GLYCERIN-ONLY REACTION FOR ALLYL ALCOHOL PRODUCTION

Abstract

A process of producing allyl alcohol by reacting glycerin with ReO.sub.3—Al.sub.2O.sub.3 in the presence of gamma-valerolactone (GVL) in a reactor is described. More specifically, a process to produce allyl alcohol, comprising the step of: a) reacting glycerin with ReO.sub.3—Al.sub.2O.sub.3 in the presence of an inert solvent, GVL, in a reactor, and b) collecting the product comprising allyl alcohol.

Claims

1. A process to produce allyl alcohol, comprising the step of: a) reacting glycerin with ReO.sub.3—Al.sub.2O.sub.3 in the presence of an inert solvent in a reactor, wherein the inert solvent is gamma-valerolactone (GVL); and b) collecting the product comprising allyl alcohol.

2. The process of claim 1, wherein the process is free of additional reducing agent.

3. The process of claim 1, wherein the reaction is further carried out in the presence of at least two inert solvents.

4. The process of claim 3, wherein at least one of the two inert solvents is tetraethylene glycol dimethyl ether (tetraglyme).

5. The process of claim 1, wherein the molar ratio of the inert solvent to glycerin ranges from 2:1 to 1:2.

6. The process of claim 1, wherein the reactor is maintained at 180-200° C. for 4 hours. The process of claim 1, further comprising pretreating the glycerin.

8. The process of claim 7, wherein the pretreating step comprises washing the glycerin with an acid or treating the glycerin with an ion exchange resin.

9. The process of claim 8, wherein the ion exchange resin is a macroreticular sulfonated polystyrene-divinylbenzene resin.

10. The process of claim 7, wherein the pretreating step further comprises washing the glycerin with water.

11. The process of claim 1, wherein the product comprises a vapor component and a liquid component.

12. The process of claim 11, further comprising removing the vapor component from the reactor.

13. The process of claim 11, further comprising distilling the vapor component with a solvent.

14. The process of claim 11, further comprising removing the ReO.sub.3—Al.sub.2O.sub.3 from the liquid component.

15. The process of claim 14, further comprising separating the gamma-valerolactone from the remaining liquid component by hydrogenation and distillation.

16. The process of claim 1, wherein the product further comprises acrolein.

17. The process of claim 16, wherein the acrolein is separated by distillation and subsequently hydrogenated to form n-propanol.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0033] FIG. 1. presents a synthesis strategy from glycerin to allyl alcohol.

[0034] FIG. 2. provides a schematic of an experimental setup 100 in Example 1 and Comparative Examples 1-3.

[0035] FIG. 3. provides a schematic of process flow diagram of this disclosure.

DETAILED DESCRIPTION

[0036] The disclosure provides a novel method of producing allyl alcohol from glycerin, particularly using ReO.sub.3/Al.sub.2O.sub.3 catalyst system in the presence of an inert solvent to minimize octene isomers. The disclosure also describes steps of pretreating the glycerin feedstock to minimize solid residue.

[0037] Conventionally, converting glycerin to allyl alcohol typically requires an excess (10 equivalents or more) of a secondary alcohol to function as both the reductant and the solvent. The reaction is carried out in a close vessel at temperatures above 170° C. This would lead to production of 3-octanone from oxidative dehydrogenation, as well as octene isomers formed as the result of dehydration reactions. The formation of a high level of octene isomers increases the cost of making allyl alcohol using an MTO/3-octanol catalyst system.

[0038] According to this disclosure, the use of glycerin to make allyl alcohol without using 3-octanol and a catalyst reduces, or eliminates, the drawback of octene isomers formation. A heterogeneous catalyst (ReO.sub.3—Al.sub.2O.sub.3) is used with an inert solvent in the reaction system while achieving the same or better allyl alcohol production.

[0039] According to this disclosure, the glycerin may be produced or derived from any suitable source, including bio-glycerin derived from bio-fuel production, non-bio-glycerin derived from conventional petrochemical processes, or obtained from commercial suppliers.

[0040] The heterogeneous catalyst ReO.sub.3—Al.sub.2O.sub.3 is prepared according to Lwin et al., Activation of Surface ReO.sub.x Sites on Al.sub.2O.sub.3 Catalysts for Olefin Metathesis, ACS Catal. 2015, 5, 11, 6807-6814. Although known for use in metathesis, the heterogenous catalyst ReO.sub.3—Al.sub.2O.sub.3 has not heretofore been used for deoxydehydration reactions such as the ones provided in the instant disclosure. The prepared heterogeneous catalysts may contain 5% to 40% of ReO.sub.3 over Al.sub.2O.sub.3. The ReO.sub.3—Al.sub.2O.sub.3 heterogeneous catalyst is present in the range of from 1 mole % to 13 mole %, from 7 mole % to 30 mole %, from 3 mole %, to 13 mole %, from 1 mole % to 3 mole %, from 3 mole % to 7 mole %, 7 mole % to 13 mole %, or from 13 mole % to 30 mole % of glycerin, wherein the mole ratio was calculated based on the amount of ReO.sub.3 in the catalyst versus the amount of glycerin used in the reaction. The use of ReO.sub.3—Al.sub.2O.sub.3 is advantageous over ReO.sub.3 catalyst (as shown in the comparative examples below) because the heterogeneous catalyst system is easier to recover from the reaction mixture and can therefore be recycled to reduce the cost.

[0041] Glycerin, represented by the chemical formula HOCH.sub.2(CHOH)CH.sub.2OH, is also referred to as trihydroxypropane or glycerol. Although the purity of the glycerin converted to allyl alcohol via the herein disclosed catalyst and method does not limit the scope of this disclosure, it can be 80 wt.% or higher, 90 wt.% or higher, or 95 wt.% or higher, in embodiments, in order to reduce the production of reaction byproducts. In embodiments, the glycerin is obtained as a byproduct from the synthesis of bio-diesel via transesterification of vegetable oil and alcohol. This type of glycerin may be referred to as bio-glycerin or crude glycerin, and the produced allyl alcohol may thus be considered ‘bio-allyl alcohol’. As used herein, ‘bio-glycerol’, ‘bio-glycerin’, ‘crude glycerin’, and ‘crude glycerol’ refer to glycerin obtained as a byproduct of bio-diesel production, and ‘bio-allyl alcohol’ refers to allyl alcohol derived from bio-glycerin. In embodiments, the glycerin converted to allyl alcohol via the herein disclosed rhenium catalyst and method comprises bio-glycerin, and the product comprises bio-allyl alcohol. In embodiments, the glycerin converted to allyl alcohol via the herein disclosed rhenium catalyst and method comprises non-bio-glycerin, and the product comprises non-bio-allyl alcohol. In embodiments, the glycerin converted to allyl alcohol via the herein disclosed rhenium catalyst and method comprises bio- and non-bioglycerin, and the product comprises bio-allyl alcohol and non-bio-allyl alcohol. In certain embodiments, at least 20, 30, 40, 50, 60, 70, 80, or 90 mole percent of the glycerin converted to allyl alcohol according to this disclosure comprises bio-glycerin. In other embodiments, at least 20, 30, 40, 50, 60, 70, 80, or 90 mole percent of the glycerin converted to allyl alcohol according to this disclosure comprises non-bio-glycerin.

[0042] The conversion of glycerin to allyl alcohol via this disclosure is a liquid phase reaction by adding the inert solvent, and the conversion conditions can comprise a reaction temperature of greater than 140° C., 150° C., 160° C., 170° C., 180° C., 190° C., or 200° C. The reaction can be carried out under ambient pressure, and the reaction temperature can be increased to the operating temperature within 30 minutes in the presence of the ReO.sub.2 and/or ReO.sub.3 catalyst disclosed herein.

[0043] Inert solvents can be used including tetraethylene glycoldimethyl ether (tetraglyme), γ-Valerolactone (GVL), propylene carbonate, acetophenone. It is noted that the solvents with low boiling point are susceptible to decomposition under the reaction condition. Some solvents with high boiling point may decompose, or inhibit the conversion from, glycerin to allyl alcohol. GVL is used as an inert solvent because it remains stable throughout the conversion reaction while satisfying the goal of keeping reaction products in liquid phase. However, it is expected that other inert solvents with similar properties may also be used in combination with or in place of GVL.

[0044] An allyl alcohol (AA) selectivity can be defined as:

AA Selectivity=(([AA].sub.produced)/([Glycerin].sub.feed−[Glycerin].sub.unreacted))×100%   (1)

wherein [AA].sub.produced is the molar amount of produced allyl alcohol, [Glycerin].sub.feed is the molar amount of glycerin in the glycerin feed to the reaction, and [Glycerin].sub.unreacted is the molar amount of unreacted glycerin in the reaction product. The catalyst and method of this disclosure may provide for a selectivity to allyl alcohol that is, in certain embodiments, greater than or equal to 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90%. It is noted that in the 3-octanol-free reaction, glycerin serves not only as a reactant, but also a reducing agent. Therefore, in calculating AA selectivity, it is assumed that 50% or more of the glycerin is used as the reducing agent, and the [Glycerin].sub.feed excludes the 50% glycerin.

[0045] A glycerin conversion can be defined as:

Glycerin Conversion=(([Glycerin].sub.feed−[Glycerin].sub.unreacted)/([Glycerin].sub.feed))×100%   (2)

wherein [Glycerin].sub.feed is the molar amount of glycerin in the feed to the reaction, and [Glycerin].sub.unreacted is the molar amount of unreacted glycerin in the reaction product. The catalyst and method of this disclosure may provide for a glycerin conversion that is, in certain embodiments, greater than or equal to 50, 60, 70, 75, or 80 mole percent, or in the range of from 50 to 100 mole percent, from 60 to 100 mole percent, from 70 to 100 mole percent, from 70 to 90 mole percent, or from 80 to 90 mole percent. It is noted that in the 3-octanol-free reaction, glycerin serves not only as a reactant, but also a reducing agent. Therefore, in calculating glycerin selectivity, it is assumed that 50% or more of the glycerin is used as the reducing agent, and the [Glycerin].sub.feed excludes the 50% glycerin.

[0046] The yield of allyl alcohol (defined by the glycerin conversion multiplied by the AA selectivity) provided by the catalyst and method of this disclosure may, in embodiments, be greater than or equal to 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 85%, or 90%.

[0047] As noted above, the use of methyltrioxorhenium (MTO) in a reaction where 3-octanol is utilized as solvent, 3-octanone along with byproduct octene isomers form as the result of dehydration reactions. For each mole of allyl alcohol produced, one mole of 3-octanol was converted into undesirable octene isomers. The following examples were carried out to address this problem.

EXAMPLE 1

[0048] FIG. 2 is a schematic of an experimental setup 100 utilized in this experiment. In a 100 mL three neck round-bottom flask 10 were placed 56.5 mmol (5.2 g) of glycerin, 49.9 mmol (5.0 g) GVL and 2.6 mmol ReO.sub.3 from ReO.sub.3—Al.sub.2O.sub.3 catalyst (2.0 g of 30% ReO.sub.3—Al.sub.2O.sub.3). The flask 10 was connected to a distillation apparatus 20 (including thermocouple, distillation column 21 and collecting flask 22). The temperature in the reaction mixture was measured and controlled by an immersed thermocouple 30. The system was heated up to the operating temperature using a heating mantle 40. About 30 minutes later, distillation was initiated. The reaction subsequently remained at the operating temperature for an additional 3.5 hours. Once the reaction was completed and the reaction mixture cooled to room temperature, the products were drained back to reaction mixtures for Nuclear Magnetic Resonance spectroscopy (NMR) analysis. A typical NMR sample was prepared by mixing reaction products (1.5 g), 3-hydroxyl-tetrahydrofuran (0.1 g, as internal reference for NMR quantification), and dimethyl sulfoxide-d6 (1.5 g, NMR solvent). A sample for quantitative .sup.1D .sup.13C NMR experiment was collected to quantify the reaction mixture.

[0049] The results are provided in Table 1 shown below.

COMPARATIVE EXAMPLE 1-3

ReO3/3-Octanol, REO2/3-Octanol and MTO/3-Octanol Catalyst System

[0050] The same process as in Example 1 was repeated, except the ReO.sub.3-Al.sub.2O.sub.3 catalyst and GVL solvent were replaced with 0.66 mmol (0.143 g) ReO.sub.2, 13.8 mmol (1.27 g) glycerin, 105.9 mmol (13.8 g) 3-octanol (Comp. Ex. 1), 2.7 mmol (0.63 g) of ReO.sub.3, 56.4 mmol (5.2 g) glycerin, 274.0 mmol (35.7 g) 3-octanol (Comp. Ex. 2), or 1.3 mmol (0.324 g) of MTO, 25.6 mmol (2.36 g) glycerin, 367.0 mmol (47.8 g) 3-otcanol (Comp. Ex. 3).

[0051] Three catalyst systems are also provided as a comparison: one comprising rhenium dioxide; a second comprising rhenium trioxide; and a third comprising MTO/3-octanol catalyst system were utilized to convert glycerin to allyl alcohol. As solvent and reductant, 3-octanol was employed. Specifically, glycerin (obtained from SIGMA ALDRICH) was exposed to the catalyst at a temperature of 170° C. for a time period of 0.1 to 4 hours. Rhenium dioxide, rhenium trioxide, MTO, and 3-octanol were obtained from SIGMA ALDRICH.

[0052] The allyl alcohol selectivity calculated as per Equation (1), the molar percent glycerin conversion calculated as per Equation (2), and the mole ratio of octene isomers to allyl alcohol in the product comprising allyl alcohol are also shown in Table 2 below.

TABLE-US-00002 TABLE 1 Comparison of ReO.sub.3—Al.sub.2O.sub.3/GVL, ReO.sub.2/ReO.sub.3/MTO with 3-Octanol Example # Example 1 Comp. Ex. 1 Comp. Ex. 2 Comp. Ex. 3 Catalyst ReO.sub.3—Al.sub.2O.sub.3 & ReO.sub.2 & 3- ReO.sub.3 & 3- MTO & 3- system/solvent GVL Octanol Octanol Octanol Solvent/Glycerin 1 N/A N/A N/A ratio Catalyst 4.5 4.8 4.8 5.1 (% Molar) Glycerin 99.7 70 86 100 Conversion (% Molar) AA Selectivity 54 82 70 90 (% Molar) Acrolein (% 44 / / / Molar)

[0053] As can be seen in Table 1, the glycerin-only process in Example 1 has a 99.7% conversion rate, comparable to the MTO/3-Octanol process in Comparative Example 3. Example 1 completely eliminates octene isomer and other 3-octanol-derived byproducts. It is also to be noted that the AA selectivity in Example 1 indicates at least 50% of the glycerin serves as the reducing agent in the glycerin-to-AA reaction, thereby eliminating the need for the more expensive 3-octanol as the reducing agent. The relatively low AA selectivity in Example 1 is the result of the fact that 44% of glycerin is being converted to acrolein, which can be converted to allyl alcohol through selective hydrogenation or n-propanol. Overall valuable chemical (AA+acrolein) selectivity is at about 98%. Please note that at least half of the glycerin feed is being used as reducing agent, as opposed to the three comparative examples where 3-octanol served as the reducing agent and would generate byproducts such as octene. In theory, at least 50% of glycerin is used as a reducing agent during this reaction. As a consequence, acrolein is produced from glycerin reduction. The overall economic benefit of this reaction is not using 3-octanol or other expensive secondary alcohol as a reducing agent. Additionally, the acrolein byproduct can be further converted to allyl alcohol through selective hydrogenation, thereby adding value to the process.

[0054] The GVL-glycerin ratio was varied, which plays an important role in the product distribution (allyl alcohol and acrolein), although the total yield of allyl alcohol and acrolein remained at 40 to 50 mole percent. The highest allyl alcohol selectivity of 54% was achieved when using 1/1 weight ratio of GVL/glycerin, as shown in Table 2 below. In addition, undesired by-products have three major function groups: acid/ester, alkene, and ether, which may be further converted to oxygenates through hydrogenation.

TABLE-US-00003 TABLE 2 Comparison between GVL/glycerin ratio GVL/glycerin (weight) 3.9/1 2.8/1 1/1 1/2.9 Glycerin conversion 99.8% 97.9% 99.7% 95.7% AA selectivity   36%   36%   54%   50% Acrolein selectivity   52%   48%   44%   30%

[0055] With different GVL/glycerin ratio, the 1/1 ratio provides the highest allyl alcohol selectivity (54%) as compared to the 3.9/1 or 2.8/1 ratio (36%). Additionally, the 1/1 GVL/glycerin ratio provides almost identical glycerin conversion rate (99.7%) to the highest conversion rate when using 3.9/1 ratio (99.8%). Acrolein selectivity of the 1/1 GVL/glycerin ratio is 44%, which is lower than the 3.9/1 ratio (52%), but still in the acceptable 20+% range.

[0056] It is shown that the glycerin/GVL/ReO.sub.3—Al.sub.2O.sub.3 system of this disclosure provides a low cost option to produce allyl alcohol and other valuable chemicals from glycerin by eliminating the need of 3-octanol (or other secondary alcohols) as reaction reductant. The glycerin/GVL/ReO.sub.3—Al.sub.2O.sub.3 system also offers a feasible option to recycle rhenium in a commercial scale process, as discussed below.

Commercial Process of Allyl Alcohol Production from Glycerin

[0057] In a larger scale production of allyl alcohol, a process flow diagram is illustrated in FIG. 3. The commercial grade crude glycerin typically comprises salts that could deactivate the catalysts, especially the ReOx. Therefore, pretreating the crude glycerin to remove the salts would increasing the overall efficiency the crude glycerin feedstock first undergoes acid wash 301, followed by water wash 303. Alternatively, an ion-exchange treatment can be used to remove the salts in the crude glycerin.

[0058] The pretreated glycerin is then mixed with γ-valerolactone solvent, and the mixture is introduced into a reactor 305 with catalyst to convert into allyl alcohol and other byproducts, such as acrolein, as well as certain heavy components.

[0059] In one embodiment, the reactor is a slurry reactor where the catalyst and reactor solution are present in the form of slurry. Different reactor configuration is possible, for example, in one embodiment the reactor is a fixed bead reactive distillation unit, where the catalyst is in the form of a fixed bed, and the products are separated from the top of the column. Other reactor configurations may also be used.

[0060] The reactor 305 is configured such that allyl alcohol, acrolein, water and other low boiling point byproduct are removed from the reactor 305 in vapor form and introduced into a distillation column 311, whereas the catalyst, GVL solvent, and impurities with high boiling point (heavies) are removed from the bottom of the reactor 305.

[0061] In the distillation column 311, the lighter acrolein is removed from the top, whereas the heavier allyl alcohol and water are separated and introduced into a separate extractive distillation unit 317.

[0062] In the extractive distillation unit 317, an additional solvent can be added to break the azeotrope between allyl alcohol and water in order to recover the allyl alcohol. In one embodiment, propylene glycol can be added as the solvent, but other solvent may also be used, non-limiting examples include toluene, xylene and mixtures thereof. The feed into the extractive distillation unit 317 has temperature at 25-75° C. and pressure at 0.5-2 atm, and in the unit 317 the temperature is maintained at about 50° C. and the pressure is maintained between 0.5 and 1 atm. The unit 317 is configured to introduce the solvent at the top of the column, and the feed from the bottom of the unit in a countercurrent flow. The solvent-to-feed ratio changes the separation efficiency. In one embodiment, the solvent-to-feed ratio is maintained at 5-to-1, but other ratios may also be chosen by a person skilled in the art, depending on the conditions. For example, ratios ranging from 10/1 to 2/1 may be used. After recovering the allyl alcohol, the remaining water and added solvent can further be separated in an additional distillation column 319.

[0063] The acrolein separated from the distillation column 311 is then hydrogenated in a hydrogenation unit 313 to form n-propanol, which can be further separated from the unreacted acrolein by using an additional distillation column 315. The recovered n-propanol can be used in other processes.

[0064] The catalyst, GVL solvent and high boiling point impurities (heavies) are removed from the bottom of reactor 305 and fed into a settler 321, which separates catalyst from the remaining stream. The catalyst can therefore be recycled and optionally further reactivated.

[0065] The effluent from the settler 321 now contains the GVL solvent with the heavy impurities, and is introduced into a hydrogenation unit 323 to convert the heavy impurities into low boiling point byproducts, so that they can be separated from GVL solvent in the distillation column 325. The low boiling point byproducts can be used as fuels or lactic acid that may have other applications. The separated GVL solvent can be reintroduced to mix with further glycerin by a pump 331.

[0066] The overall process shows that the glycerin/GVL/ReO.sub.3—Al.sub.2O.sub.3 conversion process can efficiently produce allyl alcohol with high selectivity, while also producing other valuable chemicals such as acrolein and n-propanol.

[0067] While certain embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the teachings of this disclosure.

[0068] Numerous other modifications, equivalents, and alternatives, will become apparent to those skilled in the art once the above disclosure is fully appreciated. It is intended that the following claims be interpreted to embrace such modifications, equivalents, and alternatives where applicable. Accordingly, the scope of protection is not limited by the description set out above but is only limited by the claims which follow, that scope including equivalents of the subject matter of the claims.

[0069] The following references are incorporated by reference in their entirety for all purposes. [0070] U.S. Pat. No. 3,044,850 [0071] U.S. Pat. No. 3,274, 121 [0072] U.S. Pat. No. 4,215,077 [0073] U.S. Pat. No. 5,444,141 [0074] Arceo et al., Chemical Communications, 2009, 23, 3357 [0075] Lwin et al., Activation of Surface ReO.sub.x Sites on Al.sub.2O.sub.3 Catalysts for Olefin Metathesis, ACS Catal. 2015, 5, 11, 6807-6814 [0076] Shiramizu and Toste, Angew. Chem. Int. Ed. 2012, Vol. 51, pp. 8082-8086 [0077] Yi et al., ChemSusChem, 2012, 5, 1401