Abstract:
2,3-Cycloalkenopyridines of the formula ##STR1## are prepared by reacting a cycloalkanone or cycloalkenone of the formula ##STR2## with an oxo compound of the formula ##STR3## where Z is an aliphatic carbon chain which is unsubstituted or has hydrocarbon substituents and R 1 , R 2  and R 3  are hydrogen or lower alkyl groups and ammonia in the presence of a dehydrating and dehydrogenating catalyst at a temperature of about 250° to 550° C.

Description:
BACKGROUND OF THE INVENTION 
     The invention is directed to a process for the production of 2,3-cycloalkenopyridines by the catalytic reaction of a cycloalkanone or cycloalkenone with an aliphatic oxo compound at elevated temperature. The 2,3-cycloalkenopyridines are important intermediate products for the production of medicines, plant protective agents and synthetic resins. 
     It is known to produce 2,3-cyclohexenopyridine by the catalytic dehydrogenation of decahydroquinoline (Berichte Vol. 67 (1934) pages 1715 to 1729). The yield is merely 36%. It is already known to produce 2,3-cyclopentenpyridine, 2,3-cyclohexenopyridine and 2,3-cycloheptenopyridine from the corresponding cycloalkanones (Annalen Vol. 478 (1939) pages 176 to 196, Helv. Chem. Acta Vol. 28 (1945) pages 1677 to 1683), in each using 4 intermediate steps. The disadvantage of these processes is that they are very expensive and the highest yield is 40%. 
     Furthermore, it is known to produce 2,3-cycloalkenopyridine by reaction of cycloalkanones with 3-aminoacroleins in the liquid phase at 120° C. using triethylamine and piperidine acetate as catalyst (Tetrahedron Letters No. 38 (1970) pages 3291 to 3294). This process requires as the starting materials the relatively difficulty accessible aminoacroleins. Besides despite 24 hours reaction time the yields of the desired cycloalkenopyridines are only 30 to 60%. 
     SUMMARY OF THE INVENTION 
     There has now been found a process for the production of 2,3-cycloalkenopyridines by the catalytic reaction of a cycloalkanone or cycloalkenone with an aliphatic oxo compound at elevated temperature wherein the cycloalkanone or cycloalkenone is reacted with an aliphatic oxo compound which has an unsaturated carbon to carbon double bond on the carbon atoms adjacent to the oxo group in the gas phase and with ammonia and in the presence of a dehydrating and dehydrogenating catalyst at a temperature of about 250° to 550° C. In this process the cycloalkanone or cycloalkenone is reacted with simple, easily accessible substances. High yields have been produced. 
     According to the invention (1) a cycloalkenone or preferably a cycloalkanone of the general formula ##STR4## in which Z is an aliphatic carbon atom chain, preferably with 2 to 16 carbon atoms, which in a given case in branched and whose branchings in a given case are closed to a ring or several rings, or especially an aliphatic carbon chain with 3 to 10 carbon atoms, which chain may be branched, e.g., an alkylene group with or without a lower alkyl side chain, methyl being the preferred side chain is reacted (2) with an oxo compound of the general formula ##STR5## in which R 1 , R 2  and R 3  are the same or different and are hydrogen or lower alkyl groups with preferably 1 to 6, especially 1 to 2, carbon atoms and in which in a given case the alkyl groups can be branched, and (3) with ammonia to form a compound of the general formula ##STR6## in which Z, R 1 , R 2  and R 3  are as defined above. Z is a hydrocarbon group. 
     As cycloalkanones there can be used for example cyclobutanone, cyclopentadecanone, cyclohexadecanone, cyclooctadecanone, 3,5,5-trimethyl cyclohexanone, camphor, 1-decalone, 2-butyl cyclohexanone, 2-propyl cyclohexanone, 8-ketotricyclodecane, carvone, and especially cyclopentanone, cyclohexanone, cycloheptanone, cyclooctanone, cyclodecanone, cyclododecanone, 2-methyl cyclohexanone, 3-methyl cyclohexanone, 2,2,4-trimethyl cyclopentanone and menthone. An example of a cycloalkenone is isophorone. 
     Suitable oxo compounds are for example, methacrolein, crotonaldehyde, methyl vinyl ketone, ethyl vinyl ketone, 3-penten-2-one, hexyl vinyl ketone, heptyl vinyl ketone, 3-octene-2-one, and expecially acrolein. 
     The reaction conditions such as temperature and pressure and the proportions of the reacting substances and the residence time in a given case to a certain extent are dependent upon each other according to the type of reacting substances and the type of catalyst. 
     In general, the reaction is carried out at a temperature between 250° and 550° C. In most cases there are preferred temperatures between 300° and 500° C., especially between 350° and 450° C. It is advantageous to work at pressures of about 1 to 4 bar. However, there can also be used lower or higher pressures although it is suitable not to substantially deviate from this pressure range since it permits the use of simple apparatus. 
     The proportions of cycloalkanone or cycloalkenone to oxo compound (II) can be selected substantially at random, both stoichiometric as well as under or over stoichiometric being usable. Generally, it is advantageous to add about 0.5 to 10 moles of oxo compound per mole of cycloalkanone or cycloalkenone. Preferably there are used about 1 to 5 moles, especially 2 to 4 moles of oxo compound (II) per mole of cycloalkanone or cycloalkenone. 
     The ammonia can be present in the reaction in substantially any proportions from under stoichiometric to over stoichiometric. In most cases it is suitable to have present at least 0.5 mole of ammonia per mole of cycloalkanone or cycloalkenone, however, there can be as much as about 100 moles of ammonia per mole of cycloalkanone or cycloalkenone. Advantageously, there are employed about 1 to 20 moles of ammonia, preferably 2 to 15 moles of ammonia, especially 3 to 12 moles of ammonia, per mole of cycloalkanone or cycloalkenone. 
     The reaction takes place in the gas phase. It can be expedient to dilute the gases of cycloalkanone or cycloalkenone, oxo compound and ammonia with inert gases. As inert gases there can be employed, for example, steam, air and especially nitrogen. Generally, it is expedient to use in all not more than about 20 moles of inert gas per mole of cycloalkanone or cycloalkenone. Preferably, there are used about 0.5 to 10 moles, particularly 1 to 5 moles of inert gas per mole of cycloalkanone or cycloalkenone. 
     As catalysts there can be employed those which have a dehydrating and dehydrogenating action. For example, these include the catalysts described in Hydrocarbon Processing, Vol. 47 (1968) pages 103 to 107 which are aluminum compounds such as aluminum oxide and aluminum silicate, optionally with addition of other metal oxides and fluorides. The entire disclosure of the Hydrocarbon Processing article is hereby incorporated by reference and relied upon. 
     With advantage there is used in the process catalysts produced according to German Offenlegungsschrift No. 2 151 417 and related Beschke U.S. Pat. No. 3,898,177; according to German OS No. 2 224 160 and related Beschke U.S. Pat. No. 3,960,766; and according to German OS No. 2 239 801 and related Beschke U.S. Pat. No. 3,917,542. The entire disclosure of Beschke Pat. Nos. 3,898,177; 3,917,542 and 3,960,766 are hereby incorporated by reference and relied upon. 
     These catalysts are prepared by treating with oxygen at temperatures of 550° to 1200° C. compounds of the elements Al, F and O which compounds also contain at least one element of the second, third or fourth groups of the periodic system (German Offenlegungsschrift No. 2 151 417 and related Beschke U.S. Pat. No. 3,898,177) or at least two elements of the second, fourth, fifth or sixth groups of the periodic system (German Offenlegungsschrift No. 2 224 160 and related Beschke U.S. Pat. No. 3,960,766) or at least one element of the second main group of the periodic system (German Offenlegungsschrift No. 2 239 801 and related Beschke U.S. Pat. No. 3,971,542). The catalysts are used in a fixed bed or preferably in a fluidized bed. 
     Beschke U.S. Pat. No. 3,898,177 describes the catalyst in claim 1 as consisting essentially of oxygen containing compounds of Al, F, at least one of the elements B and Si and at least one element from the second and fourth groups of the periodic system selected from the group consisting of Mg, Ba, Zn, Sn and Zr, said catalyst having been prepared by heating in the presence of oxygen at a temperature of 600° to 800° C.: 
     1. aluminum, aluminum oxide or an aluminum compound convertible to the oxide at said temperature; 
     2. a compound of fluorine, said fluorine having been added as ammonium fluoride, ammonium hydrogen fluoride, hydrogen fluoride, fluoboric acid, fluosilicic acid, boron trifluoride, magnesium fluoborate, magnesium fluosilicate, zinc fluosilicate or barium fluosilicate; 
     3. boron, silicon, boric oxide, silica or a compound of boron or silica convertible to the oxide at said temperature; and, 
     4. magnesium, zinc, tin, zirconium, magnesium oxide, zinc oxide, tin oxide or a compound of zirconium or barium convertible to the oxide at said temperature, the atomic ratio of Al to F being from 1000:25 to 1000:800 and the atomic ratio of Al to the total of (3) and (4) being from 1000:5 to 1000:200, the atomic ratio of the total of boron and silicon to the other element from the second and fourth groups being between 1 to 10 and 10 to 1. 
     Beschke U.S. Pat. No. 3,917,542 in claim 1 describes the catalyst as having been prepared by heating at 600° to 800° C. In the presence of gaseous oxygen, (1) aluminum metal, aluminum oxide or a compound of aluminum convertible to the oxide upon heating with gaseous oxygen at 600° to 800° C., (2) ammonium fluoride, hydrogen fluoride or a fluoride of an element of the second main group of the periodic system and (3) at least one element of the second main group of the periodic system, the oxide of said element or a compound of said element convertible to the oxide in the presence of gaseous oxygen at a temperature of 600° to 800° C., said catalyst consisting essentially of the elements Al, F, O and the element of the second main group of the periodic system. 
     Beschke U.S. Pat. No. 3,960,766 in claim 1 describes the catalyst as consisting essentially of the product obtained by treating with oxygen at a temperature of 550° to 1200° C. compounds of the elements Al, F and O and at least two other elements selected from the second, fourth, fifth and sixth groups of the periodic system, said two other elements being selected from the group consisting of Mg, Ba, Zr, Sn, Ti, P, Ta, Sb and S, the ratios of the elements being Al to F of between 1000 to 10 and 1000 to 800 and of Al to the elements of the second, fourth, fifth and sixth groups being between 1000 to 5 and 1000 to 2000. 
     Especially advantageous is a procedure using the apparatus and method of German OS No. 2 449 340 and related Beschke U.S. application Ser. No. 622,488 filed Oct. 15, 1975 in which instead of the reactants mentioned in the German OS No. 2 449 340 and Beschke cycloalkanone or cycloalkenone and oxo compound are fed into the reactor separate from the ammonia. Generally, the residence time in the reactor is between 0.2 and 5.0 seconds. The entire disclosure of the Beschke U.S. application Ser. No. 622,488 is hereby incorporated by reference and relied upon. 
     The working up of the gas mixture resulting from the reaction can take place in customary manner by washing the gases with a liquid, especially water or methanol and by further separation by means of extraction and distillation. With especial advantage there is employed the procedure of German OS No. 2 554 946 and related Beschke U.S. application Ser. No. 748,041 filed Dec. 6, 1976 in which the gas mixture is not washed but cooled and as a result partially condensed in such manner that any possible excess ammonia remains in the residual gas and with this is directly recycled. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The single FIGURE of the drawing is a schematic illustration of an apparatus suitable for carrying out the invention. 
    
    
     Referring more specifically to the drawing, there is used a tubular reactor 10 provided with cooling and heating devices (not shown). The reactor suitably contains in the middle portion 11 gas distribution plates 30, but in the lower part 12 and the upper part 13 there is free space. The first reaction gas is led into the reactor from below through line 14 and so regulated that the catalyst in the reactor forms a fluidized bed. The other reactant gases are led through line 15 into the fluidized bed. The reaction mixture is drawn off from the reactor in the upper part thereof through the line 16. A portion of the catalyst is always transported via line 17 from the reactor 10 to a regenerator 20. This regenerator also is advantageously constructed similar to the reactor 10. The regenerator also suitably contains gas distribution plates 32 in the middle portion but there is free space in the lower portion 22 and in the upper portion 23. The oxygen or oxygen containing gas is led into the regenerator 20 from below through line 24. The gas flow is so regulated that the catalyst present in the regenerator forms a fluidized bed. The gas escaping from the regenerator via line 25 is discarded. A portion of the catalyst is continuously relieved from the regenerator 20 via line 26 into the reactor 10. 
     Unless otherwise indicated all parts and percentages are by weight. 
     The process can comprise, consist essentially of or consist of the steps set forth and the materials can comprise, consist essentially of or consist of those set forth. 
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Example 1 
     There was used the apparatus of the drawing (also disclosed in German OS No. 2 449 340 and Beschke U.S. application Ser. No. 622,488). Reactor 10 and regenerator 20 consisted of tubes 70 mm wide which had in their lower portions a free space 12 or 22 which was 200 mm high; thereover at intervals of 50 mm there were provided 40 wire screens with meshes of 5 mm (30 and 32) each in the spaces 11 and 21. There were provided above free spaces 13 and 23 having a height of 600 mm and a width of up to 160 mm. 
     There were led into the reactor 10 in gaseous form in uniform flow hourly from below via line 14 a gas mixture of 1500 normal liters (i.e., measured at standard pressure and temperature) of nitrogen and 2150 normal liters of ammonia. In a vaporizer there was prepared hourly a gas mixture from 2130 grams of acrolein and 325 normal liters of nitrogen. In a further vaporizer there was prepared a similar gaseous mixture from 1820 grams of cyclododecanone and 325 normal liters of nitrogen. These gaseous mixtures were combined and from the side via line 15 were led into the fluidized layer 130 mm above the bottom of the reactor at a temperature of 250° C. 
     The reactor contained 2.0 kg of catalyst which was produced according to Beschke U.S. Pat. No. 3,960,766 Example 1a (and German Offenlegungsschrift No. 2 224 160) from aluminum oxide, magnesium nitrate and titanium tetrafluoride and had an atomic ratio of aluminum to magnesium to titanium to fluorine of 1000:25:25:100. The catalyst had a particle size between 0.4 and 1.0 mm. The temperature in the reactor was held at 440° C. The reaction mixture leaving via line 16 and which was free from acrolein and cyclododecanone was led at a temperature of 250° C. into a gas washing apparatus in which the 2,3-cyclododecenopyridine and the pyridine and 3-methyl pyridine byproducts were washed out by means of methanol. The remaining residual gas of ammonia and nitrogen was recycled into the reactor. 
     The regenerator 20 contained an additional 2.0 kg of the catalyst. There were introduced into the regenerator from below via line 24 hourly 3000 normal liters of air. The temperature in the regenerator was held at 440° C. In a steady stream there were transferred hourly from the reactor to the regenerator 1.4 kg of catalyst and likewise there were returned 1.4 kg of catalyst from the regenerator to the reactor. 
     The cyclododecanone reaction was 98%. There were recovered hourly 1895 grams of 2,3-cyclododecenopyridine, 378 grams of pyridine and 1164 grams of 3-methyl pyridine as well as 25 grams of unreacted cyclododecanone. This corresponds to a yield of cyclododecenopyridine of 88.6%, based on the reacted cyclododecanone as well as 12.5% of pyridine and 32.9% of 3-methyl pyridine based on the acrolein added. The 2,3-cyclododecenopyridine had a boiling point of 141° to 144° C. at 5 mbar. Its hydrochloride had a melting point (decomposition point) of 220° C. 
     In the following examples, there was used the same procedure as in Example 1. 
     Example 2 
     
         ______________________________________Starting Materials:          Cycloheptanone, acrolein and          ammonia in the molar ratios of          1:2.8:11.2Catalyst:      As in Example 1Reaction Temperature:          430° C.Reaction:      100% of the cycloheptanoneProduct:       2,3-cycloheptenopyridine          B.P. 104 to 114° C. at 17 mbar,          M.P. of the hydrochloride 158° C.Yield:         69% based on the reacted          cycloheptanoneByproducts:    11% pyridine and 30% 3-methyl          pyridine based on the acrolein          added______________________________________ 
    
     Example 3 
     
         ______________________________________Starting Materials:           Cyclopentanone, acrolein and           ammonia in the molar ratios of           1:2.8:11.2Catalyst:       As in Example 1Reaction Temperature:           420° C.Reaction:       100% of the cyclopentanoneProduct:        2,3-cyclopentenopyridine,           B.P. 78 to 83° C. at 17 mbar, M.P.           (decomposition point) of the           hydrochloride 153° C.Yield:          64% based on the reacted cyclo-           pentanoneByproducts:     12% pyridine and 31% 3-methyl           pyridine based on the acrolein           added______________________________________ 
    
     EXAMPLE 4 
     
         ______________________________________Starting Materials:           3-methyl-5-dimethylcyclohexanone,           acrolein and ammonia in the           molar ratios of 1:3:12Catalyst:       As in Example 1Reaction Temperature:           440° C.Reaction:       100% of the 3-methyl-5-dimethyl-           cyclohexanoneProduct:        Isomeric mixture of 60% 5-methyl-           7-dimethyl-5,6,7,8-tetrahydro-           quinoline and 40% 5-dimethyl-7-           methyl-5,6,7,8-tetrahydroquinoline           B.P. 115 to 120° C. at 17 mbarYield:          A total of 71% based on the           reacted cyclohexanoneByproducts:     12% pyridine and 29% 3-methyl           pyridine based on the acrolein           added______________________________________ 
    
     Example 5 
     
         ______________________________________Starting Materials:           Cyclohexanone, acrolein and           ammonia in the molar ratios of           1:2.9:9.6Catalyst:       According to Beschke U.S.           Pat. No. 3,898,177 Example 5 (and           German OS 2 151 417) from           aluminum oxide, magnesium           nitrate and fluosilicic acid,           atomic ratio aluminum to           magnesium to silicon to fluorine           of 1000:24:25:156Reaction Temperature:           400° C.Reaction:       94% of the cyclohexanoneProduct:        2,3-cyclohexenopyridine, B.P.           95 to 99° C. at 17 mbar, M.P. of           the hydrochloride 134° C.Yield:          53% based on the reacted           cyclohexanoneByproducts:     15% pyridine and 25% 3-methyl           pyridine based on the acrolein           added______________________________________ 
    
     Example 6 
     
         ______________________________________Starting Materials:           Cyclohexanone, acrolein and           ammonia in the molar ratios           of 1:2.4:6Catalyst:       According to Beschke U.S.           Pat. No. 3,917,542 Example 1 (and           German OS 2 239 801) from           aluminum oxide, magnesium nitrate           and ammonium hydrogen fluoride           in the atomic ratio aluminum to           magnesium to fluorine of           1000:25:50Reaction Temperature:           370° C.Reaction:       92% of the cyclohexanoneProduct:        2,3-cyclohexenopyridine, B.P.           95 to 99° C. at 17 mbar, M.P. of the           hydrochloride 134° C.Yield:          58% based on the reacted           cyclohexanoneByproducts:     14% pyridine and 21% 3-methyl           pyridine based on the acrolein           added______________________________________ 
    
     Example 7 
     
         ______________________________________Starting Materials:          Cyclododecanone, crotonaldehyde          and ammonia in the molar ratios          of 1:2:8Catalyst:      As in Example 1Reaction Temperature:          430° C.Reaction:      100% of the cyclododecanoneProduct:       2,3-cyclododeceno-4-methyl          pyridine, B.P. 172 to 183° C.          at 6 mbarYield:         37% based on the reacted          cyclododecanoneByproducts:    8% pyridine, 11% 2-methyl pyridine          and 21% 4-methyl pyridine based          on the crotonaldehyde added______________________________________ 
    
     Example 8 
     
         ______________________________________Starting Materials:           Cyclohexanone, methacrolein           and ammonia in the molar ratios           of 1:3:6Catalyst:       As in Example 1Reaction Temperature:           420° C.Reaction:       100% of the cyclohexanoneProduct:        2,3-cyclohexeno-5-methyl pyridine,           B.P. 96 to 102° C. at 13 mbarYield:          64% based on the reacted           cyclohexanoneByproducts:     5% pyridine and 27% 3,5-dimethyl           pyridine based on the methacrolein           added______________________________________ 
    
     Example 9 
     
         ______________________________________Starting Materials:            Cyclododecanone, methyl vinyl            ketone and ammonia in the molar            ratios 1:2.6:10.4Catalyst:        As in Example 1Reaction Temperature:            420° C.Reaction:        100% of the cyclododecanoneProduct:         2,3-cyclododeceno-6-methyl            pyridine, B.P. 146 to 158° C.            at 3 mbarYield:           73% based on the reacted cyclo-            dodecanoneByproducts:      27% collidine mixture based on            the methyl vinyl ketone added______________________________________ 
    
     Example 10 
     
         ______________________________________Starting Materials:            Cyclohexanone, acrolein and            ammonia in the molar ratio            1:1:4Catalyst:        Aluminum silicate consisting            of 87% SiO.sub.2 and 13% Al.sub.2 O.sub.3,            BET surface area 500 m.sup.2 /g,            particle size 0.4 to 1.0 mm,            pore volume 0.75 cm.sup.3 /g, pore            diameter 60 angstromsReaction Temperature:            440° C.Reaction:        100% of the cyclohexanoneProduct:         2,3-cyclohexenopyridine, B.P.            95 to 99° C. at 17 mbar, M.P. of            the hydrochloride 134° C.Yield:           38% based on the reacted cyclo-            hexanoneByproducts:      13% pyridine and 34% 3-methyl            pyridine based on the acrolein            added______________________________________ 
    
     Example 11 
     
         ______________________________________Starting Materials:          2,2,4(2,4,4)-trimethylcyclo-          pentanone (TMCP-on of the firm          VEBA), acrolein and ammonia in          the molar ratios 1:3:12Catalyst:      As in Example 1Reaction Temperature:          420° C.Reaction:      100% of the trimethylcyclopentanoneProduct:       Mixture of 1&#39;-dimethyl-3&#39;-methyl-          2,3-cyclopentenopyridine and          1&#39;-methyl-3&#39;-dimethyl-2,3-          cyclopentenopyridine, B.P. 88 to          103° C. at 14 mbarYield:         37% based on the reacted          trimethylcyclopentanoneByproducts:    31% pyridine and 36% 3-methyl-          pyridine based on the acrolein          added______________________________________ 
    
     EXAMPLE 12 
     
         ______________________________________Starting Materials:            Isophorone (3,5,5-trimethyl-            2-cyclohexenone), acrolein and            ammonia in the molar ratios of            1:3:10Catalyst:        As in Example 1Reaction Temperature:            420° C.Reaction:        94% of the isophoroneProduct:         (a) 5-dimethyl-7-methyl-5,6-            dihydroquinoline            (b) 5-dimethyl-7-methyl-5,6,7,8-            tetrahydroquinoline            (c) 5,7-dimethyl quinolineYield:           55% ((a) 5%, (b) 16%, (c) 34%)            based on the reacted isophoroneByproducts:      16% pyridine and 30% 3-methyl            pyridine based on the acrolein            added______________________________________