative crystallizer  9 , 2,6-K2NDA is selectively precipitated as water is evaporated. The water vapor exits the crystallizer, and is condensed by overhead exchanger  12 . The water is then routed through line  13  to other portions of the finishing section in order to provide a dilution medium. The contents of the first evaporative crystallizer  9  exit through  14  to centrifuge  15 . In centrifuge  15 , mother liquor containing KNA, 2,3-K2NDA, and KHCO 3  are rejected, exit at  16 , and are recycled back to the salt formation reactor in another section of the integrated process. The K2NDA solids are combined with recycle stream  17  containing KHCO 3  and 2,6-K2NDA and added to the second stage evaporative crystallizer  10 . In  10  2,6-K2NDA is again selectively precipitated as water evaporates and exits the crystallizer. The water is condensed by overhead exchanger  18  and is directed into line  13 . The purified K2NDA slurry leaves the second stage evaporative crystallizer through  19  and is directed to centrifuge  20 . In centrifuge  20  mother liquor containing KHCO 3  is separated from purified 2,6-K2NDA and recycled back to the first stage evaporative crystallizer  9  through  11 .  
         [0045]    The purified solid 2,6-K2NDA is dissolved with water from overhead line  13  and transported through line  21  to an activated carbon guard bed  22 . The 2,6-K2NDA solution then passes through the activated carbon guard bed  22  to remove residual trace impurities that could affect the color of the final product.  
         [0046]    The 2,6-K2NDA solution exits the activated carbon bed  22  via line  23  and is directed to the C 02  precipitation reactor  24 . CO 2  is added to reactor  24  through line  25 . In reactor  24  the monopotassium salt of 2,6-NDA, KHNDA, is selectively precipitated from the 2,6-K2NDA solution. The KHNDA is then directed out of the reactor through line  26  to centrifuge  27 . The mother liquor, containing KHCO 3  and unreacted 2,6-K2NDA, is separated from the solid KHNDA and is recycled back to the second stage evaporative crystallizer  10  via line  17 . The solid KHNDA is slurried with water from recycle line  28  and directed through line  29  to disproportionation reactor  30 . CO 2  is added to reactor  30  through line  31 . The KHNDA is reacted in the presence of 50 psig CO 2  and about 150° C. in disproportionation reactor  30  to form solid 2,6-NDA and 2,6-K2NDA. The reactor effluent from this step is directed through  32  to centrifuge  33 .  
         [0047]    This is the point where the present invention provides a very efficient method of making the process more economical. The solid 2,6-NDA is separated from the mother liquor and exits through  35  to a section for further purification and reduction of potassium levels. The centrate containing predominantly 2,6-K2NDA is directed through  34  to a two-stage reverse osmosis section,  36  &amp;  38 . In  36  the K2NDA feed enters a reverse osmosis stage operated at a lower pressure. Concentrate exits at  37  and is directed to a second reverse osmosis stage  38  operated at higher pressure, and permeate (water) exits at  39  and connects with a water recycle line which is directed back to the disproportionation step. The concentrate from  38  exits into line  25  which recycles back to the CO 2  precipitation step and water from the second stage reverse osmosis exits at  40 .  
         [0048]    The present invention will be more clearly understood from the following examples. It is understood that these examples are presented only to illustrate some embodiments of the invention and are not intended to limit the scope thereof.  
       EXAMPLES 1-8  
       [0049]    Examples 1-8 were performed to investigate the separation of 2,3-KHNDA from 2,6-KHNDA in the CO 2  precipitation step. In these experiments, aqueous solutions containing 5% molar 2,3-K2NDA based on 2,6-K2NDA were contacted with CO 2  at 100° C. and various CO 2  pressures. The results in Table 1 show that the precipitate obtained by this process contained essentially no 2,3-NDA impurity.  
                                                                                           TABLE 1                           (Separation of 2,3 - NDA from 2,6 - NDA)                Ex. 1   Ex. 2   Ex. 3   Ex. 4   Ex. 5   Ex. 6   Ex. 7   Ex. 8                        Initial solution weight (g)   50   50   59   52   50   50   50   52       % K2NDA in initial solution   20   20   20   20   20   20   20   20       2,3/2,6 molar ratio   0.05   0.05   0.05   0.05   0.05   0.05   0.05   0.05       CO 3 /2,6 molar ratio   0.15   0.15   0.15   0.15   0.15   0.15   0.15   0.15       CO 2 pressure (psig)   400   400   400   400   200   200   200   200       Contact time (hr)   1   1   1   1   1   1   1   1       Temperature (° C.)   100   100   100   100   100   100   100   100       Precipitate weight (g)   6.5   7.48   6.5   7.6   5.41   5.23   4.95   6.58       2,6 - NDA in precipitate   80.8   78   79   79.8   79.5   79.5   80.2   80.1       (% w)       2,3 - NDA in precipitate   135   160   125   &lt;60   &lt;60   &lt;60   &lt;60   45       (ppm)       K in precipitate (% w)   13.7   14.9   14.5   13.8   14.2   14.2   13.6   14       2,3/2,6 molar ratio in   2 × 10 −4     2 × 10 −4     2 × 10 −4     &lt;8 × 10 −5     &lt;8 × 10 −5     &lt;8 × 10 −5     &lt;8 × 10 −5     &lt;6 × 10 −5         product                  
 
       EXAMPLES 9-13  
       [0050]    Reverse osmosis experiments were carried out using a 3 wt % solution of 2,6-K2NDA. The pH and conductivity of the test solution were 9.2 and 16,100 μS/cm, respectively. A Rochem Disc Tube TM (DT) module, scaled down to 110th of the standard 169 membrane module was used for all examples. Examples 9-13 were performed at low pressure using an FT30 membrane. In the low pressure test, the system was operated below 900 psig. Examples 14-19 were carried out using an FT-30 membrane in a low pressure module and an HP31 membrane in a high pressure module. The low pressure module was operated below 900 psig up to a 75% water recovery, and then a switch was made to the high pressure module operated below 1800 psig. The initial feed volume was 62 liters. Based on the calculated feed concentration of 3 wt %, a volume reduction requirement of 85% was assumed to achieve the goal of 20 wt % K2NDA in the resulting stream. The results obtained are set forth in Tables 2 and 3 and clearly show excellent salt rejection achieved. The flux rates obtained in these examples after normalization with respect to temperature and pressure range from about 25 to about 70 gal/sq.ft-day.  
                                                                   TABLE 2                           (Results of low pressure reverse osmosis test)                Ex. 9   Ex. 10   Ex. 11   Ex. 12   Ex. 13                        % recovery   0   25   50   75   85       K2NDA in feed   28000   35000   53000   107000   155000       (ppm)       K2NDA in   30   37   58   99   264       permeate (ppm)       % rejection   99.9   99.9   99.9   99.9   99.8       Pressure (psig)   500   525   525   750   850       Flux (gal/sq.   32.7   37.6   31.8   24.1   11.1       ft. - day)       Temperature   73   83   94   98   102       (° F.)                  
 
         [0051]    [0051]                                                                           TABLE 3                           (Results of low pressure/high pressure reverse osmosis test)                Ex. 14   Ex. 15   Ex. 16   Ex. 17   Ex. 18   Ex. 19                        % recovery   0   25   50   75   75   85       K2NDA in   27000   35000   57000   103000   105000   178000       feed (ppm)       K2NDA in   59   81   168   399   151   495       permeate (ppm)       % rejection   99.8   99.8   99.7   99.6   99.9   99.7       Pressure (psig)   500   525   525   680   1000   1400       Flux (gal/sq.   27.5   30.3   26 18.8   37.6   23.1       ft - day)       Temperature   76   90   94   102   106   115       (° F.)

Technology Classification (CPC): 1