US20090287026A1 - Method for producing fluorinated organic compounds - Google Patents
Method for producing fluorinated organic compounds Download PDFInfo
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- US20090287026A1 US20090287026A1 US12/466,271 US46627109A US2009287026A1 US 20090287026 A1 US20090287026 A1 US 20090287026A1 US 46627109 A US46627109 A US 46627109A US 2009287026 A1 US2009287026 A1 US 2009287026A1
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- 150000004812 organic fluorine compounds Chemical class 0.000 title claims description 5
- 238000004519 manufacturing process Methods 0.000 title description 10
- 238000000034 method Methods 0.000 claims abstract description 46
- 230000008569 process Effects 0.000 claims abstract description 39
- SMCNZLDHTZESTK-UHFFFAOYSA-N 2-chloro-1,1,1,2-tetrafluoropropane Chemical compound CC(F)(Cl)C(F)(F)F SMCNZLDHTZESTK-UHFFFAOYSA-N 0.000 claims abstract description 30
- FXRLMCRCYDHQFW-UHFFFAOYSA-N 2,3,3,3-tetrafluoropropene Chemical compound FC(=C)C(F)(F)F FXRLMCRCYDHQFW-UHFFFAOYSA-N 0.000 claims abstract description 28
- OQISUJXQFPPARX-UHFFFAOYSA-N 2-chloro-3,3,3-trifluoroprop-1-ene Chemical compound FC(F)(F)C(Cl)=C OQISUJXQFPPARX-UHFFFAOYSA-N 0.000 claims abstract description 24
- PGJHURKAWUJHLJ-UHFFFAOYSA-N 1,1,2,3-tetrafluoroprop-1-ene Chemical compound FCC(F)=C(F)F PGJHURKAWUJHLJ-UHFFFAOYSA-N 0.000 claims abstract description 6
- KRHYYFGTRYWZRS-UHFFFAOYSA-N Fluorane Chemical compound F KRHYYFGTRYWZRS-UHFFFAOYSA-N 0.000 claims abstract description 6
- 229910000040 hydrogen fluoride Inorganic materials 0.000 claims abstract description 6
- 238000004064 recycling Methods 0.000 claims abstract description 3
- 150000001875 compounds Chemical class 0.000 claims description 68
- 239000003054 catalyst Substances 0.000 claims description 67
- 238000006243 chemical reaction Methods 0.000 claims description 48
- 238000003682 fluorination reaction Methods 0.000 claims description 41
- 238000007033 dehydrochlorination reaction Methods 0.000 claims description 22
- UMGQVBVEWTXECF-UHFFFAOYSA-N 1,1,2,3-tetrachloroprop-1-ene Chemical compound ClCC(Cl)=C(Cl)Cl UMGQVBVEWTXECF-UHFFFAOYSA-N 0.000 claims description 15
- 239000007791 liquid phase Substances 0.000 claims description 13
- 239000000047 product Substances 0.000 claims description 12
- 239000013067 intermediate product Substances 0.000 claims description 11
- 229910052739 hydrogen Inorganic materials 0.000 claims description 10
- 229910052801 chlorine Inorganic materials 0.000 claims description 9
- 239000012025 fluorinating agent Substances 0.000 claims description 7
- 238000010574 gas phase reaction Methods 0.000 claims description 5
- WGRYCAMDZAHQMF-UHFFFAOYSA-N CClC Chemical compound CClC WGRYCAMDZAHQMF-UHFFFAOYSA-N 0.000 claims description 4
- 230000004888 barrier function Effects 0.000 claims description 2
- 239000007789 gas Substances 0.000 description 12
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 7
- 239000000460 chlorine Substances 0.000 description 7
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 6
- 239000012071 phase Substances 0.000 description 6
- -1 2-chloro-3 Chemical compound 0.000 description 5
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 5
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 5
- VMPVEPPRYRXYNP-UHFFFAOYSA-I antimony(5+);pentachloride Chemical compound Cl[Sb](Cl)(Cl)(Cl)Cl VMPVEPPRYRXYNP-UHFFFAOYSA-I 0.000 description 5
- 239000012530 fluid Substances 0.000 description 5
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 4
- 229910021578 Iron(III) chloride Inorganic materials 0.000 description 4
- 238000006555 catalytic reaction Methods 0.000 description 4
- 229910052731 fluorine Inorganic materials 0.000 description 4
- 239000000543 intermediate Substances 0.000 description 4
- 229910052742 iron Inorganic materials 0.000 description 4
- RBTARNINKXHZNM-UHFFFAOYSA-K iron trichloride Chemical compound Cl[Fe](Cl)Cl RBTARNINKXHZNM-UHFFFAOYSA-K 0.000 description 4
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 3
- YCKRFDGAMUMZLT-UHFFFAOYSA-N Fluorine atom Chemical compound [F] YCKRFDGAMUMZLT-UHFFFAOYSA-N 0.000 description 3
- 150000001336 alkenes Chemical class 0.000 description 3
- 230000003197 catalytic effect Effects 0.000 description 3
- 229910052804 chromium Inorganic materials 0.000 description 3
- 239000011651 chromium Substances 0.000 description 3
- 238000004821 distillation Methods 0.000 description 3
- 239000011737 fluorine Substances 0.000 description 3
- CDOOAUSHHFGWSA-OWOJBTEDSA-N (e)-1,3,3,3-tetrafluoroprop-1-ene Chemical compound F\C=C\C(F)(F)F CDOOAUSHHFGWSA-OWOJBTEDSA-N 0.000 description 2
- 229910021630 Antimony pentafluoride Inorganic materials 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 229910000792 Monel Inorganic materials 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- CBENFWSGALASAD-UHFFFAOYSA-N Ozone Chemical compound [O-][O+]=O CBENFWSGALASAD-UHFFFAOYSA-N 0.000 description 2
- 229910003074 TiCl4 Inorganic materials 0.000 description 2
- 229910021627 Tin(IV) chloride Inorganic materials 0.000 description 2
- 230000004075 alteration Effects 0.000 description 2
- VBVBHWZYQGJZLR-UHFFFAOYSA-I antimony pentafluoride Chemical compound F[Sb](F)(F)(F)F VBVBHWZYQGJZLR-UHFFFAOYSA-I 0.000 description 2
- 239000007795 chemical reaction product Substances 0.000 description 2
- NEHMKBQYUWJMIP-UHFFFAOYSA-N chloromethane Chemical compound ClC NEHMKBQYUWJMIP-UHFFFAOYSA-N 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 238000006704 dehydrohalogenation reaction Methods 0.000 description 2
- 239000002274 desiccant Substances 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- QDOXWKRWXJOMAK-UHFFFAOYSA-N dichromium trioxide Chemical compound O=[Cr]O[Cr]=O QDOXWKRWXJOMAK-UHFFFAOYSA-N 0.000 description 2
- 229920002313 fluoropolymer Polymers 0.000 description 2
- 239000004811 fluoropolymer Substances 0.000 description 2
- 229910000856 hastalloy Inorganic materials 0.000 description 2
- 239000008240 homogeneous mixture Substances 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 229910001026 inconel Inorganic materials 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 229910052763 palladium Inorganic materials 0.000 description 2
- 239000011541 reaction mixture Substances 0.000 description 2
- BFKJFAAPBSQJPD-UHFFFAOYSA-N tetrafluoroethene Chemical group FC(F)=C(F)F BFKJFAAPBSQJPD-UHFFFAOYSA-N 0.000 description 2
- HPGGPRDJHPYFRM-UHFFFAOYSA-J tin(iv) chloride Chemical compound Cl[Sn](Cl)(Cl)Cl HPGGPRDJHPYFRM-UHFFFAOYSA-J 0.000 description 2
- XJDNKRIXUMDJCW-UHFFFAOYSA-J titanium tetrachloride Chemical compound Cl[Ti](Cl)(Cl)Cl XJDNKRIXUMDJCW-UHFFFAOYSA-J 0.000 description 2
- SHXHPUAKLCCLDV-UHFFFAOYSA-N 1,1,1-trifluoropentane-2,4-dione Chemical compound CC(=O)CC(=O)C(F)(F)F SHXHPUAKLCCLDV-UHFFFAOYSA-N 0.000 description 1
- CDOOAUSHHFGWSA-UHFFFAOYSA-N 1,3,3,3-tetrafluoropropene Chemical compound FC=CC(F)(F)F CDOOAUSHHFGWSA-UHFFFAOYSA-N 0.000 description 1
- FDMFUZHCIRHGRG-UHFFFAOYSA-N 3,3,3-trifluoroprop-1-ene Chemical compound FC(F)(F)C=C FDMFUZHCIRHGRG-UHFFFAOYSA-N 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N Alumina Chemical class [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 239000004604 Blowing Agent Substances 0.000 description 1
- KZBUYRJDOAKODT-UHFFFAOYSA-N Chlorine Chemical compound ClCl KZBUYRJDOAKODT-UHFFFAOYSA-N 0.000 description 1
- ZAMOUSCENKQFHK-UHFFFAOYSA-N Chlorine atom Chemical compound [Cl] ZAMOUSCENKQFHK-UHFFFAOYSA-N 0.000 description 1
- VOPWNXZWBYDODV-UHFFFAOYSA-N Chlorodifluoromethane Chemical compound FC(F)Cl VOPWNXZWBYDODV-UHFFFAOYSA-N 0.000 description 1
- 239000003082 abrasive agent Substances 0.000 description 1
- 150000001298 alcohols Chemical class 0.000 description 1
- 229910052787 antimony Inorganic materials 0.000 description 1
- FAPDDOBMIUGHIN-UHFFFAOYSA-K antimony trichloride Chemical compound Cl[Sb](Cl)Cl FAPDDOBMIUGHIN-UHFFFAOYSA-K 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000000969 carrier Substances 0.000 description 1
- 238000005796 dehydrofluorination reaction Methods 0.000 description 1
- 239000003989 dielectric material Substances 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 125000000816 ethylene group Chemical group [H]C([H])([*:1])C([H])([H])[*:2] 0.000 description 1
- 239000004088 foaming agent Substances 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 239000003701 inert diluent Substances 0.000 description 1
- 239000011968 lewis acid catalyst Substances 0.000 description 1
- 229940074869 marquis Drugs 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910001510 metal chloride Inorganic materials 0.000 description 1
- 229910001512 metal fluoride Inorganic materials 0.000 description 1
- 229910001507 metal halide Inorganic materials 0.000 description 1
- 150000005309 metal halides Chemical class 0.000 description 1
- 229940050176 methyl chloride Drugs 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 238000006116 polymerization reaction Methods 0.000 description 1
- VBUNOIXRZNJNAD-UHFFFAOYSA-N ponazuril Chemical compound CC1=CC(N2C(N(C)C(=O)NC2=O)=O)=CC=C1OC1=CC=C(S(=O)(=O)C(F)(F)F)C=C1 VBUNOIXRZNJNAD-UHFFFAOYSA-N 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000000135 prohibitive effect Effects 0.000 description 1
- 239000003380 propellant Substances 0.000 description 1
- 238000000197 pyrolysis Methods 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- 239000003507 refrigerant Substances 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- QHMQWEPBXSHHLH-UHFFFAOYSA-N sulfur tetrafluoride Chemical compound FS(F)(F)F QHMQWEPBXSHHLH-UHFFFAOYSA-N 0.000 description 1
- 229910052716 thallium Inorganic materials 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- 238000010977 unit operation Methods 0.000 description 1
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C17/00—Preparation of halogenated hydrocarbons
- C07C17/013—Preparation of halogenated hydrocarbons by addition of halogens
- C07C17/04—Preparation of halogenated hydrocarbons by addition of halogens to unsaturated halogenated hydrocarbons
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C21/00—Acyclic unsaturated compounds containing halogen atoms
- C07C21/02—Acyclic unsaturated compounds containing halogen atoms containing carbon-to-carbon double bonds
- C07C21/18—Acyclic unsaturated compounds containing halogen atoms containing carbon-to-carbon double bonds containing fluorine
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C17/00—Preparation of halogenated hydrocarbons
- C07C17/07—Preparation of halogenated hydrocarbons by addition of hydrogen halides
- C07C17/087—Preparation of halogenated hydrocarbons by addition of hydrogen halides to unsaturated halogenated hydrocarbons
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C17/00—Preparation of halogenated hydrocarbons
- C07C17/093—Preparation of halogenated hydrocarbons by replacement by halogens
- C07C17/20—Preparation of halogenated hydrocarbons by replacement by halogens of halogen atoms by other halogen atoms
- C07C17/202—Preparation of halogenated hydrocarbons by replacement by halogens of halogen atoms by other halogen atoms two or more compounds being involved in the reaction
- C07C17/204—Preparation of halogenated hydrocarbons by replacement by halogens of halogen atoms by other halogen atoms two or more compounds being involved in the reaction the other compound being a halogen
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C17/00—Preparation of halogenated hydrocarbons
- C07C17/093—Preparation of halogenated hydrocarbons by replacement by halogens
- C07C17/20—Preparation of halogenated hydrocarbons by replacement by halogens of halogen atoms by other halogen atoms
- C07C17/202—Preparation of halogenated hydrocarbons by replacement by halogens of halogen atoms by other halogen atoms two or more compounds being involved in the reaction
- C07C17/206—Preparation of halogenated hydrocarbons by replacement by halogens of halogen atoms by other halogen atoms two or more compounds being involved in the reaction the other compound being HX
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C17/00—Preparation of halogenated hydrocarbons
- C07C17/25—Preparation of halogenated hydrocarbons by splitting-off hydrogen halides from halogenated hydrocarbons
Definitions
- This invention relates to novel methods for preparing fluorinated organic compounds, and more particularly to methods of producing fluorinated olefins.
- Hydrofluorocarbons in particular hydrofluoroalkenes such as tetrafluoropropenes (including 2,3,3,3-tetrafluoro-1-propene (HFO-1234yf) and 1,3,3,3-tetrafluoro-1-propene (HFO-1234ze)) have been disclosed to be effective refrigerants, fire extinguishants, heat transfer media, propellants, foaming agents, blowing agents, gaseous dielectrics, sterilant carriers, polymerization media, particulate removal fluids, carrier fluids, buffing abrasive agents, displacement drying agents and power cycle working fluids.
- CFCs chlorofluorocarbons
- HCFCs hydrochlorofluorocarbons
- U.S. Pat. No. 2,931,840 (Marquis) describes a method of making fluorine containing olefins by pyrolysis of methyl chloride and tetrafluoroethylene or chlorodifluoromethane. This process is a relatively low yield process and a very large percentage of the organic starting material is converted in this process to unwanted and/or unimportant byproducts.
- Multi-step methods of producing HFO-1234yf and HFO-1234ze are described in US 2007/0197842 (Mukhopadhyay et al.). More particularly, this publication describes a method for producing HFO-1234yf that involves converting tetrachloropropenes into an intermediate trifluoropropene, such as 2-chloro-3,3,3,-trifluoro-1-propene (HCFO-1233xf), which can subsequently be converted into 2-chloro-1,1,1,2-tetrafluoropropane (HCFC-244bb), which can subsequently be converted into HFO-1234yf.
- Such a method involves a series of reactors.
- Applicants have found a method of producing HFO-1234yf from tetrachloropropene (TCP) that involves using a single reactor or reactor system to conduct two different reaction steps contemporaneously, namely fluorination of tetrachloropropene to produce an HFCO-1233xf intermediate and dehydrochlorination of HCFC-244bb to produce HFO-1234yf.
- TCP tetrachloropropene
- the present invention reduces the unit operations and processing equipment. This results in a more economical process from an initial capital and operating cost versus conducting the 3-steps sequentially.
- an aspect of the invention provides a process for producing tetrafluoropropene comprising: (a) catalytically fluorinating at least one tetrafluoropropene in a first reactor to produce HCFO-1233xf; (b) reacting said HCFO-1233xf with hydrogen fluoride in a second reactor to produce HCFC-244bb; (c) recycling at least a portion of said HCFC-244bb back to said first reactor as recycled HCFC-244bb; and (d) catalytically dehydrochlorinating said recycled HCFC-244bb in said first reactor to produce HFO-1234yf.
- a process for producing tetrafluoropropene comprising: (a) introducing one or more feed streams into a first reactor containing a fluorination catalyst and a dehydrochlorination catalyst, wherein said feed streams collectively comprise tetrachloropropene, hydrogen fluoride, and HCFC-244bb; (b) contacting said one or more feed streams with said fluorination catalyst and said dehydrochlorination catalyst to produce a first intermediate product stream comprising HCFO-1233xf and HFO-1234yf; (c) converting at least a portion of said HCFO-1233xf into HCFC-244bb in a second reactor to produce a second intermediate product stream; (d) separating said intermediate product stream into a product stream rich in HFO-1234yf and a recycle product stream rich in HCFC-244bb; and (e) introducing said recycle product stream into said first reactor as said one or more feed streams.
- FIG. 1 is a block flow diagram showing the production of HFO-1234yf from TCP according to a preferred embodiment of the invention.
- FIG. 2 is a process flow diagram showing a preferred embodiment of the invention.
- Applicants have discovered an integrated method for producing fluorinated organic compounds, including hydrofluoropropenes such as HFO-1234yf, which preferably comprises converting at least one compound of formula C(X) 2 ⁇ CClC(X) 3 , and more preferably at least one compound of Formula (I):
- each X is independently H or Cl, and Z is independently H or Cl.
- the compound of Formula (II) is CF 3 CF ⁇ CH 2 .
- the method comprises: (a) reacting, preferably fluorinating, and even more preferably fluorinating in the presence of HF, a compound of Formula (I), preferably a tetrachloropropene, and even more preferably a tetrachloropropene selected from the group consisting of CH 2 ⁇ CClCCl 3 , CCl 2 ⁇ CClCH 2 Cl, CHCl ⁇ CClCCl 2 H, and combinations of these, in a gas and/or liquid phase reaction in the presence of at least a first catalyst to produce at least one compound of formula C(X) 2 ⁇ CClCF 3 , and preferably of Formula (IA):
- X is H or Cl, such as a monochloro-trifluoro-propene, preferably HCFO-1233xf; (b) reacting at least one compound produced from step (a), preferably a compound of Formula (IA), in a gas and/or liquid phase and preferably in the presence of at least a catalyst, preferably a second catalyst which is different than the first catalyst, to produce at least one compound of formula C(X) 3 CClYC(X) 3 , wherein X and Y are independently H, F, or Cl, and preferably of Formula (IB):
- steps (a) and (c) are performed in a single reactor or reactor zone.
- steps (a) and (c) may be performed in a hydrofluorination zone and a dehydrochlorination zone, respectively, of a single reactor.
- the reaction zones are preferably separated by a physical barrier.
- a single reactor may comprise a shell and tube, whereby step (a) is performed on the shell side of the reactor, and step (c) is performed on the tube side of the reactor, or vice-a-versa.
- step (a) is performed on the shell side of the reactor
- step (c) is performed on the tube side of the reactor, or vice-a-versa.
- the converting step involves reacting said compound(s) by fluorinating said compound(s) with a fluorinating agent, preferably selected from HF, F 2 , and FCl, and more preferably HF, in a gas phase, to produce hydrochlorofluoroolefin that is at least trifluorinated, such as HCFO-1233xf.
- a fluorinating agent preferably selected from HF, F 2 , and FCl, and more preferably HF
- hydrochlorofluoroolefin that is at least trifluorinated, such as HCFO-1233xf.
- this is a gas phase reaction that is at least partially catalyzed.
- the preferred fluorination of the compound of Formula (I) is preferably carried out under conditions effective to provide a Formula (I) conversion of at least about 50%, more preferably at least about 75%, and even more preferably at least about 90%. In certain preferred embodiments the conversion is at least about 95%, and more preferably at least about 97%.
- the conversion of the compound of Formula (I) comprises reacting such compound under conditions effective to produce at least one compound of Formula (IA), such as monochlorotrifluoropropene (preferably HCFO-1233xf)) at a selectivity of at least about 50%, more preferably at least about 70%, more preferably at least about 80%, and even more preferably at least about 90%, with selectivities of about 95% or greater being achieved in certain embodiments.
- at least one compound of Formula (IA) such as monochlorotrifluoropropene (preferably HCFO-1233xf)) at a selectivity of at least about 50%, more preferably at least about 70%, more preferably at least about 80%, and even more preferably at least about 90%, with selectivities of about 95% or greater being achieved in certain embodiments.
- the fluorination reaction step can be carried out in the liquid phase or in the gas phase, or in a combination of gas and liquid phases, and it is contemplated that the reaction can be carried out batch wise, continuous, or a combination of these.
- the reaction is at least partially a catalyzed reaction, and is preferably carried out on a continuous basis by introducing a stream containing the compound of Formula (I), into one or more reaction vessels, such as a tubular reactor.
- Particularly preferred reactor systems include single reactor systems using a series of reactors, multistage reactors, or a combination reactor design.
- the reactor is preferably segregated into alternating beds of fluorination and dehydrochlorination zones or contains a homogeneous mixture of fluorination and dehydrochlorination catalysts.
- the stream containing the compound of Formula (I) is heated to a temperature of from about 80° C. to about 400° C., more preferably from about 150° C. to about 400° C., and in certain embodiments preferably about 300° C., and introduced into a reaction vessel, which is maintained at the desired temperature, preferably from about 80° C. to about 700° C., more preferably from about 90° C. to about 600° C., even more preferably in certain embodiments from about 400° C. to about 600° C., more preferably from about 450° C. to about 600° C., where it is preferably contacted with catalyst and fluorinating agent, such as HF.
- catalyst and fluorinating agent such as HF
- the exothermic fluorination of the Compound of Formula (I) and the endothermic dehydrochlorination of Formula (IB) are preferably performed in the same reactor.
- the exothermic properties of the fluorination are balanced with the endothermic properties of the dehydrochlorination.
- the vessel is comprised of materials which are resistant to corrosion as Hastelloy, Inconel, Monel and/or fluoropolymers linings.
- the vessel contains catalyst, for example a fixed or fluid catalyst bed, packed with a suitable fluorination catalyst, with suitable means to ensure that the reaction mixture is maintained with the desired reaction temperature range.
- catalyst for example a fixed or fluid catalyst bed, packed with a suitable fluorination catalyst, with suitable means to ensure that the reaction mixture is maintained with the desired reaction temperature range.
- the fluorination reaction step may be preformed using a wide variety of process parameters and process conditions in view of the overall teachings contained herein.
- this reaction step comprise a gas phase reaction, preferably in the presence of catalyst, and even more preferably a chromium-based catalyst (such as Cr 2 O 3 catalyst), an iron-based catalyst (such as FeCl 3 on carbon (designated herein as FeCl 3 /C for convenience), and combinations of these.
- the catalyst is a combination of the two aforementioned catalysts, where the reaction vessel contains in a first zone the chromium-based catalyst and in a second zone the iron-based catalyst.
- the temperature of the reaction in the chromium-based catalyst reaction is preferably kept at a temperature of from about 200° C. to about 600° C. and even more preferably from about 250° C. to about 500° C.
- the temperature of the reaction in the iron-based catalyst reaction zone is preferably kept at a temperature of from about 80° C. to about 300° C. and even more preferably from about 100° C. to about 250° C.
- reaction pressures may be used for the fluorination reaction, depending again on relevant factors such as the specific catalyst being used and the most desired reaction product.
- the reaction pressure can be, for example, superatmospheric, atmospheric or under vacuum and in certain preferred embodiments is from about 1 to about 200 psia, and in certain embodiments from about 1 to about 120 psia.
- an inert diluent gas such as nitrogen, may be used in combination with the other reactor feed(s).
- the compound of Formula (IA), preferably produced as described above, is preferably subject to further fluorination reaction(s) involving a fluorinating agent, preferably selected from HF, F 2 , and FCl, and more preferably HF, to produce a compound of Formula (IB), preferably HCFC-244bb.
- a fluorinating agent preferably selected from HF, F 2 , and FCl, and more preferably HF
- this is a liquid phase reaction that is at least partially catalyzed.
- this reaction is performed in a reactor separate from the reactor used to perform the fluorination of Formula (I) and the dehydrochlorination of Formula (IB).
- the fluorination of the compound of Formula (IA) is preferably carried out under conditions effective to provide a Formula (IA) conversion of at least about 40%, more preferably at least about 50%, and even more preferably at least about 60%.
- the conversion of the compound of Formula (IA) comprises reacting such compound under conditions effective to produce at least one monochlorotetrafluoropropane, preferably HCFC-244bb, at a selectivity of at least about 70%, more preferably at least about 80%, and even more preferably at least about 85%, with selectivities of about 90% or greater being achieved in certain embodiments.
- this fluorination reaction step can be carried out in the liquid phase or in the gas phase, or in a combination of gas and liquid phases, and it is contemplated that the reaction can be carried out batch wise, continuous, or a combination of these.
- the reaction can be catalytic or non-catalytic.
- a catalytic process is used.
- Lewis acid catalyst such as metal-halide catalysts, including antimony halides, tin halides, thallium halides, iron halides, and combinations of two or more of these, are preferred in certain embodiments.
- Metal chlorides and metal fluorides are particularly preferred. Examples of particularly preferred catalysts of this type include SbCl 5 , SbCl 3 , SbF 5 , SnCl 4 , TiCl 4 , FeCl 3 and combinations of two or more of these.
- the reaction is at least partially a catalyzed reaction, and is preferably carried out on a continuous basis by introducing a stream containing the compound of Formula (IA) into one or more reaction vessels, such as a tubular reactor.
- the stream containing the compound of Formula (IA) is preheated to a temperature of from about 50° C. to about 400° C., and in certain embodiments preferably about 80° C. In other embodiments, it is preferred that the stream containing the compound of Formula (IA), is preheated to a temperature of from about 150° C. to about 400° C., preferably about 300° C.
- This steam preferably after preheating, is then preferably introduced into a reaction vessel (preferably a tube reactor), which is maintained at the desired temperature, preferably from about 50° C. to about 250° C., more preferably from about 50° C. to about 150° C., where it is preferably contacted with catalyst and fluorinating agent, such as HF.
- a reaction vessel preferably a tube reactor
- the vessel is comprised of materials which are resistant to corrosion as Hastelloy, Inconel, Monel and/or fluoropolymers linings.
- the vessel contains catalyst, for example a fixed or fluid catalyst bed, packed with a suitable fluorination catalyst, with suitable means to ensure that the reaction mixture is maintained within about the desired reaction temperature range.
- catalyst for example a fixed or fluid catalyst bed, packed with a suitable fluorination catalyst, with suitable means to ensure that the reaction mixture is maintained within about the desired reaction temperature range.
- the fluorination reaction step may be preformed using a wide variety of process parameters and process conditions in view of the overall teachings contained herein.
- this reaction step comprises a liquid phase reaction, preferably in the presence of catalyst, and even more preferably an Sb-based catalyst, such as catalyst which is about 50 wt % SbCl 5 /C.
- Sb-based catalyst such as catalyst which is about 50 wt % SbCl 5 /C.
- Other catalysts which may be used include: from about 3 to about 6 wt % FeCl 3 /C; SbF 5 /C; about 20 wt % SnCl 4 /C; about 23 wt % TiCl 4 /C; and activated carbon.
- the catalyst comprises Cl 2 and HF pre-treated SbCl 5 /C.
- reaction pressures may be used for the fluorination reaction, depending again on relevant factors such as the specific catalyst being used and the most desired reaction product.
- the reaction pressure can be, for example, superatmospheric, atmospheric or under vacuum and in certain preferred embodiments is from about 1 to about 200 psia, more preferably in certain embodiments from about 1 to about 120 psia.
- One preferred reaction step in accordance with the present invention may be described by those reactions in which the compound of Formula (IB) is dehydrohalogenated to produce a compound of Formula (II).
- the reaction is performed contemporaneously with the fluorination of the compound of Formula (I) and in the same reactor or reactor system that is used to fluorinate the compound of Formula (I).
- the dehydrohalogenation of Formula (IB) involves a gas phase catalytic reaction.
- Preferred dehydrochlorination catalysts include carbon- and/or metal-based catalyst, preferably activated carbon, a nickel-based catalyst (such as Ni-mesh) and combinations of these.
- catalysts and catalyst supports may be used, including palladium on carbon, palladium-based catalyst (including palladium on aluminum oxides), and it is expected that many other catalysts may be used depending on the requirements of particular embodiments in view of the teachings contained herein. Of course, two or more any of these catalysts, or other catalysts not named here, may be used in combination.
- the conversion of the Formula (IB) compound is at least about 60%, more preferably at least about 75%, and even more preferably at least about 90%.
- the selectivity to compound of Formula (II), preferably HFO-1234yf is at least about 50%, more preferably at least about 70% and more preferably at least about 80%.
- FIGS. 1 and 2 shown is an integrated process for the production of HFO-1234yf from tetrachloropropene (TCP) in three reaction steps where the first (exothermic) and third (endothermic) reactions are carried out in a single reactor or reaction zone.
- TCP tetrachloropropene
- Step 1 Hydrofluorination of TCP to HCFO-1233xf and dehydrochlorination of intermediate HCFC-244bb (formed in a separate reactor as described below) occur in a single reactor system using a series of reactors or multi-stage reactor, or combination of reactor design, as illustrated on the attached process flowsheet.
- the reactor is either segregated into alternating beds of fluorination/dehydrochlorination zones or a homogeneous mixture of fluorination catalyst and dehydrochlorination catalyst.
- the exotherm of the hydrofluorination reaction is used to balance the endotherm of the dehydrochlorination reaction.
- Step 2 The reactor effluent containing HCFO-1233xf, HFO-1234yf, HCFC-244bb, HCl and any unreacted TCP and intermediates are cooled and condensed into a liquid and are fed as an intermediate product stream into a liquid phase reactor containing antimony pentachloride catalyst for hydrofluorination of HCFO-1233xf to HCFC-244bb.
- Step 3 The combined mixture of HCFO-1233xf, HCFC-244bb, HFO-1234yf and HCl exit the liquid reactor system as a second intermediate product stream and are processed via a catalyst stripper so that most of the unreacted HF and catalyst are refluxed back to the second reactor.
- Step 4 The effluent from the catalyst stripper is fed to a recycle column, such as a distillation column, to separate the HCFO-1233xf, HCFC-244bb and HF from the HFO-1234yf.
- the HCFO-1233xf, HCFC-244bb and HF exit the bottom of distillation column and are recycled back to the first reactor.
- Step 5 The distillate from the distillation column is fed to additional equipment such as HCl recovery column to separate desired product HFO-1234yf from HCl.
- the HCl may be scrubbed out and desired product HFO-1234yf may be recovered by drying in sieves or another suitable drying agent.
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Abstract
Description
- The present application is related to and claims the priority benefit of U.S. Provisional Application No. 61/053,647, which was filed on May 15, 2008, and which is incorporated herein by reference.
- (1) Field of Invention
- This invention relates to novel methods for preparing fluorinated organic compounds, and more particularly to methods of producing fluorinated olefins.
- (2) Description of Related Art
- Hydrofluorocarbons (HFC's), in particular hydrofluoroalkenes such as tetrafluoropropenes (including 2,3,3,3-tetrafluoro-1-propene (HFO-1234yf) and 1,3,3,3-tetrafluoro-1-propene (HFO-1234ze)) have been disclosed to be effective refrigerants, fire extinguishants, heat transfer media, propellants, foaming agents, blowing agents, gaseous dielectrics, sterilant carriers, polymerization media, particulate removal fluids, carrier fluids, buffing abrasive agents, displacement drying agents and power cycle working fluids. Unlike chlorofluorocarbons (CFCs) and hydrochlorofluorocarbons (HCFCs), both of which potentially damage the Earth's ozone layer, HFCs do not contain chlorine and thus pose no threat to the ozone layer.
- Several methods of preparing hydrofluoroalkenes are known. For example, U.S. Pat. No. 4,900,874 (Ihara et al.) describes a method of making fluorine containing olefins by contacting hydrogen gas with fluorinated alcohols. Although this appears to be a relatively high-yield process, for commercial scale production the handling of hydrogen gas at high temperature raises difficult safety-related questions. Also, the cost of producing hydrogen gas, such as building an on-site hydrogen plant, can be in many situations prohibitive.
- U.S. Pat. No. 2,931,840 (Marquis) describes a method of making fluorine containing olefins by pyrolysis of methyl chloride and tetrafluoroethylene or chlorodifluoromethane. This process is a relatively low yield process and a very large percentage of the organic starting material is converted in this process to unwanted and/or unimportant byproducts.
- The preparation of HFO-1234yf from trifluoroacetylacetone and sulfur tetrafluoride has been described. See Banks, et al., Journal of Fluorine Chemistry, Vol. 82, Iss. 2, p. 171-174 (1997). Also, U.S. Pat. No. 5,162,594 (Krespan) discloses a process wherein tetrafluoroethylene is reacted with another fluorinated ethylene in the liquid phase to produce a polyfluoroolefin product.
- Multi-step methods of producing HFO-1234yf and HFO-1234ze are described in US 2007/0197842 (Mukhopadhyay et al.). More particularly, this publication describes a method for producing HFO-1234yf that involves converting tetrachloropropenes into an intermediate trifluoropropene, such as 2-chloro-3,3,3,-trifluoro-1-propene (HCFO-1233xf), which can subsequently be converted into 2-chloro-1,1,1,2-tetrafluoropropane (HCFC-244bb), which can subsequently be converted into HFO-1234yf. Such a method involves a series of reactors.
- There remains a need for a method for producing HFO-1234yf that is more efficient and economically practical. This invention satisfies these needs among others.
- Applicants have found a method of producing HFO-1234yf from tetrachloropropene (TCP) that involves using a single reactor or reactor system to conduct two different reaction steps contemporaneously, namely fluorination of tetrachloropropene to produce an HFCO-1233xf intermediate and dehydrochlorination of HCFC-244bb to produce HFO-1234yf. Compared to conventional three-step processes for the manufacture of HFO-1234yf from TCP via three separate reactors, the present invention reduces the unit operations and processing equipment. This results in a more economical process from an initial capital and operating cost versus conducting the 3-steps sequentially.
- Accordingly, an aspect of the invention provides a process for producing tetrafluoropropene comprising: (a) catalytically fluorinating at least one tetrafluoropropene in a first reactor to produce HCFO-1233xf; (b) reacting said HCFO-1233xf with hydrogen fluoride in a second reactor to produce HCFC-244bb; (c) recycling at least a portion of said HCFC-244bb back to said first reactor as recycled HCFC-244bb; and (d) catalytically dehydrochlorinating said recycled HCFC-244bb in said first reactor to produce HFO-1234yf.
- According to another aspect of the invention, provided is a process for producing tetrafluoropropene comprising: (a) introducing one or more feed streams into a first reactor containing a fluorination catalyst and a dehydrochlorination catalyst, wherein said feed streams collectively comprise tetrachloropropene, hydrogen fluoride, and HCFC-244bb; (b) contacting said one or more feed streams with said fluorination catalyst and said dehydrochlorination catalyst to produce a first intermediate product stream comprising HCFO-1233xf and HFO-1234yf; (c) converting at least a portion of said HCFO-1233xf into HCFC-244bb in a second reactor to produce a second intermediate product stream; (d) separating said intermediate product stream into a product stream rich in HFO-1234yf and a recycle product stream rich in HCFC-244bb; and (e) introducing said recycle product stream into said first reactor as said one or more feed streams.
-
FIG. 1 is a block flow diagram showing the production of HFO-1234yf from TCP according to a preferred embodiment of the invention; and -
FIG. 2 is a process flow diagram showing a preferred embodiment of the invention. - Applicants have discovered an integrated method for producing fluorinated organic compounds, including hydrofluoropropenes such as HFO-1234yf, which preferably comprises converting at least one compound of formula C(X)2═CClC(X)3, and more preferably at least one compound of Formula (I):
-
CHX═CClC(X)3 (I) - into at least one compound of Formula (II):
-
CF3CF═CHZ (II) - where each X is independently H or Cl, and Z is independently H or Cl. Preferably, the compound of Formula (II) is CF3CF═CH2.
- In a preferred aspect of the present invention, the method comprises: (a) reacting, preferably fluorinating, and even more preferably fluorinating in the presence of HF, a compound of Formula (I), preferably a tetrachloropropene, and even more preferably a tetrachloropropene selected from the group consisting of CH2═CClCCl3, CCl2═CClCH2Cl, CHCl═CClCCl2H, and combinations of these, in a gas and/or liquid phase reaction in the presence of at least a first catalyst to produce at least one compound of formula C(X)2═CClCF3, and preferably of Formula (IA):
-
CHX═CClCF3 (IA) - wherein X is H or Cl, such as a monochloro-trifluoro-propene, preferably HCFO-1233xf; (b) reacting at least one compound produced from step (a), preferably a compound of Formula (IA), in a gas and/or liquid phase and preferably in the presence of at least a catalyst, preferably a second catalyst which is different than the first catalyst, to produce at least one compound of formula C(X)3CClYC(X)3, wherein X and Y are independently H, F, or Cl, and preferably of Formula (IB):
-
CH2XCClFCF3 (IB) - wherein X is H or Cl, such as HCFC-244bb; and (c) reacting said compound of Formula (IB), in a gas and/or liquid phase, to produce at least one compound of Formula (II), preferably HFO-1234yf; wherein steps (a) and (c) are performed in a single reactor or reactor zone. In certain embodiments steps (a) and (c) may be performed in a hydrofluorination zone and a dehydrochlorination zone, respectively, of a single reactor. The reaction zones are preferably separated by a physical barrier. For example, a single reactor may comprise a shell and tube, whereby step (a) is performed on the shell side of the reactor, and step (c) is performed on the tube side of the reactor, or vice-a-versa. Each of the preferred reaction steps is described in detail below, with the headings being used for convenience but not necessarily by way of limitation.
- One preferred reaction step in accordance with the present invention may be described by those reactions in which the compound of Formula (I) is fluorinated to produce a compound of Formula (IA). In certain preferred embodiments, the converting step involves reacting said compound(s) by fluorinating said compound(s) with a fluorinating agent, preferably selected from HF, F2, and FCl, and more preferably HF, in a gas phase, to produce hydrochlorofluoroolefin that is at least trifluorinated, such as HCFO-1233xf. Preferably this is a gas phase reaction that is at least partially catalyzed.
- The preferred fluorination of the compound of Formula (I) is preferably carried out under conditions effective to provide a Formula (I) conversion of at least about 50%, more preferably at least about 75%, and even more preferably at least about 90%. In certain preferred embodiments the conversion is at least about 95%, and more preferably at least about 97%. Further in certain preferred embodiments, the conversion of the compound of Formula (I) comprises reacting such compound under conditions effective to produce at least one compound of Formula (IA), such as monochlorotrifluoropropene (preferably HCFO-1233xf)) at a selectivity of at least about 50%, more preferably at least about 70%, more preferably at least about 80%, and even more preferably at least about 90%, with selectivities of about 95% or greater being achieved in certain embodiments.
- In general, it is possible that the fluorination reaction step can be carried out in the liquid phase or in the gas phase, or in a combination of gas and liquid phases, and it is contemplated that the reaction can be carried out batch wise, continuous, or a combination of these.
- In preferred gas phase fluorination of Formula (I) compounds, the reaction is at least partially a catalyzed reaction, and is preferably carried out on a continuous basis by introducing a stream containing the compound of Formula (I), into one or more reaction vessels, such as a tubular reactor. Particularly preferred reactor systems include single reactor systems using a series of reactors, multistage reactors, or a combination reactor design. For embodiments using a single reactor, the reactor is preferably segregated into alternating beds of fluorination and dehydrochlorination zones or contains a homogeneous mixture of fluorination and dehydrochlorination catalysts.
- In certain preferred embodiments, the stream containing the compound of Formula (I), is heated to a temperature of from about 80° C. to about 400° C., more preferably from about 150° C. to about 400° C., and in certain embodiments preferably about 300° C., and introduced into a reaction vessel, which is maintained at the desired temperature, preferably from about 80° C. to about 700° C., more preferably from about 90° C. to about 600° C., even more preferably in certain embodiments from about 400° C. to about 600° C., more preferably from about 450° C. to about 600° C., where it is preferably contacted with catalyst and fluorinating agent, such as HF. As described in more detail below, the exothermic fluorination of the Compound of Formula (I) and the endothermic dehydrochlorination of Formula (IB) are preferably performed in the same reactor. Preferably the exothermic properties of the fluorination are balanced with the endothermic properties of the dehydrochlorination.
- Preferably the vessel is comprised of materials which are resistant to corrosion as Hastelloy, Inconel, Monel and/or fluoropolymers linings.
- Preferably the vessel contains catalyst, for example a fixed or fluid catalyst bed, packed with a suitable fluorination catalyst, with suitable means to ensure that the reaction mixture is maintained with the desired reaction temperature range.
- Thus, it is contemplated that the fluorination reaction step may be preformed using a wide variety of process parameters and process conditions in view of the overall teachings contained herein. However, it is preferred in certain embodiments that this reaction step comprise a gas phase reaction, preferably in the presence of catalyst, and even more preferably a chromium-based catalyst (such as Cr2O3 catalyst), an iron-based catalyst (such as FeCl3 on carbon (designated herein as FeCl3/C for convenience), and combinations of these. In preferred embodiments, the catalyst is a combination of the two aforementioned catalysts, where the reaction vessel contains in a first zone the chromium-based catalyst and in a second zone the iron-based catalyst. The temperature of the reaction in the chromium-based catalyst reaction is preferably kept at a temperature of from about 200° C. to about 600° C. and even more preferably from about 250° C. to about 500° C. The temperature of the reaction in the iron-based catalyst reaction zone is preferably kept at a temperature of from about 80° C. to about 300° C. and even more preferably from about 100° C. to about 250° C.
- In general it is also contemplated that a wide variety of reaction pressures may be used for the fluorination reaction, depending again on relevant factors such as the specific catalyst being used and the most desired reaction product. The reaction pressure can be, for example, superatmospheric, atmospheric or under vacuum and in certain preferred embodiments is from about 1 to about 200 psia, and in certain embodiments from about 1 to about 120 psia.
- In certain embodiments, an inert diluent gas, such as nitrogen, may be used in combination with the other reactor feed(s).
- It is contemplated that the amount of catalyst use will vary depending on the particular parameters present in each embodiment.
- The compound of Formula (IA), preferably produced as described above, is preferably subject to further fluorination reaction(s) involving a fluorinating agent, preferably selected from HF, F2, and FCl, and more preferably HF, to produce a compound of Formula (IB), preferably HCFC-244bb. Preferably, this is a liquid phase reaction that is at least partially catalyzed. Preferably this reaction is performed in a reactor separate from the reactor used to perform the fluorination of Formula (I) and the dehydrochlorination of Formula (IB).
- The fluorination of the compound of Formula (IA) is preferably carried out under conditions effective to provide a Formula (IA) conversion of at least about 40%, more preferably at least about 50%, and even more preferably at least about 60%. Further, in certain preferred embodiments, the conversion of the compound of Formula (IA) comprises reacting such compound under conditions effective to produce at least one monochlorotetrafluoropropane, preferably HCFC-244bb, at a selectivity of at least about 70%, more preferably at least about 80%, and even more preferably at least about 85%, with selectivities of about 90% or greater being achieved in certain embodiments.
- In general, it is possible that this fluorination reaction step can be carried out in the liquid phase or in the gas phase, or in a combination of gas and liquid phases, and it is contemplated that the reaction can be carried out batch wise, continuous, or a combination of these.
- For embodiments in which the reaction comprises a liquid phase reaction, the reaction can be catalytic or non-catalytic. Preferably, a catalytic process is used. Lewis acid catalyst, such as metal-halide catalysts, including antimony halides, tin halides, thallium halides, iron halides, and combinations of two or more of these, are preferred in certain embodiments. Metal chlorides and metal fluorides are particularly preferred. Examples of particularly preferred catalysts of this type include SbCl5, SbCl3, SbF5, SnCl4, TiCl4, FeCl3 and combinations of two or more of these.
- In preferred gas phase fluorination of Formula (IA) compounds, the reaction is at least partially a catalyzed reaction, and is preferably carried out on a continuous basis by introducing a stream containing the compound of Formula (IA) into one or more reaction vessels, such as a tubular reactor. In certain preferred embodiments, the stream containing the compound of Formula (IA) is preheated to a temperature of from about 50° C. to about 400° C., and in certain embodiments preferably about 80° C. In other embodiments, it is preferred that the stream containing the compound of Formula (IA), is preheated to a temperature of from about 150° C. to about 400° C., preferably about 300° C. This steam, preferably after preheating, is then preferably introduced into a reaction vessel (preferably a tube reactor), which is maintained at the desired temperature, preferably from about 50° C. to about 250° C., more preferably from about 50° C. to about 150° C., where it is preferably contacted with catalyst and fluorinating agent, such as HF.
- Preferably the vessel is comprised of materials which are resistant to corrosion as Hastelloy, Inconel, Monel and/or fluoropolymers linings.
- Preferably the vessel contains catalyst, for example a fixed or fluid catalyst bed, packed with a suitable fluorination catalyst, with suitable means to ensure that the reaction mixture is maintained within about the desired reaction temperature range.
- Thus, it is contemplated that the fluorination reaction step may be preformed using a wide variety of process parameters and process conditions in view of the overall teachings contained herein. However, it is preferred in certain embodiments that this reaction step comprises a liquid phase reaction, preferably in the presence of catalyst, and even more preferably an Sb-based catalyst, such as catalyst which is about 50 wt % SbCl5/C. Other catalysts which may be used include: from about 3 to about 6 wt % FeCl3/C; SbF5/C; about 20 wt % SnCl4/C; about 23 wt % TiCl4/C; and activated carbon. Preferably the catalyst comprises Cl2 and HF pre-treated SbCl5/C.
- In general it is also contemplated that a wide variety of reaction pressures may be used for the fluorination reaction, depending again on relevant factors such as the specific catalyst being used and the most desired reaction product. The reaction pressure can be, for example, superatmospheric, atmospheric or under vacuum and in certain preferred embodiments is from about 1 to about 200 psia, more preferably in certain embodiments from about 1 to about 120 psia.
- It is contemplated that the amount of catalyst used will vary depending on the particular parameters present in each embodiment.
- One preferred reaction step in accordance with the present invention may be described by those reactions in which the compound of Formula (IB) is dehydrohalogenated to produce a compound of Formula (II). Preferably, the reaction is performed contemporaneously with the fluorination of the compound of Formula (I) and in the same reactor or reactor system that is used to fluorinate the compound of Formula (I). Preferably, the dehydrohalogenation of Formula (IB) involves a gas phase catalytic reaction. Preferred dehydrochlorination catalysts include carbon- and/or metal-based catalyst, preferably activated carbon, a nickel-based catalyst (such as Ni-mesh) and combinations of these. Other catalysts and catalyst supports may be used, including palladium on carbon, palladium-based catalyst (including palladium on aluminum oxides), and it is expected that many other catalysts may be used depending on the requirements of particular embodiments in view of the teachings contained herein. Of course, two or more any of these catalysts, or other catalysts not named here, may be used in combination.
- Preferably in such dehydrofluorination embodiments as described in this section, the conversion of the Formula (IB) compound is at least about 60%, more preferably at least about 75%, and even more preferably at least about 90%. Preferably in such embodiments, the selectivity to compound of Formula (II), preferably HFO-1234yf, is at least about 50%, more preferably at least about 70% and more preferably at least about 80%.
- The following prophetic example is a preferred embodiment that is provided to further illustrate certain aspect of the invention.
- With reference to
FIGS. 1 and 2 , shown is an integrated process for the production of HFO-1234yf from tetrachloropropene (TCP) in three reaction steps where the first (exothermic) and third (endothermic) reactions are carried out in a single reactor or reaction zone. The process is summarized as follows: - Step 1: Hydrofluorination of TCP to HCFO-1233xf and dehydrochlorination of intermediate HCFC-244bb (formed in a separate reactor as described below) occur in a single reactor system using a series of reactors or multi-stage reactor, or combination of reactor design, as illustrated on the attached process flowsheet. The reactor is either segregated into alternating beds of fluorination/dehydrochlorination zones or a homogeneous mixture of fluorination catalyst and dehydrochlorination catalyst. The exotherm of the hydrofluorination reaction is used to balance the endotherm of the dehydrochlorination reaction.
Step 2: The reactor effluent containing HCFO-1233xf, HFO-1234yf, HCFC-244bb, HCl and any unreacted TCP and intermediates are cooled and condensed into a liquid and are fed as an intermediate product stream into a liquid phase reactor containing antimony pentachloride catalyst for hydrofluorination of HCFO-1233xf to HCFC-244bb.
Step 3: The combined mixture of HCFO-1233xf, HCFC-244bb, HFO-1234yf and HCl exit the liquid reactor system as a second intermediate product stream and are processed via a catalyst stripper so that most of the unreacted HF and catalyst are refluxed back to the second reactor. If desired, further conversion of HCFO-1233xf may be accomplished in a post-catalysis section comprised of SbCl5/C catalyst fitted to the exit of the catalyst stripper.
Step 4: The effluent from the catalyst stripper is fed to a recycle column, such as a distillation column, to separate the HCFO-1233xf, HCFC-244bb and HF from the HFO-1234yf. The HCFO-1233xf, HCFC-244bb and HF exit the bottom of distillation column and are recycled back to the first reactor.
Step 5: The distillate from the distillation column is fed to additional equipment such as HCl recovery column to separate desired product HFO-1234yf from HCl. Alternatively, the HCl may be scrubbed out and desired product HFO-1234yf may be recovered by drying in sieves or another suitable drying agent. - Having thus described a few particular embodiments of the invention, it will be apparent to those skilled in the art, in view of the teachings contained herein, that various alterations, modifications, and improvements not specifically described are available and within the scope of the present invention. Such alterations, modifications, and improvements, as are made obvious by this disclosure, are intended to be part of this description though not expressly stated herein, and are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description is by way of example only, and not limiting. The invention is limited only as defined in the following claims and equivalents thereto.
Claims (20)
CHX═CClC(X)3 (I)
CHX═CClCF3 (IA)
CH2XCClFCF3 (IB)
CF3CF═CHZ (II)
CHX═CClC(X)3 (I)
CH2XCClFCF3 (IB)
CHX═CClCF3 (IA)
CF3CF═CHZ (II)
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CN2009801172144A CN102026944A (en) | 2008-05-15 | 2009-05-15 | Method for producing fluorinated organic compounds |
KR1020107027699A KR101653207B1 (en) | 2008-05-15 | 2009-05-15 | Method for Producing Fluorinated Organic Compounds |
JP2011509726A JP5355686B2 (en) | 2008-05-15 | 2009-05-15 | Process for producing fluorinated organic compounds |
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CN101941884A (en) * | 2010-09-07 | 2011-01-12 | 西安近代化学研究所 | Liquid phase fluorination reaction device |
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Also Published As
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US20110207974A9 (en) | 2011-08-25 |
CN102026944A (en) | 2011-04-20 |
MX2010012034A (en) | 2010-11-30 |
EP2274260A1 (en) | 2011-01-19 |
JP2011520909A (en) | 2011-07-21 |
US8067649B2 (en) | 2011-11-29 |
EP2274260A4 (en) | 2014-04-23 |
KR101653207B1 (en) | 2016-09-01 |
JP5355686B2 (en) | 2013-11-27 |
WO2009140563A1 (en) | 2009-11-19 |
KR20110022592A (en) | 2011-03-07 |
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