WO2016031777A1 - ハイドロフルオロオレフィンの製造方法 - Google Patents
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- WO2016031777A1 WO2016031777A1 PCT/JP2015/073748 JP2015073748W WO2016031777A1 WO 2016031777 A1 WO2016031777 A1 WO 2016031777A1 JP 2015073748 W JP2015073748 W JP 2015073748W WO 2016031777 A1 WO2016031777 A1 WO 2016031777A1
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Definitions
- the present invention relates to a method for producing a hydrofluoroolefin.
- HFO-1234yf 2,3,3,3-tetrafluoropropene (CF 3 CF ⁇ CH 2 )
- CF 3 CF ⁇ CH 2 chlorofluorocarbons used in refrigerants and the like. It is useful as an alternative compound for chlorofluorocarbons.
- a method for producing HFO-1234yf for example, 1,1-dichloro-2,2,3,3,3-pentafluoropropane (CF 3 CF 2 CHCl 2 ) (hereinafter also referred to as “HCFC-225ca”).
- CFO-1214ya 1,1-dichloro-2,3,3,3-tetrafluoropropene (CF 3 CF ⁇ CCl 2 ) (hereinafter also referred to as “CFO-1214ya”).
- a method of obtaining HFO-1234yf by reacting CFO-1214ya with hydrogen and reducing it may be mentioned.
- Examples of a method for obtaining HFO-1234yf by reducing CFO-1214ya include the following method (i) disclosed in Patent Document 1. (I) In the presence of a palladium catalyst supported on alumina, CFO-1214ya and hydrogen gas are reacted at 100 to 400 ° C., preferably 125 to 350 ° C., based on the reaction represented by the following formula (6). Method. CF 3 CF ⁇ CCl 2 + 2H 2 ⁇ CF 3 CF ⁇ CH 2 + 2HCl (6)
- HFC-254eb 1,1,1,2-tetrafluoropropane
- HFO-1243zf 3,3,3-trifluoropropene
- HFO-1243zf has a boiling point close to that of the target product, HFO-1234yf, and thus is difficult to separate and remove by subsequent distillation. Therefore, HFO-1243zf remains as an impurity in HFO-1234yf obtained by distillation, and a separate purification step is necessary to obtain a high-purity product.
- Patent Document 2 discloses the following method (ii) as a method for carrying out a similar reduction reaction.
- RfCF CX 2 (where Rf represents a fluoroalkyl group having 1 to 10 carbon atoms, X represents chlorine, bromine or iodine) at 5 to 200 ° C.
- RfCF ⁇ CH 2 by reacting with hydrogen.
- Rf is CF 3- , that is, the target product is HFO-1234yf
- the target product and the hyperreductant are difficult to separate by distillation as in the case of method (i).
- the present invention is a reaction in which a chlorine atom in a raw material chlorofluoroolefin is substituted with a hydrogen atom to produce a hydrofluoroolefin, a perreduct obtained by adding hydrogen to the chlorofluoroolefin, or a fluorine atom together with a chlorine atom of the chlorofluoroolefin.
- Another object of the present invention is to provide a method for producing a hydrofluoroolefin in which the by-product of a perreduct that is substituted with a hydrogen atom is suppressed.
- a manufacturing method of The catalyst includes at least one platinum group element selected from the group consisting of palladium and platinum, manganese, copper, aluminum, gold, lithium, sodium, potassium, magnesium, silver, zinc, cadmium, indium, silicon, germanium,
- CZX CClY (1) (X is a fluorine atom or a chlorine atom, Y is a fluorine atom, a chlorine atom or a hydrogen atom, and Z is a fluorine atom or CF 3 )
- CZX ′ CHY ′ (2) (When X is a fluorine atom, X ′ is a fluorine atom; when X is a chlorine atom, X ′ is a hydrogen atom; when Y is a fluorine atom, Y ′ is a fluorine atom; and Y is chlorine. In the case of an atom or a hydrogen atom, Y ′ is a hydrogen atom, and Z is the same as Z in the formula (1).)
- the ratio of chlorofluoroolefin and hydrogen introduced into the catalyst layer is expressed as a ratio (H 2 / Cl) of the number of moles of chlorine atoms and the total number of moles of hydrogen in the chlorofluoroolefin, 0.1
- the chlorofluoroolefin is chlorotrifluoroethylene, trans-1,2-dichloro-1,2-difluoroethylene, cis-1,2-dichloro-1,2-difluoroethylene, 1,1-dichloro- Any one of [1] to [12], which is at least one selected from the group consisting of 2,3,3,3-tetrafluoropropene and 1-chloro-2,3,3,3-tetrafluoropropene
- the manufacturing method of hydrofluoroolefin of description is at least one selected from the group consisting of 2,3,3,3-tetrafluoropropene and 1-chloro-2,3,3,3-tetrafluoropropene.
- the by-product of a perreducted product in which a fluorine atom is substituted with a hydrogen atom together with a chlorine atom in a raw material chlorofluoroolefin is suppressed, and a target hydrofluoroolefin is easily purified with high purity. can get.
- the present invention provides a hydrofluoroolefin obtained by reacting a chlorofluoroolefin represented by the formula (1) with hydrogen in the presence of a catalyst supported on a carrier to obtain a hydrofluoroolefin represented by the formula (2). It is a manufacturing method of an olefin.
- the catalyst used in the production method includes at least one platinum group element selected from the group consisting of palladium and platinum, manganese, copper, aluminum, gold, lithium, sodium, potassium, magnesium, silver, zinc,
- the catalyst is made of an alloy containing at least one second element selected from the group consisting of cadmium, indium, silicon, germanium, tin, lead, arsenic, antimony and bismuth.
- the present invention is a method for producing a hydrofluoroolefin represented by the above formula (2) by reacting a chlorofluoroolefin represented by the above formula (1) with hydrogen.
- a chlorofluoroolefin represented by the above formula (1) which is one of the raw materials, and the reaction product when the chlorofluoroolefin is used will be described.
- the chlorofluoroolefin which is one of the raw materials of the present invention is a compound represented by the formula (1).
- chlorofluoroolefins represented by the above formula (1) chlorotrifluoroethylene, trans-1,2-dichloro-1 is preferred because the product is expected as an alternative refrigerant that has high cooling efficiency and is friendly to the global environment.
- trans isomer is represented by adding (E) to the beginning of the compound name or chemical formula
- cis isomer is represented by adding (Z) to the beginning of the compound name or chemical formula.
- Chlorotrifluoroethylene can be produced by dechlorination of 1,1,2-trichloro-1,2,2-trifluoroethane or thermal decomposition of chlorodifluoromethane and dichlorofluoromethane.
- (E) -1,2-dichloro-1,2-difluoroethylene and (Z) -1,2-dichloro-1,2-difluoroethylene can be produced by a thermal decomposition reaction of dichlorofluoromethane.
- CFO-1214ya can be manufactured by a known method. For example, there is a method in which HCFC-225ca is brought into contact with an alkaline aqueous solution in the presence of a phase transfer catalyst and subjected to dehydrofluorination reaction. In the reaction, dichloropentafluoropropane containing HCFC-225ca (hereinafter also referred to as “HCFC-225”) can be used, and only the HCFC-225ca in HCFC-225 is selectively defluorinated by the phase transfer catalyst. Hydrogenated. After the reaction, CFO-1214ya can be separated and recovered by a known method such as distillation.
- HCFC-225ca dichloropentafluoropropane containing HCFC-225ca
- HCFC-225 including the HCFC-225ca can be produced by reacting tetrafluoroethylene and dichlorofluoromethane in the presence of a catalyst such as aluminum chloride.
- HCFC-225 obtained by the reaction includes HCFC-225ca and 1,3-dichloro-1,2,2,3,3-pentafluoropropane (CHClFCF 2 CClF 2 ) (hereinafter referred to as “HCFC-225cb”).
- HCFC-225aa 2,2-dichloro-1,1,3,3,3-pentafluoropropane
- CHF 2 CCl 2 CF 3 2,2-dichloro-1,1,3,3,3-pentafluoropropane
- HCFC-225bb 3-dichloro-1,1,2,3,3-pentafluoropropane
- Commercially available HCFC-225 including HCFC-225ca may be used.
- AK225 Asahiklin (trademark) AK225 (manufactured by Asahi Glass Co., Ltd., a mixture of 48 mol% of HCFC-225ca and 52 mol% of HCFC-225cb, hereinafter referred to as “AK225”).
- TBAB tetrabutylammonium bromide
- HCFO-1224yd is produced as an intermediate when CFO-1214ya and hydrogen are reacted to obtain HFO-1234yf.
- the target reaction product obtained by the production method of the present invention is a compound represented by the formula (2).
- the types of X ′, Y ′ and Z in the formula (2) have a corresponding relationship with the types of X, Y and Z of the chlorofluoroolefin represented by the formula (1) which is one of the raw materials.
- X in the formula (1) is a fluorine atom
- X ′ is a fluorine atom.
- X ′ is a hydrogen atom.
- Y in the formula (1) is a fluorine atom
- Y ′ is a fluorine atom.
- Y ′ is a hydrogen atom.
- Z in the formula (1) is the same as Z in the formula (1).
- HCFO-1224yd obtained by the reaction represented by the following formula (6) is the target reaction product.
- HFO-1234yf obtained by the reaction represented by the following formula (7) is the target reaction product.
- the catalyst in the present invention is made of an alloy containing a specific platinum group element and a second element.
- the specific platinum group element in the present invention is at least one platinum group element selected from the group consisting of palladium and platinum. When it consists of either one of palladium and platinum, palladium or platinum forms an alloy with the second element. Moreover, when it consists of both palladium and platinum, a mixture and an alloy may be sufficient as palladium and platinum. In the case of a mixture, at least one of palladium and platinum forms an alloy with the second element. In the case of an alloy of palladium and platinum, the alloy is called a palladium-platinum alloy.
- the catalyst made of palladium has a higher conversion rate and selectivity for the hydrogen reduction reaction. On the other hand, a catalyst made of platinum has higher acid resistance and longer catalyst life.
- the platinum group element refers to the specific platinum group element, and the simple substance is referred to as a platinum group metal.
- the second element is at least selected from the group consisting of manganese, copper, aluminum, gold, lithium, sodium, potassium, magnesium, silver, zinc, cadmium, indium, silicon, germanium, tin, lead, arsenic, antimony, and bismuth.
- One type When the reaction of the present invention is carried out using the above platinum group element alone as a catalyst, the hydrogen reduction activity of the platinum group metal is too high, and the overreduced product is easily produced as a byproduct.
- an alloy of a platinum group element and a predetermined second element is used as a catalyst, the hydrogen reduction activity of the platinum group metal is suppressed, and the by-product of the overreduced body is suppressed.
- the durability of the catalyst can be improved by using an alloy.
- alloy solid solution of the platinum group element and the second element is performed in an atmosphere of an inert gas such as nitrogen gas or argon gas, or in a trace amount.
- an inert gas such as nitrogen gas or argon gas
- the second element is at least one selected from the group consisting of manganese, copper, aluminum, gold, silver, zinc, cadmium, indium, silicon, germanium, tin, lead, arsenic, antimony and bismuth, which does not easily react with water. Further, at least one selected from the group consisting of manganese, copper, aluminum, gold, silver, zinc, indium, silicon, germanium, tin, antimony, and bismuth is more preferable because of its low environmental impact and toxicity. preferable. Since the hydrogen reduction reaction involves dehydrochlorination, the periphery of the catalyst charged in the reactor is in an acidic atmosphere.
- At least one selected from the group consisting of copper, gold, tin, antimony and bismuth is more preferable, and at least one selected from the group consisting of copper, tin, antimony and bismuth is particularly preferable.
- the content ratio of the platinum group element and the second element in the alloy is 60:40 to 99: 1 in terms of mass ratio from the viewpoint of further suppressing the by-product of the overreduced product. preferable.
- the catalyst may contain, for example, a metal element such as iron, cobalt, or nickel as an element other than the platinum group element and the second element, and is contained in an alloy with the platinum group element or the second element. It may be.
- the elements other than the platinum group element and the second element may be one type or two or more types.
- the content ratio of the “element other than the platinum group element and the second element” is the total amount of the platinum group element and the second element. The amount is preferably 0.01 to 20 parts by mass with respect to 100 parts by mass.
- the catalyst is used by being supported on a carrier. It is preferable to use a carrier for dispersing and supporting the alloy.
- a carrier for dispersing and supporting the alloy.
- the carrier include carbon-based materials such as activated carbon, carbon black, and carbon fiber, and oxide-based materials such as alumina, silica, titania, and zirconia.
- activated carbon and alumina are preferable from the viewpoint that the specific surface area is relatively large and the alloy is easily supported, and activated carbon is more preferable from the viewpoint that the by-product of the overreduced substance can be further suppressed.
- Examples of the activated carbon include activated carbon prepared from fruit shells such as wood, charcoal, and coconut shells, peat, lignite, and coal.
- Examples of the activated carbon include aggregates of formed coal having a length of about 2 to 5 mm, crushed coal having a size of about 4 to 50 mesh, and granular coal. Of these, aggregates of the above-mentioned coals or crushed coals of 4 to 20 mesh are preferable.
- alumina examples include ⁇ -alumina, ⁇ -alumina, and ⁇ -alumina having different crystal states.
- Alumina can be used widely from ⁇ -alumina having a relatively large specific surface area to ⁇ -alumina having a high crystallinity and a small specific surface area. From the viewpoint of easy filling of the catalyst into the reaction tube and easy flow of the raw material gas, it is preferable to use a molded type alumina support which is molded into a spherical shape or a pellet shape.
- the supported amount of the alloy catalyst is preferably 0.1 to 10% by mass, and more preferably 0.5 to 1.0% by mass with respect to the carrier. If the supported amount is equal to or higher than the lower limit, the reaction rate between chlorofluoroolefin and hydrogen is improved. It becomes easy to suppress the by-product of the body, and it becomes easy to obtain the catalyst.
- the specific surface area of the catalyst-loaded support is preferably 10 ⁇ 2000m 2 / g, more preferably 100 ⁇ 1500m 2 / g. If the specific surface area of the catalyst-carrying support is not less than the lower limit, the reaction rate between chlorofluoroolefin and hydrogen is further improved. On the other hand, if the specific surface area is not more than the upper limit, the by-product of the hyperreductant can be more easily suppressed. .
- the specific surface area of the catalyst-supported carrier is measured by a method based on an N 2 gas adsorption method, for example, the BET method.
- the catalyst-supported carrier can be produced by a known method. For example, an impregnation method, a colloid method, etc. are mentioned.
- the impregnation method is the most common method for producing a catalyst-supported carrier.
- the catalyst metal salt solution is brought into contact with the carrier, the catalyst metal salt is adsorbed on the surface of the carrier, the impregnated carrier is dried, the reducing agent is brought into contact with the metal salt on the carrier surface, and the metal salt is reduced.
- the reducing agent may be a reducing gas such as ammonia, hydrazine or sodium borohydride, or a reducing gas such as hydrogen.
- carrier particles carrying metal fine particles can be obtained by adsorbing a metal fine particle dispersion on the surface of the carrier and drying it.
- the metal fine particle dispersion is obtained by dissolving a metal salt in a solvent and reducing with a reducing agent.
- a polymer organic compound may be used as a protective agent, or may not be used.
- Commonly used protective agents include polyvinylpyrrolidone, polyethyleneimine, polyallylamine, poly (N-carboxymethyl) allylamine, poly (N, N-dicarboxymethyl) allylamine, poly (N-carboxymethyl) ethyleneimine, etc. Are known.
- reaction The reaction may be performed in the gas phase or in the liquid phase as long as the above-described catalyst is used.
- Examples of the reaction method include the following method ( ⁇ ) or method ( ⁇ ).
- Method ( ⁇ ) A method in which chlorofluoroolefin and hydrogen are reacted in the gas phase in the presence of a catalyst.
- Method ( ⁇ ) A method in which chlorofluoroolefin and hydrogen are reacted in the liquid phase in the presence of a catalyst.
- Examples of the method ( ⁇ ) include a method in which chlorofluoroolefin and hydrogen are introduced into a reactor filled with a catalyst-supporting carrier and reacted in the gas phase.
- a specific example of the method is a method in which a gas containing chlorofluoroolefin gas and hydrogen gas (hereinafter also referred to as “raw material mixed gas”) is introduced into the reactor and reacted.
- the catalyst layer is obtained by filling the reactor with the above-described catalyst-supporting carrier.
- the packing density of the catalyst-supporting carrier is preferably 0.5 to 1 g / cm 3 and more preferably 0.6 to 0.8 g / cm 3 . If the packing density is equal to or higher than the lower limit, the amount of the catalyst-supported carrier per unit volume is large, and the amount of gas to be reacted can be increased, so that the productivity is improved. It is possible to prevent the temperature of the catalyst layer, which will be described later, from rising excessively, and to easily maintain the maximum temperature of the catalyst layer, which will be described later, below a desired temperature.
- a typical flow reactor used for a gas-solid heterogeneous catalytic reaction in which the catalyst-supporting carrier is solid and the reaction fluid is gas can be used.
- Such flow-type reactors are roughly classified into fixed bed reactors and fluidized bed reactors.
- the fixed bed reactor in order to reduce the pressure loss of the reaction fluid, various molded bodies of the catalyst support are filled.
- a system in which a catalyst-supporting carrier is packed, moved by its gravity, and extracted from the bottom of the reactor and regenerated is called a moving bed, as in a fixed bed reactor.
- the catalyst layer is operated by the reaction fluid so that the catalyst layer exhibits characteristics like a fluid, the catalyst-supported carrier particles are suspended in the reaction fluid and moved in the reactor.
- either a fixed bed reactor or a fluidized bed reactor can be used, but a fixed bed reactor capable of appropriately controlling the reaction temperature is preferable in order to suppress catalyst deterioration without reducing the selectivity of the catalytic reaction.
- a fixed bed reactor there are a tubular reactor and a tank reactor, and the tubular reactor can be preferably used because of easy control of the reaction temperature.
- a multi-tube heat exchange type reaction in which a large number of reaction tubes having a small diameter are arranged in parallel and a heat medium is circulated outside can be employed.
- a plurality of catalyst layers are provided.
- the catalyst layer may be at least one stage, and may be two or more stages.
- reaction temperature in the catalyst layer decreases, the reaction rate of the catalyst decreases. Therefore, it is preferable to keep the reaction temperature in the catalyst layer at a desired temperature so that a high reaction rate can be maintained.
- a method of heating the catalyst layer from the outside with a heat medium or the like can be mentioned.
- the chlorofluoroolefin and hydrogen usually react in a part of the catalyst layer (hereinafter referred to as “reaction zone”).
- reaction zone the temperature upstream of the reaction zone in the catalyst layer is usually maintained by heating.
- the temperature on the upstream side of the reaction zone maintained by the heating is referred to as “catalyst layer temperature”.
- the temperature of the catalyst layer is a gas phase reaction, the temperature is higher than the dew point of the raw material mixed gas.
- the chlorofluoroolefin considering the reactivity, it is preferably 50 ° C. or higher, more preferably 60 ° C. or higher.
- HCFO-1224yd having a boiling point of 15 to 17 ° C. is estimated as the chlorofluoroolefin, it is preferably 20 ° C. or higher, more preferably 30 ° C. or higher.
- the catalyst usually deteriorates with time as the reaction proceeds.
- the reaction zone starts from the introduction of the raw material mixed gas at the beginning of the reaction.
- the catalyst in the introduction portion of the raw material mixed gas deteriorates with time as the reaction proceeds, the reaction zone moves downstream in the gas flow direction. Since the high temperature product gas generated in the reaction zone flows in the vicinity of the downstream side of the reaction zone, the vicinity of the downstream side is usually the highest temperature in the catalyst layer.
- the temperature of the region of the catalyst layer having the highest temperature is referred to as “the maximum temperature of the catalyst layer”.
- the temperature further downstream from the downstream vicinity is usually lower than the maximum temperature of the catalyst layer as the distance from the reaction zone increases.
- the measuring method using an insertion type thermometer is mentioned, for example.
- the region showing the maximum temperature of the catalyst layer also moves along with the movement of the reaction zone. Therefore, by previously placing the measurement part of the insertion type thermometer in the gas introduction part of the catalyst layer, by moving the measurement part downstream in the gas flow direction with the progress of the reaction after the start of the reaction, The maximum temperature of the catalyst layer can be measured.
- the “gas introduction part” means a part where the raw material mixed gas of the catalyst layer is introduced.
- the reaction is preferably carried out by controlling the maximum temperature of the catalyst layer to 130 ° C. or less, and more preferably carried out by controlling to 100 ° C. or less. If the maximum temperature of the catalyst layer is set to the upper limit value or less, an excessive temperature increase of the catalyst layer due to reaction heat can be suppressed.
- the number of hydrogen introduction sites is not particularly limited, and may be 2 or 3 or more.
- the number of hydrogen introduction points is two, one point from the gas introduction part that introduces hydrogen contained in the raw material mixed gas and one part that introduces only hydrogen gas (hereinafter referred to as “hydrogen introduction part”) .)) In a total of two places. From the viewpoint of simplifying the process, two locations are preferable.
- the reaction zone in the catalyst layer can be dispersed without changing the amount of chlorofluoroolefin introduced, and the generation of reaction heat can be prevented from being concentrated in one place, so that local excess of the catalyst layer can be achieved without reducing productivity. From the viewpoint of suppressing heat generation, three or more locations are preferable.
- the ratio of dividing hydrogen is that the reaction zone is dispersed and the maximum temperature of the catalyst layer is easily kept low. preferable.
- a gas introduction part of the catalyst layer (the uppermost stream side in the gas flow direction) using a mixed gas of a part of hydrogen introduced into the catalyst layer and the total amount of chlorofluoroolefin as a raw material mixed gas. And the remaining hydrogen is introduced from one or more hydrogen introduction portions downstream of the gas introduction portion ( ⁇ 1-1). As a result, further hydrogen is introduced from the hydrogen introduction part into the gas flowing from the upstream (usually a product gas after a part of the chlorofluoroolefin has reacted with hydrogen), and the hydrogen is downstream from the hydrogen introduction part. Reacts with unreacted chlorofluoroolefin on the side.
- the product gas in which the chlorofluoroolefin and hydrogen are sufficiently reacted is discharged from a gas discharge portion located on the most downstream side in the gas flow direction of the catalyst layer.
- the most downstream hydrogen introduction part in the gas flow direction is a catalyst layer between the hydrogen introduction part and the gas discharge part, and hydrogen introduced from the hydrogen introduction part and unreacted chlorofluoroolefin are separated from each other. It is preferable to be provided at a position where sufficient reaction is possible.
- a method for introducing hydrogen for example, a part of hydrogen is introduced from the gas introduction part of the first catalyst layer together with the chlorofluoroolefin, and the remaining part of the catalyst layer is introduced. There is a method of introducing hydrogen from the hydrogen filling part of the catalyst layer in the second and subsequent stages.
- Examples of a method for suppressing the maximum temperature of the catalyst layer other than the method ( ⁇ 1) to a desired temperature include a method of circulating an inert gas through the catalyst layer together with the chlorofluoroolefin and hydrogen (method ( ⁇ 2)).
- a method of circulating an inert gas through the catalyst layer together with the chlorofluoroolefin and hydrogen (method ( ⁇ 2)).
- a diluent gas other than the inert gas can be used instead of the inert gas or together with the inert gas.
- Examples of the inert gas include nitrogen gas, rare gas, and chlorofluorocarbons inert to hydrogenation reaction.
- Examples of the diluent gas other than the inert gas include hydrogen chloride.
- the amount of the inert gas introduced into the catalyst layer is such that the maximum temperature of the catalyst layer is easily maintained low, the by-product of the overreduced substance is easily suppressed, and the deterioration of the catalyst is easily suppressed.
- 0.1 mol or more is preferable with respect to mol, and 0.5 mol or more is more preferable.
- the introduction amount of the inert gas is preferably 10 mol or less, more preferably 4 mol or less with respect to 1 mol of the chlorofluoroolefin, from the viewpoint of the recovery rate of the inert gas.
- the temperature of the heating medium for heating the reactor is set to a lower temperature with the dew point of the raw material mixed gas being the lower limit.
- a method (method ( ⁇ 3)) By keeping the temperature of the heat medium low, it is possible to remove the reaction heat more quickly and suppress an excessive temperature rise of the catalyst layer.
- the lower the temperature of the catalyst layer is, the more advantageous it is to suppress the by-product of HFO-1234yf and a hyperreduct that is difficult to separate, so that the temperature is higher than the dew point and 50 ° C. It is preferable to make it less than.
- the dew point is higher than the dew point and not higher than 30 ° C.
- a method for suppressing the maximum temperature of the catalyst layer to a desired temperature it is preferable to use the method ( ⁇ 1), the method ( ⁇ 2) or the method ( ⁇ 3), or a combination of two or three of these methods.
- the reaction pressure is preferably normal pressure from the viewpoint of handleability.
- the contact time of the chlorofluoroolefin gas with the catalyst is preferably 4 to 60 seconds, more preferably 8 to 40 seconds. This contact time is the contact time of the chlorofluoroolefin gas calculated from the amount of gas introduced into the reactor and the volume of the catalyst layer.
- the ratio of chlorofluoroolefin and hydrogen introduced into the catalyst layer is the ratio of the number of moles of chlorine atoms in the chlorofluoroolefin to the total number of moles of hydrogen (H 2 / Cl), the value is preferably 0.7 or less, more preferably 0.6 or less, and even more preferably 0.5 or less.
- the ratio (H 2 / Cl) is preferably 0.1 or more and more preferably 0.2 or more from the viewpoint of the yield of the reaction product.
- the linear velocity u of the chlorofluoroolefin gas represented by the following formula (8) in the catalyst layer is preferably 0.1 to 100 cm / second, and preferably 1 to 30 cm / second. More preferred.
- This linear velocity u is the linear velocity of the chlorofluoroolefin gas calculated from the amount of gas introduced into the reactor and the catalyst layer volume. If the linear velocity u of the chlorofluoroolefin gas is equal to or higher than the lower limit, productivity is improved. When the linear velocity u of the chlorofluoroolefin gas is not more than the upper limit value, the reaction rate between the chlorofluoroolefin and hydrogen is improved.
- W shows the density
- V represents the flow volume (cm ⁇ 3 > / sec) of the total gas which distribute
- S represents the cross-sectional area (cm 2 ) of the catalyst layer with respect to the gas flow direction.
- Examples of the reactor used in the method ( ⁇ ) include known reactors that can be filled with a catalyst to form a catalyst layer.
- Examples of the material for the reactor include glass, iron, nickel, and alloys containing these as main components.
- the product gas after the reaction includes unreacted raw materials, reaction intermediates, and hydrogen chloride in addition to the target hydrofluoroolefin.
- Hydrogen chloride contained in the product gas can be removed by blowing the product gas into an alkaline aqueous solution to neutralize it.
- alkali used in the alkaline aqueous solution include sodium hydroxide and potassium hydroxide.
- a known method such as distillation can be employed as a method for separating the hydrofluoroolefin and unreacted chlorofluoroolefin from the product gas.
- the chlorofluoroolefin separated from the product gas after the reaction can be reused.
- the separated HCFO-1224yd may be reacted with hydrogen as a chlorofluoroolefin together with CFO-1214ya, or may be reacted with hydrogen only with HCFO-1224yd separately from CFO-1214ya.
- HCFO-1224yd is an intermediate for obtaining HFO-1234yf from the above-mentioned CFO-1214ya, and therefore usually has a small proportion of HCFO-1224yd.
- the ratio of HCFO-1224yd to the total amount of CFO-1214ya and HCFO-1224yd is preferably 50 mol% or less, more preferably 25 mol% or less.
- ⁇ Method ( ⁇ )> In the method ( ⁇ ), it is preferable to use a medium.
- the medium include water and organic solvents such as alcohol.
- the amount of the medium used is preferably 10 to 100 parts by mass with respect to 100 parts by mass of the chlorofluoroolefin.
- a method for supplying hydrogen a method in which hydrogen gas is blown into a liquid containing a catalyst-supporting carrier, a chlorofluoroolefin, and a medium to be used as required, or a medium in which hydrogen is previously dissolved by pressurization is used as a catalyst-supporting carrier and chlorofluoro
- the method of adding to the liquid containing an olefin, etc. are mentioned.
- the reaction of chlorofluoroolefin and hydrogen in the method ( ⁇ ) may be a batch method or a continuous method.
- the reaction temperature in the method ( ⁇ ) is preferably 0 to 150 ° C., more preferably 20 to 100 ° C. If reaction temperature is more than a lower limit, the reaction rate of a chlorofluoro olefin and hydrogen will improve. If reaction temperature is 150 degrees C or less, it will be easy to suppress the byproduct of a hyperreductant.
- the reaction pressure in the method ( ⁇ ) is preferably 0.01 to 5 MPaG, more preferably 0.1 to 1 MPaG in terms of gauge pressure.
- the reaction time is preferably 1 to 50 hours for a batch system, and 1 to 60 seconds for a continuous system.
- the supply amount of hydrogen in the method ( ⁇ ) is the ratio of the number of moles of chlorine atoms in the chlorofluoroolefin to the number of moles of hydrogen to be supplied (H 2 / Cl, since it is easy to suppress by-product formation of the hyperreductant. ) Is preferably 0.7 or less, more preferably 0.6 or less, and even more preferably 0.5 or less.
- the ratio (H 2 / Cl) is preferably 0.1 or more, and more preferably 0.2 or more, from the viewpoint of the yield of HFO-1234yf.
- the supply amount of hydrogen means the amount of hydrogen dissolved in the reaction solution.
- the reaction liquid after the reaction contains unreacted raw materials, reaction intermediates, and hydrogen chloride in addition to the target hydrofluoroolefin.
- Hydrogen chloride contained in the reaction solution can be removed by adding an alkali to the reaction solution to neutralize it.
- alkali include sodium hydroxide and potassium hydroxide. You may add the said alkali previously to the reaction liquid used for reaction.
- a known method such as distillation can be employed as a method for separating hydrofluoroolefin and unreacted chlorofluoroolefin from the reaction solution.
- the chlorofluoroolefin separated from the reaction solution can be reused.
- separated HCFO-1224yd may be reacted with hydrogen as a raw material chlorofluoroolefin together with CFO-1214ya, or separated from CFO-1214ya and reacted with hydrogen only with HCFO-1224yd.
- Examples of the reactor used in the method ( ⁇ ) include known reactors in which a reaction raw material can be brought into contact with each other in the presence of a catalyst to cause a liquid phase reaction.
- Examples of the material for the reactor include glass; iron, nickel, and alloys containing these as main components.
- Metals such as platinum group elements and second elements have different chemisorption capabilities of hydrogen depending on the element (see New Catalytic Chemistry, Second Edition, Sankyo Publishing Co., p181, “Metal adsorption capacity” in Table 8-1) .
- the second element used in the present invention has a lower hydrogen chemisorption capacity than the platinum group metal. Therefore, in the present invention, it is considered that the hydrogen adsorption force on the surface of the platinum group metal is suppressed by alloying the platinum group element and the second element.
- the reaction apparatus 101 shown in the schematic diagram of FIG. 1 was used.
- the reaction apparatus 101 includes two reaction tubes 110A and 110B and a salt bath 130 in which these are immersed.
- the reaction tube 110A has two catalyst filling portions 113a and 114a on the inlet 111a side and the outlet 112a side.
- the reaction tube 110B has two catalyst filling portions 113b and 114b on the inlet 111b side and the outlet 112b side.
- the outlet 112a of the reaction tube 110A and the inlet 111b of the reaction tube 110B are connected by a pipe.
- reaction tubes 110A and 110B reaction tubes made of Inconel (trademark) 600 having an inner diameter of 2.54 cm and a length of 100 cm were used. Also, activated carbon (BET specific surface area 1100 m 2 / g) is used as a carrier, platinum and gold are supported by a known method using chloroplatinic acid and gold chloride, and heat-treated at 500 ° C. for 3 hours under a nitrogen gas flow. Thus, alloying treatment was performed to produce a catalyst-supporting carrier.
- Pd—Au / C It was a supported activated carbon (hereinafter referred to as “Pd—Au / C”).
- the catalyst filling portion 114a on the outlet 112a side of the reaction tube 110A was filled with the Pd—Au / C to form a catalyst layer 120A having a height of 40 cm.
- the catalyst filling portions 113b and 114b on the inlet 111b side and the outlet 112b side of the reaction tube 110B were filled with the Pd—Au / C, respectively, to form a catalyst layer 120B and a catalyst layer 120C each having a height of 40 cm.
- the packing density of Pd—Au / C in the catalyst layers 120A to 120C was 0.73 g / cm 3 .
- the reaction tube 110A and the reaction tube 110B were immersed in the salt bath 130 so that the catalyst layers 120A to 120C were all immersed, and the catalyst layers 120A to 120C were heated to 80 ° C.
- the contact time of the chlorofluoroolefin gas (A) with respect to the catalyst layers 120A to 120C was 18 seconds, and the linear velocity u of the chlorofluoroolefin gas (A) was 7 cm / second.
- the hydrogen gas (B) 50% of the hydrogen gas (B) was introduced from the inlet 111a of the reaction tube 110A together with the chlorofluoroolefin gas (A), and the remainder was introduced into a pipe portion connecting the reaction tube 110A and the reaction tube 110B. That is, the hydrogen gas (B) is divided into two portions of the catalyst layer 120A (0 cm point) and the catalyst layer 120B (40 cm point) in the catalyst layer (catalyst layer length 120 cm) composed of the catalyst layers 120A to 120C. Introduced. The maximum temperatures of the catalyst layers 120A to 120C during the reaction were measured by insertion type thermometers 140A to 140C inserted in the catalyst layers, respectively.
- Pd—Cu / C palladium-copper catalyst-supported activated carbon
- the reaction was carried out in the same manner as in Example 1 except that palladium-tin catalyst-supported activated carbon (referred to as “Pd—Sn / C”) carrying part was used.
- Pd—Sn / C palladium-tin catalyst-supported activated carbon
- the reaction was carried out in the same manner as in Example 1 except that palladium-bismuth catalyst-supported activated carbon (referred to as “Pd—Bi / C”) was used.
- Pd—Bi / C palladium-bismuth catalyst-supported activated carbon
- Example 5 A palladium-gold catalyst-supported ⁇ -alumina (hereinafter referred to as “Pd—Au / ⁇ -Al”) using ⁇ -alumina (BET specific surface area of 130 m 2 / g) instead of activated carbon was used as the carrier. Were reacted in the same manner as in Example 1. As a result of GC analysis of the product gas (D), the content of HFC-254eb was 10.0% by volume, and the content of HFO-1243zf relative to HFO-1234yf was 610 volume ppm.
- Comparative Example 3 Comparative Example 2 except that palladium-supported ⁇ -alumina (hereinafter referred to as “Pd / Al”) using ⁇ -alumina (BET specific surface area of 130 m 2 / g) instead of activated carbon was used as the carrier. The reaction was conducted in the same manner. As a result of GC analysis of the product gas (D), the content of HFC-254eb was 17.2% by volume, and the content of HFO-1243zf relative to HFO-1234yf was 700 ppm by volume.
- Example 6 A palladium-gold catalyst-supported ⁇ -alumina (hereinafter referred to as “Pd—Au / ⁇ -Al”) using ⁇ -alumina (BET specific surface area 12 m 2 / g) instead of activated carbon was used as the carrier.
- the reaction was carried out in the same manner as in Example 1.
- the content of HFC-254eb was 7.3 vol%
- the content of HFO-1234zf with respect to HFO-1234yf was 45 ppm by volume.
- Example 4 Example 1 except that palladium-supported ⁇ -alumina (hereinafter referred to as “Pd / ⁇ -Al”) using ⁇ -alumina (BET specific surface area 12 m 2 / g) instead of activated carbon was used as the carrier.
- Pd / ⁇ -Al palladium-supported ⁇ -alumina
- BET specific surface area 12 m 2 / g ⁇ -alumina
- the reaction was carried out in the same manner as above.
- the content of HFC-254eb was 25.8% by volume
- the content of HFO-1234zf relative to HFO-1234yf was 125 ppm by volume.
- Table 1 shows the conditions of Examples 1 to 6 and Comparative Examples 1 to 4, the contents of HFC-254eb in the product gas (D), and the contents of HFO-1243zf relative to HFO-1234yf.
- the amount of HFO-1243zf with respect to HFO-1234yf was a remarkably low value of 0 ppm by volume while the amount was suppressed to 8.4% by volume or less.
- Comparative Examples 3 and 4 in which a second element such as gold was not used were used. In comparison, the production of the hyperreductants HFC-254eb and HFO-1243zf was suppressed.
- the hydrofluoroolefin obtained by the production method of the present invention has high purity because the by-product of the overreduced product is suppressed. Therefore, the obtained hydrofluoroolefin can be used as a refrigerant in place of chlorofluorocarbons or other chlorofluorocarbons without requiring a purification separation means. It should be noted that the entire content of the specification, claims, abstract and drawings of Japanese Patent Application No. 2014-170502 filed on August 25, 2014 is cited here as disclosure of the specification of the present invention. Incorporated.
Abstract
Description
HFO-1234yfの製造方法としては、例えば、1,1-ジクロロ-2,2,3,3,3-ペンタフルオロプロパン(CF3CF2CHCl2)(以下、「HCFC-225ca」とも称する。)を脱フッ化水素反応して1,1-ジクロロ-2,3,3,3-テトラフルオロプロペン(CF3CF=CCl2)(以下、「CFO-1214ya」とも称する。)を得た後、該CFO-1214yaを水素と反応させて還元することでHFO-1234yfを得る方法が挙げられる。
CF3CF=CCl2+2H2→CF3CF=CH2+2HCl ・・・(6)
過還元体が多いと、目的物の収率が下がるため、製造効率が低下する。また、HFO-1243zfは、目的物であるHFO-1234yfと沸点が近いため、後段の蒸留によって分離除去しにくい。そのため、蒸留によって得られるHFO-1234yfに、HFO-1243zfが不純物として残り、高純度の製品を得るには分離精製工程が別途必要である。
CF2=CClF+H2→CF2=CHF+HCl ・・・(9)
さらに、特許文献4には、下記方法(iv)が開示されている。
(iv)活性炭に担持されたパラジウム触媒存在下に、1,2-ジクロロジフルオロエチレンと水素ガスとを、150~600℃、好ましくは200~400℃にて、下記式(10)で示される反応に基づき反応させる方法。
CClF=CClF+2H2→CHF=CHF+2HCl ・・・(10)
しかし、方法(iii)および方法(iv)においても、目的物と共に過還元体が副生するため、目的物の純度が低下する。
[1]担体に担持された触媒の存在下に、下記式(1)で表されるクロロフルオロオレフィンを水素と反応させて下記式(2)で表されるハイドロフルオロオレフィンを得る、ハイドロフルオロオレフィンの製造方法であって、
前記触媒は、パラジウムおよび白金からなる群より選ばれる少なくとも1種の白金族元素と、マンガン、銅、アルミニウム、金、リチウム、ナトリウム、カリウム、マグネシウム、銀、亜鉛、カドミウム、インジウム、ケイ素、ゲルマニウム、スズ、鉛、ヒ素、アンチモンおよびビスマスからなる群より選ばれる少なくとも1種の第2の元素とを含む合金からなる触媒であることを特徴とする、ハイドロフルオロオレフィンの製造方法。
CZX=CClY ・・・(1)
(Xはフッ素原子または塩素原子であり、Yはフッ素原子、塩素原子または水素原子であり、Zはフッ素原子またはCF3である。)
CZX’=CHY’ ・・・(2)
(前記Xがフッ素原子の場合X’はフッ素原子であり、前記Xが塩素原子の場合X’は水素原子であり、前記Yがフッ素原子の場合Y’はフッ素原子であり、前記Yが塩素原子または水素原子の場合Y’は水素原子であり、Zは前記式(1)のZと同じである。)
[3]前記合金における前記白金族元素と前記第2の元素との含有比率(白金族元素:第2の元素)が、質量比で60:40~99:1である、[1]または[2]に記載のハイドロフルオロオレフィンの製造方法。
[4]前記触媒が、パラジウムと、銅、金、スズ、アンチモンおよびビスマスらなる群より選ばれる少なくとも1種の第2の元素との合金からなる触媒である、[1]~[3]のいずれかに記載のハイドロフルオロオレフィンの製造方法。
[6]前記担体が、アルミナ、シリカ、チタニアおよびジルコニアからなる群より選ばれる少なくとも1種である、[1]~[4]のいずれかに記載のハイドロフルオロオレフィンの製造方法。
[7]前記合金触媒の担持量が担体に対して0.1~10質量%である、[1]~[6]のいずれかに記載のハイドロフルオロオレフィンの製造方法。
[9]前記クロロフルオロオレフィンと前記水素を前記触媒層のガス導入部に導入するとともに、前記触媒層のガス導入部とガス排出部との間の少なくとも1か所から前記水素を導入する、[8]に記載のハイドロフルオロオレフィンの製造方法。
[10]前記触媒層の最高温度を130℃以下に制御して反応を行う、[8]または[9]に記載のハイドロフルオロオレフィンの製造方法。
[11]前記触媒層に導入するクロロフルオロオレフィンと水素の割合が、クロロフルオロオレフィン中の塩素原子のモル数と水素の総モル数との比(H2/Cl)で表わして、0.1~0.7である、[8]~[10]のいずれかに記載のハイドロフルオロオレフィンの製造方法。
[13]前記クロロフルオロオレフィンが、クロロトリフルオロエチレン、トランス-1,2-ジクロロ-1,2-ジフルオロエチレン、シス-1,2-ジクロロ-1,2-ジフルオロエチレン、1,1-ジクロロ-2,3,3,3-テトラフルオロプロペンおよび1-クロロ-2,3,3,3-テトラフルオロプロペンからなる群より選ばれる少なくとも1種である、[1]~[12]のいずれかに記載のハイドロフルオロオレフィンの製造方法。
[14]1,1-ジクロロ-2,3,3,3-テトラフルオロプロペンから2,3,3,3-テトラフルオロプロペンを製造する、[1]~[12]のいずれかに記載のハイドロフルオロオレフィンの製造方法。
本発明は、担体に担持された触媒の存在下に、前記式(1)で表されるクロロフルオロオレフィンを水素と反応させて前記式(2)で表されるハイドロフルオロオレフィンを得る、ハイドロフルオロオレフィンの製造方法である。
また、該製造方法に用いられる上記触媒は、パラジウムおよび白金からなる群より選ばれる少なくとも1種の白金族元素と、マンガン、銅、アルミニウム、金、リチウム、ナトリウム、カリウム、マグネシウム、銀、亜鉛、カドミウム、インジウム、ケイ素、ゲルマニウム、スズ、鉛、ヒ素、アンチモンおよびビスマスからなる群より選ばれる少なくとも1種の第2の元素とを含む合金からなる触媒である。
本発明は、上記式(1)で表されるクロロフルオロオレフィンと水素とを反応させて、上記式(2)で表されるハイドロフルオロオレフィンを製造する方法である。
以下、原料の一つである上記式(1)で表されるクロロフルオロオレフィンと、該クロロフルオロオレフィンを用いた場合の反応生成物について説明する。
本発明の原料の一つであるクロロフルオロオレフィンは、前記式(1)で表される化合物である。前記式(1)で表されるクロロフルオロオレフィンの中でも、生成物が高冷却効率、地球環境に優しい代替冷媒として期待されている点から、クロロトリフルオロエチレン、トランス-1,2-ジクロロ-1,2-ジフルオロエチレン、シス-1,2-ジクロロ-1,2-ジフルオロエチレン、CFO-1214ya、1-クロロ-2,3,3,3-テトラフルオロプロペン(以下、「HCFO-1224yd」とも称する。)が好ましい。また、CFO-1214yaとHCFO-1224ydとの混合物も好ましい。
なお、以下、幾何異性体のうち、トランス体を化合物名や化学式の頭に(E)を付して表し、シス体を化合物名や化学式の頭に(Z)を付して表す。
前記HCFC-225caを含むHCFC-225は、市販品を使用してもよい。市販品としては、アサヒクリン(商標)AK225(旭硝子社製、HCFC-225caの48モル%と、HCFC-225cbの52モル%の混合物。以下、「AK225」という。)等が挙げられる。
前記相間移動触媒としては、テトラブチルアンモニウムブロマイド(TBAB)が好ましい。
本発明の製造方法で得られる目的の反応生成物は、前記式(2)で表される化合物である。前記式(2)のX’、Y’、Zの種類は、原料の一つである前記式(1)で表されるクロロフルオロオレフィンのX、Y、Zの種類に対応関係がある。
前記式(1)におけるXがフッ素原子の場合、X’はフッ素原子である。Xが塩素原子の場合、X’は水素原子である。
前記式(1)におけるYがフッ素原子の場合、Y’はフッ素原子である。Yが塩素原子または水素原子の場合、Y’は水素原子である。
前記式(1)におけるZは、上記式(1)のZと同じである。
CFCl=CF2+H2→CHF=CF2+HCl ・・・(3)
(E)-CFCl=CFCl+2H2→(E)-CHF=CHF+2HCl ・・・(4)
(Z)-CFCl=CFCl+2H2→(Z)-CHF=CHF+2HCl ・・・(5)
CF3CF=CCl2+2H2→CF3CF=CH2+2HCl ・・・(6)
CF3CF=CHCl+H2→CF3CF=CH2+HCl ・・・(7)
本発明における触媒は、特定の白金族元素と第2の元素とを含む合金からなる。
本発明における特定の白金族元素は、パラジウムおよび白金からなる群より選ばれる少なくとも1種の白金族元素である。パラジウムおよび白金のいずれか一方からなる場合、パラジウムまたは白金は、第2の元素と合金を形成している。また、パラジウムおよび白金の両方からなる場合、パラジウムおよび白金は、混合物であってもよく、合金であってもよい。混合物である場合、パラジウムおよび白金の少なくとも一方が第2の元素と合金を形成している。パラジウムと白金の合金である場合、該合金をパラジウム-白金合金と呼ぶ。
パラジウムからなる触媒は、水素還元反応に対してより高い転化率、選択率を有する。一方、白金からなる触媒は、より高い耐酸性を有し、触媒寿命がより長い。いずれの特徴をも享受する点から、特定の白金族元素としてはパラジウムおよび白金の両方を用いることが好ましく、パラジウム-白金合金がより好ましい。
以下、特に言及しない限り、白金族元素とは上記特定の白金族元素をいい、その単体を白金族金属という。
上記白金族元素の単体を触媒として本発明の反応を行うと、白金族金属の水素還元活性が高すぎ、過還元体が副生しやすくなる。一方、白金族元素と所定の第2の元素との合金を触媒とすると、白金族金属の水素還元活性が抑えられ、過還元体の副生が抑制される。また、合金にすることにより、触媒耐久性の向上も図られる。
これら過還元体の副生の抑制と触媒耐久性の向上効果をさらに高めるため、白金族元素および第2の元素の合金固溶化を、窒素ガス、アルゴンガス等の不活性ガスの雰囲気下または微量水素を含有した還元雰囲気下で加熱処理して行うと、白金族元素と第2の元素とがより均一な状態で合金化されるのでより好ましい。
白金族元素および第2の元素以外の元素が含まれている場合の、該「白金族元素および第2の元素以外の元素」の含有割合は、白金族元素と第2の元素の合計量の100質量部に対して、0.01~20質量部が好ましい。
前記触媒は担体に担持して使用される。合金を分散担持するために担体を用いることが好適である。
担体としては、活性炭、カーボンブラック、カーボンファイバー等のカーボン系材料、アルミナ、シリカ、チタニア、ジルコニア等の酸化物系材料等が挙げられる。中でも、比表面積が比較的大きく、合金を担持させやすい点から、活性炭、アルミナが好ましく、過還元体の副生をより抑制できる点から、活性炭がより好ましい。
活性炭の形態としては、長さ2~5mm程度の成形炭の集合物、4~50メッシュ程度の破砕炭、粒状炭等が挙げられる。中でも、前記成形炭の集合物、または4~20メッシュの破砕炭が好ましい。
触媒担持担体の比表面積は、N2ガス吸着法、例えば、BET法に準拠した方法で測定される。
触媒担持担体は、公知の方法により製造することができる。たとえば、含浸法やコロイド法等が挙げられる。
含浸法は触媒担持担体製造方法の最も一般的な方法である。担体に触媒金属塩溶液を接触させ、担体の表面に触媒金属の塩を吸着させ、含浸させた担体を乾燥させた後、担体表面の金属塩に還元剤を接触させ、金属塩を還元して触媒金属成分を担体表面に担持させる手法である。還元剤としては、アンモニア、ヒドラジン、水素化ホウ素ナトリウムなどの還元作用のある化合物や水素などの還元性ガスでもよくアルコール類、アルデヒド類、有機酸及びその塩、水素化ホウ素及びその塩、ヒドラジン類の還元性液でもよい。
コロイド法は金属微粒子分散液を担体表面に吸着させ、乾燥させることより、金属微粒子を担持した担体粒子が得られる。金属微粒子分散液は、金属塩を溶媒に溶解し、還元剤により還元されることから得られる。金属微粒子の分散性を上げるため、保護剤として高分子有機化合物を使用してもよく、使用しなくてもよい。一般的に使用された保護剤はポリビニルピロリドン、ポリエチレンイミン、ポリアリルアミン、ポリ(N-カルボキシメチル)アリルアミン、ポリ(N,N-ジカルボキシメチル)アリルアミン、ポリ(N-カルボキシメチル)エチレンイミン等が知られている。
反応は、上述の触媒を用いていれば、気相で行ってもよく、液相で行ってもよい。
反応方法は、下記の方法(α)または方法(β)が挙げられる。
方法(α):触媒存在下に、クロロフルオロオレフィンと水素とを気相で反応させる方法。方法(β):触媒存在下に、クロロフルオロオレフィンと水素とを液相で反応させる方法。
方法(α)としては、例えば、触媒担持担体が充填された反応器に、クロロフルオロオレフィンと水素とを導入して気相で反応させる方法が挙げられる。該方法の具体例としては、該反応器にクロロフルオロオレフィンガスと水素ガスとを含むガス(以下、「原料混合ガス」とも称する。)を導入して反応させる方法が挙げられる。
流動床反応器では、反応流体によって触媒層があたかも流体のような特性を示すような操作を行うため、触媒担持担体粒子は、反応流体中に懸濁され反応器内を移動する。
本発明では、固定床反応器、流動床反応器のいずれも使用できるが、触媒反応の選択性を低下させず触媒劣化を抑えるために、反応温度を適切に制御できる固定床反応器が好ましい。固定床反応器としては、管型反応器と槽型反応器があり、反応温度の制御しやすさから管型反応器が好ましく用いることができる。さらに、管径の小さい反応管を多数並列に配置し、外側に熱媒体を循環させる多管熱交換式反応などが採用できる。なお、反応器を複数直列に設ける場合、複数の触媒層が設けられることになる。
触媒層は、少なくとも一段あればよく、二段以上あってもよい。
クロロフルオロオレフィンと水素とは、通常、触媒層の一部の領域(以下、「反応域」という。)で反応する。触媒層中の反応温度を所望の温度に保つ場合、通常、触媒層のうち反応域の上流側の温度を加熱により維持する。本明細書では、この加熱により維持する反応域の上流側の温度を「触媒層の温度」という。
例えば、クロロフルオロオレフィンとして沸点が46℃のCFO-1214yaを用いる場合、反応性を考慮して、50℃以上が好ましく、60℃以上がより好ましい。また、クロロフルオロオレフィンとして沸点が推定で15~17℃のHCFO-1224ydを用いる場合、20℃以上が好ましく、30℃以上がより好ましい。
反応域の下流側近傍には、反応域で生成した温度の高い生成ガスが流れこむため、該下流側近傍は、通常、触媒層の中でも最も高温になっている。本明細書では、この最も高温になっている触媒層の領域の温度を「触媒層の最高温度」という。該下流側近傍からさらに下流側の温度は、通常、反応域から離れるにつれ、触媒層の最高温度から低くなっている。
なお、本明細書において「ガス導入部」とは、触媒層の原料混合ガスを導入する箇所を意味する。
方法(α1)において、水素の導入箇所の数は特に限定されず、2箇所であってもよく、3箇所以上であってもよい。水素の導入箇所の数が2箇所の場合としては、原料混合ガス中に含まれる水素を導入するガス導入部からの1箇所と、水素ガスのみを導入する箇所(以下、「水素導入部」という。)の1箇所の合計2箇所を設ける場合が挙げられる。
プロセスを簡略化できる観点からは、2箇所が好ましい。クロロフルオロオレフィンの導入量を変化させずに触媒層における反応域を分散でき、反応熱の発生が1箇所に集中することを防げ、そのため生産性を低下させずに、触媒層の局所的な過剰発熱を抑制できる観点からは、3箇所以上が好ましい。
水素を分割して導入する場合の水素を分割する割合は、反応域を分散させ、触媒層の最高温度を低く維持しやすい点からは、水素を各箇所に均等に分割して導入するのが好ましい。
方法(α1-1)において、ガス導入部と最初の水素導入部との間で、原料混合ガス中の水素の少なくとも一部が、クロロフルオロオレフィンと反応していることが好ましい。また、ガスの流れ方向の最下流側の水素導入部は、該水素導入部とガス排出部との間の触媒層で、該水素導入部から導入された水素と未反応のクロロフルオロオレフィンとを充分に反応させることができる位置に設けられることが好ましい。
不活性ガスとしては、窒素ガス、希ガス、水素化反応に不活性なフロン類等が挙げられる。不活性ガス以外の希釈ガスとしては塩化水素等が挙げられる。
方法(α3)においては、前記触媒層の温度は、低い温度であるほどHFO-1234yfと分離困難な過還元体の副生を抑制するのに有利であることより、露点よりも高くかつ50℃未満とすることが好ましい。より好ましくは、露点よりも高くかつ30℃以下である。
触媒層の最高温度を所望の温度に抑える方法は、方法(α1)、方法(α2)もしくは方法(α3)、またはこれらの方法のうち2つもしくは3つを併用することが好ましい。
クロロフルオロオレフィンガスの触媒との接触時間は、4~60秒が好ましく、8~40秒がより好ましい。この接触時間は、反応器に導入されるガス量と触媒層体積から計算されるクロロフルオロオレフィンガスの接触時間である。
u=(W/100)×V/S ・・・(8)
ただし、式(8)中、Wは前記触媒層を流通する全ガス中のクロロフルオロオレフィンガスの濃度(モル%)を示し、Vは前記触媒層を流通する全ガスの流量(cm3/秒)を示し、Sは前記触媒層のガスの流通方向に対する断面積(cm2)を示す。
反応器の材質としては、例えば、ガラス、鉄、ニッケル、またはこれらを主成分とする合金等が挙げられる。
生成ガスに含まれる塩化水素は、該生成ガスをアルカリ水溶液に吹き込んで中和することにより除去できる。前記アルカリ水溶液に使用するアルカリとしては、水酸化ナトリウム、水酸化カリウム等が挙げられる。
反応後の生成ガスから分離したクロロフルオロオレフィンは再利用できる。例えば、分離したHCFO-1224ydは、CFO-1214yaと共にクロロフルオロオレフィンとして水素と反応させてもよく、CFO-1214yaとは別にHCFO-1224ydのみで水素と反応させてもよい。
クロロフルオロオレフィンとしてCFO-1214yaとHCFO-1224ydの混合物を使用する場合、HCFO-1224ydは上記CFO-1214yaからHFO-1234yfを得る際の中間体であることから、通常、HCFO-1224ydの割合の少ない混合物が使用される。よって、CFO-1214yaとHCFO-1224ydの合計量に対するHCFO-1224ydの割合は50モル%以下が好ましく、25モル%以下がより好ましい。
方法(β)においては、媒体を使用することが好ましい。媒体としては、水、アルコール等の有機溶媒等が挙げられる。
媒体の使用量は、クロロフルオロオレフィン100質量部に対して、10~100質量部が好ましい。
方法(β)におけるクロロフルオロオレフィンと水素の反応は、回分式でもよく、連続式でもよい。
方法(β)における反応圧力は、ゲージ圧で0.01~5MPaGが好ましく、0.1~1MPaGがより好ましい。
方法(β)における反応時間は、回分式であれば1~50時間が好ましく、連続式であれば1~60秒が好ましい。
前記アルカリは、反応に使用する反応液に予め添加してもよい。
反応液から分離したクロロフルオロオレフィンは再利用できる。例えば、分離したHCFO-1224ydは、CFO-1214yaと共に、原料のクロロフルオロオレフィンとして水素と反応させてもよく、CFO-1214yaと分離してHCFO-1224ydのみで水素と反応させてもよい。
反応器の材質としては、例えば、ガラス;鉄、ニッケル、またはこれらを主成分とする合金等が挙げられる。
以上説明したように、担体に担持された前記合金触媒を用いることにより、過還元体の副生が抑制されたハイドロフルオロオレフィンが得られる。
パラジウムまたは白金を特定の第2の元素と合金化することにより、該白金族金属が有する水素還元活性が低減され、過還元体の副生が抑制されると推定される。その結果、目的物の合成選択率を向上させることができる。そのメカニズムは、以下のように推定される。
本発明で用いられる第2の元素は、白金族金属よりも水素の化学吸着能が低い。そのため、本発明では、白金族元素と第2の元素とを合金化することにより、該白金族金属の表面への水素吸着力が抑えられていると考えられる。白金族金属表面への水素吸着力が抑えられているため、該白金族金属の触媒活性は抑えられる。その結果、白金族金属の過剰な水素還元活性が低減できるため、目的物の合成選択率が向上し、過還元体の副生が抑制される。
このように、本発明の製造方法によれば、過還元体の濃度が低い、高純度のハイドロフルオロオレフィンを製造することができる。
CFO-1214yaの製造:
AK225を反応原料として用いて、以下の方法によりCFO-1214yaを製造した。
HFO-1234yfの製造:
HFO-1234yfの製造には、図1の模式図に示す反応装置101を用いた。
反応装置101は、2本の反応管110A、110Bと、これらを浸漬する塩浴130とを備えている。反応管110Aは、その入口111a側と出口112a側に2箇所の触媒充填部113a、114aを有する。同様に、反応管110Bは、その入口111b側と出口112b側に2箇所の触媒充填部113b、114bを有する。反応管110Aの出口112aと反応管110Bの入口111bは配管で連結されている。
製造例1で得られたCFO-1214yaからなるクロロフルオロオレフィンガス(A)、水素ガス(B)、および窒素ガス(C)を、総量のモル比が水素/CFO-1214ya/窒素=1/1/2となるように反応管110Aおよび110Bに流通させた。触媒層120A~120Cに対するクロロフルオロオレフィンガス(A)の接触時間は18秒とし、クロロフルオロオレフィンガス(A)の線速度uは7cm/秒とした。
反応中の触媒層120A~120Cの最高温度は、それら触媒層にそれぞれ挿入した挿し込み型の温度計140A~140Cにより測定した。
触媒担持担体としてPd-Au/Cに代えて、実施例1と同様の活性炭の100質量部に対して、パラジウム-銅合金(パラジウム:銅=87:13(質量比))の0.5質量部を担持させた、パラジウム-銅触媒担持活性炭(「Pd-Cu/C」と称する。)を用いた以外は、実施例1と同様にして反応を行った。
生成ガス(D)をGC分析したところ、HFC-254ebの含有量は6.3体積%、HFO-1234yfに対するHFO-1243zfの含有量は0体積ppmであった。
触媒担持担体としてPd-Au/Cに代えて、実施例1と同様の活性炭の100質量部に対して、パラジウム-スズ合金(パラジウム:スズ=78:22(質量比))の0.5質量部を担持させた、パラジウム-スズ触媒担持活性炭(「Pd-Sn/C」と称する。)を用いた以外は、実施例1と同様にして反応を行った。
生成ガス(D)をGC分析したところ、HFC-254ebの含有量は8.4体積%、HFO-1234yfに対するHFO-1243zfの含有量は0体積ppmであった。
触媒担持担体としてPd-Au/Cに代えて、実施例1と同様の活性炭の100質量部に対して、パラジウム-ビスマス合金(パラジウム:ビスマス=67:33(質量比))の0.5質量部を担持させた、パラジウム-ビスマス触媒担持活性炭(「Pd-Bi/C」と称する。)を用いた以外は、実施例1と同様にして反応を行った。
生成ガス(D)をGC分析したところ、HFC-254ebの含有量は2.3体積%、HFO-1234yfに対するHFO-1243zfの含有量は0体積ppmであった。
触媒担持担体としてPd-Au/Cに代えて、実施例1と同様の活性炭の100質量部に対して、パラジウム-ルテニウム合金(パラジウム:ルテニウム=80.8:19.2(質量比))の0.5質量部を担持させた、パラジウム-ルテニウム触媒担持活性炭(「Pd-Ru/C」と称する。)を用いた以外は、実施例1と同様にして反応を行った。
生成ガス(D)をGC分析したところ、HFC-254ebの含有量は18.4体積%、HFO-1234yfに対するHFO-1243zfの含有量は0体積ppmであった。
触媒担持担体としてPd-Au/Cに代えて、実施例1と同様の活性炭の100質量部に対して、0.5質量部のパラジウムを担持させた、パラジウム触媒担持活性炭(以下、「Pd/C」と称する。)を用いた以外は、実施例1と同様にして反応を行った。
生成ガス(D)をGC分析したところ、HFC-254ebの含有量は10.1体積%、HFO-1234yfに対するHFO-1243zfの含有量は1220体積ppmであった。
担体として、活性炭に代えてγ-アルミナ(BET比表面積130m2/g)を用いたパラジウム-金触媒担持γ-アルミナ(以下、「Pd-Au/γ-Al」と称する。)を用いた以外は、実施例1と同様にして反応を行った。
生成ガス(D)をGC分析したところ、HFC-254ebの含有量は10.0体積%、HFO-1234yfに対するHFO-1243zfの含有量は610体積ppmであった。
担体として、活性炭に代えてγ-アルミナ(BET比表面積130m2/g)を用いたパラジウム触媒担持γ-アルミナ(以下、「Pd/Al」と称する。)を用いた以外は、比較例2と同様にして反応を行った。
生成ガス(D)をGC分析したところ、HFC-254ebの含有量は17.2体積%、HFO-1234yfに対するHFO-1243zfの含有量は700体積ppmであった。
担体として、活性炭に代えてα-アルミナ(BET比表面積12m2/g)を用いたパラジウム-金触媒担持α-アルミナ(以下、「Pd-Au/α-Al」と称する。)を用いた以外は、実施例1と同様にして反応を行った。
生成ガス(D)をGC分析したところ、HFC-254ebの含有量は7.3体積%、HFO-1234yfに対するHFO-1234zfの含有量は45体積ppmであった。
担体として、活性炭に代えてα-アルミナ(BET比表面積12m2/g)を用いたパラジウム触媒担持α-アルミナ(以下、「Pd/α-Al」と称する。)を用いた以外は、実施例1と同様にして反応を行った。
生成ガス(D)をGC分析したところ、HFC-254ebの含有量は25.8体積%、HFO-1234yfに対するHFO-1234zfの含有量は125体積ppmであった。
また、パラジウムと金との合金をγ-アルミナ、α―アルミナに担持させた触媒担持担体を用いた実施例5、6では、金等の第2の元素を用いなかった比較例3、4に比べ、過還元体であるHFC-254ebおよびHFO-1243zfの生成が抑制された。
なお、2014年8月25日に出願された日本特許出願2014-170502号の明細書、特許請求の範囲、要約書および図面の全内容をここに引用し、本発明の明細書の開示として、取り入れるものである。
120A~120C 触媒層
A クロロフルオロオレフィンガス
B 水素ガス
C 窒素ガス
D 生成ガス
Claims (14)
- 担体に担持された触媒の存在下に、下記式(1)で表されるクロロフルオロオレフィンを水素と反応させて下記式(2)で表されるハイドロフルオロオレフィンを得る、ハイドロフルオロオレフィンの製造方法であって、
前記触媒は、パラジウムおよび白金からなる群より選ばれる少なくとも1種の白金族元素と、マンガン、銅、アルミニウム、金、リチウム、ナトリウム、カリウム、マグネシウム、銀、亜鉛、カドミウム、インジウム、ケイ素、ゲルマニウム、スズ、鉛、ヒ素、アンチモンおよびビスマスからなる群より選ばれる少なくとも1種の第2の元素とを含む合金からなる触媒であることを特徴とする、ハイドロフルオロオレフィンの製造方法。
CZX=CClY ・・・(1)
(Xはフッ素原子または塩素原子であり、Yはフッ素原子、塩素原子または水素原子であり、Zはフッ素原子またはCF3である。)
CZX’=CHY’ ・・・(2)
(前記Xがフッ素原子の場合X’はフッ素原子であり、前記Xが塩素原子の場合X’は水素原子であり、前記Yがフッ素原子の場合Y’はフッ素原子であり、前記Yが塩素原子または水素原子の場合Y’は水素原子であり、Zは前記式(1)のZと同じである。) - 前記第2の元素が、銅、金、スズ、アンチモンおよびビスマスからなる群より選ばれる少なくとも1種である、請求項1に記載のハイドロフルオロオレフィンの製造方法。
- 前記合金における前記白金族元素と前記第2の元素との含有比率(白金族元素:第2の元素)が、質量比で60:40~99:1である、請求項1または2に記載のハイドロフルオロオレフィンの製造方法。
- 前記触媒が、パラジウムと、銅、金、スズ、アンチモンおよびビスマスらなる群より選ばれる少なくとも1種の第2の元素との合金からなる触媒である、請求項1~3のいずれか一項に記載のハイドロフルオロオレフィンの製造方法。
- 前記担体が、活性炭、カーボンブラックおよびカーボンファイバーからなる群より選ばれる少なくとも1種である、請求項1~4のいずれか一項に記載のハイドロフルオロオレフィンの製造方法。
- 前記担体が、アルミナ、シリカ、チタニアおよびジルコニアからなる群より選ばれる少なくとも1種である、請求項1~4のいずれか一項に記載のハイドロフルオロオレフィンの製造方法。
- 前記触媒の担持量が担体に対して0.1~10質量%である、請求項1~6のいずれか一項に記載のハイドロフルオロオレフィンの製造方法。
- 前記触媒を担持した担体が充填された触媒層に、前記クロロフルオロオレフィンと前記水素とを導入して気相で反応させる、請求項1~7のいずれか一項に記載のハイドロフルオロオレフィンの製造方法。
- 前記クロロフルオロオレフィンと前記水素を前記触媒層のガス導入部に導入するとともに、前記触媒層のガス導入部とガス排出部との間の少なくとも1か所から前記水素を導入する、請求項8に記載のハイドロフルオロオレフィンの製造方法。
- 前記触媒層の最高温度を130℃以下に制御して反応を行う、請求項8または9に記載のハイドロフルオロオレフィンの製造方法。
- 前記触媒層に導入するクロロフルオロオレフィンと水素の割合が、クロロフルオロオレフィン中の塩素原子のモル数と水素の総モル数との比(H2/Cl)で表わして、0.1~0.7である、請求項8~10のいずれか一項に記載のハイドロフルオロオレフィンの製造方法。
- 前記触媒を担持した担体の存在下に、前記クロロフルオロオレフィンと前記水素とを液相で反応させる、請求項1~7のいずれか一項に記載のハイドロフルオロオレフィンの製造方法。
- 前記クロロフルオロオレフィンが、クロロトリフルオロエチレン、トランス-1,2-ジクロロ-1,2-ジフルオロエチレン、シス-1,2-ジクロロ-1,2-ジフルオロエチレン、1,1-ジクロロ-2,3,3,3-テトラフルオロプロペンおよび1-クロロ-2,3,3,3-テトラフルオロプロペンからなる群より選ばれる少なくとも1種である、請求項1~12のいずれか一項に記載のハイドロフルオロオレフィンの製造方法。
- 1,1-ジクロロ-2,3,3,3-テトラフルオロプロペンから2,3,3,3-テトラフルオロプロペンを製造する、請求項1~12のいずれか一項に記載のハイドロフルオロオレフィンの製造方法。
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WO2021044983A1 (ja) * | 2019-09-06 | 2021-03-11 | Agc株式会社 | ハイドロフルオロオレフィンの製造方法 |
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