Process for the production of allyl compounds by deoxydehydration of glycerol

Abstract

A continuous-flow process for the production of allyl compounds by deoxydehydration of glycerol includes: (a) Forming a reactive solution by mixing glycerol (1) with: a carboxylic acid (2), and/or a triethyl orthoester, preferably triethyl orthoformate (TEOF); (b) Feeding the reactive solution to an inlet of a channel of a thermolysis microreactor module wherein the channel has an inner hydraulic diameter, D=4 A/P, wherein A is the area and P the perimeter of a cross-section of the channel, of not more than 1000 μm, (c) Exposing the reactive solution to thermolysis by driving a flow of the reactive solution along the channel from the inlet to an outlet, for a thermolysis time, t, at a pressure, P, and at a thermolysis temperature, T, larger than 200° C., to form thermolysis products including at least one allyl compound; and Recovering the thermolysis products at the outlet and separating the at least one allyl compound from the other thermolysis products.

Claims

1. A continuous-flow process for the production of allyl compounds by deoxydehydration of glycerol comprising: (a) forming a reactive solution by mixing glycerol (1) with: a carboxylic acid (2), or a triethyl orthoester, preferably triethyl orthoformate (TEOF), or a combination thereof, with the proviso that when used alone, the carboxylic acid (2) is present in the reactive solution in an amount of at least 2 equivalents; (b) feeding the reactive solution to an inlet of a channel of a thermolysis microreactor module wherein the channel has an inner hydraulic diameter, D=4 A/P, wherein A is the area and P the perimeter of a cross-section of the channel, of not more than 1000 μm, (c) exposing the reactive solution to thermolysis by driving a flow of the reactive solution along the channel from the inlet to an outlet, for a thermolysis time, t, at a pressure, P, and at a thermolysis temperature, T, larger than 200° C., to form thermolysis products including at least one allyl compound; and (d) recovering the thermolysis products at the outlet and separating the at least one allyl compound from the other thermolysis products.

2. The continuous-flow process according to claim 1, wherein, the triethyl orthoester is present in the reactive solution in an amount comprised between 1 and 3 equivalents, or the carboxylic acid (2) is present in the reactive solution in an amount comprised between 1 and 3 equivalents, or a combination thereof.

3. The continuous-flow process according to claim 1, wherein, the triethyl orthoester is present in the reactive solution in an amount comprised between 1 and 3 equivalents, and the carboxylic acid (2) is present in the reactive solution in an amount comprised between 0.001 and 1.5 equivalents.

4. The continuous-flow process according to claim 1, wherein the at least one allyl compound present in the thermolysis products comprises allyl alcohol and allyl formate, wherein the 3a/3b ratio defined as the relative content of allyl alcohol with respect to the total content of allyl compounds present in the thermolysis products (=allyl alcohol/(allyl alcohol+allyl formate)) is comprised between 50 and 100%.

5. The continuous-flow process according to claim 1, wherein the reactive solution has a viscosity, η, when it is fed to the inlet of the channel comprised between 0.003 and 1.1, wherein the viscosity is measured by strain-controlled rheology at a temperature of 20° C. and a shear rate of 99.8 s.sup.−1.

6. The continuous-flow process according to claim 1, wherein the carboxylic acid has 1 to 5 carbons.

7. The continuous-flow process according to claim 1, wherein the thermolysis reaction is carried out at a pressure, P, comprised between 10-75 bar (=145-1088 psi).

8. The continuous-flow process according to claim 1, wherein the thermolysis temperature, T, is comprised between 200 and 370° C.

9. The continuous-flow process according to claim 1, wherein, the reactive solution comprises both triethyl orthoformate (TEOF) and a carboxylic acid, present in amounts which do not differ from one another by more than ±20%, and wherein the thermolysis temperature is comprised between 200 and 370° C.

10. The continuous-flow process according to claim 1, wherein the separation step comprises one or more of neutralization, liquid-liquid extraction, liquid-liquid separation, gas-liquid separation, filtration on silica gel, in-line distillation.

11. An allyl production line for carrying out the continuous flow process according to claim 1 comprising: (a) sources of reactants including: a source of glycerol, and a source of a triethyl orthoester (121), preferably triethyl orthoformate (TEOF), and/or a source of carboxylic acid, (b) a solution tank (22) in fluid communication with the sources of reactants, (c) a pump bringing in fluid communication the solution tank with a thermolysis microreactor module, wherein (d) the thermolysis microreactor module comprises: a channel extending from an inlet to an outlet located downstream from the inlet, said channel having an inner hydraulic diameter, D=4 A/P, wherein A is the area and P the perimeter of a cross-section of the channel, of not more than 1000 μm, wherein the pump is located directly upstream of the inlet, a heating module arranged for heating the channel at a thermolysis temperature of at least 200° C., (e) a separating module (61) located downstream of the outlet for separating at least one allyl compound from other thermolysis products.

12. The allyl production line according to claim 11, wherein the separating module comprises one or more units selected among neutralization unit, liquid-liquid extraction unit, liquid-liquid separation unit, gas-liquid separation unit, filtration on silica gel unit, in-line distillation unit.

13. The continuous-flow process according to claim 2, wherein the triethyl orthoester is present between 1.5 and 2.5 equivalents.

14. The continuous-flow process according to claim 2, wherein the triethyl orthoester is triethyl orthoformate (TEOF).

15. The continuous-flow process according to claim 2, wherein, the carboxylic acid (2) is present in the reactive solution in an amount of between 1.5 and 2.5 equivalents.

16. The continuous-flow process according to claim 2, wherein only the carboxylic acid (2) is present and in the reactive solution in an amount of at least 2 equivalents.

17. The continuous-flow process according to claim 3, wherein both the triethyl orthoester and the carboxylic acid (2) are present in the reactive solution and the carboxylic acid (2) is present between 0.01 and 1 equivalent.

18. The continuous-flow process according to claim 4, wherein the thermolysis products (=allyl alcohol/(allyl alcohol+allyl formate)) is between 75 and 99%.

19. The continuous-flow process according to claim 5, wherein the viscosity is between 0.006 and 0.5 Pa.s.

20. The continuous-flow process according to claim 6, wherein the carboxylic acid is methanoic acid (2m) or ethanoic acid (2e).

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) Various embodiments of the present invention are illustrated in the attached Figures.

(2) FIG. 1: shows the transformations of glycerol into a selection of important building blocks.

(3) FIG. 2: shows the DODH reaction of glycerol with methanoic acid.

(4) FIG. 3: shows the DODH reaction of glycerol with triethyl orthoformate.

(5) FIG. 4: shows a continuous microreactor module suitable for carrying out the process of the present invention.

(6) FIG. 5: illustrates the combined yields of allyl alcohol and allyl formate obtained with a process according to the present invention, combining glycerol and methanoic acid at a pressure, P, a thermolysis temperature, T, and for a thermolysis time, t=6 min (a) as a function of methanoic acid concentration at T=315° C. and P=17 bar, and (b) as a function of pressure at T=315 and 345° C., with a methanoic acid contents of 1.5 equivalent.

(7) FIG. 6: illustrates the yields of allyl alcohol and allyl formate as a function of thermolysis temperature, T, obtained with a process according to the present invention, combining glycerol and methanoic acid (1.5 equiv.), at a pressure, P=69 bar, and for a thermolysis time, t=6 min.

(8) FIG. 7: illustrates the combined yields of allyl alcohol and allyl formate (a) as a function of thermolysis temperature, T, and (b) as a function of carboxylic acid concentration, obtained with a process according to the present invention carried out at a pressure, P=17 bar, and for a thermolysis time, t=6 min of a reactive solution obtained by mixing glycerol and TEOF (1 equiv.) used alone (white squares), or together with 1 equiv. of a carboxylic acid: white circles=ethanoic acid, and black circles=methanoic acid.

(9) FIG. 8: illustrates the combined yield of allyl alcohol and allyl formate as a function of thermolysis temperature, T, and contents of triethyl orthoformate (TEOF) obtained with a process according to the present invention, combining glycerol, methanoic acid (2.5 equiv.), and various concentrations of triethyl orthoformate, at a pressure, P=17 bar, and for a thermolysis time, t=6 min

DETAILED DESCRIPTION OF THE INVENTION

(10) Allyl Continuous Flow Production Line

(11) As can be seen in FIG. 4, the various steps of a continuous-flow process for the production of an allyl compound by deoxydehydration of glycerol according to the present invention can be carried out in an allyl production line comprising the following components.

(12) The production line must comprise sources of reactants including: a source (11) of glycerol (1), a source (12) of carboxylic acid (2), and/or a source (121) of a triethyl orthoester (21), preferably triethyl orthoformate (TEOF), optionally a source of other additives, such as a solvent (not illustrated and, in most cases, it is not required and it is preferred not to use a solvent or other additives).
The various sources may be provided with valves or volumetric pumps for controlling the flowrate of the various components from the corresponding sources to a solution tank (22). For example, piston pumps (or syringes) can be used to accurately control the flow of each reactant into the solution tank. The valves or volumetric pumps can be controlled by a controlling unit (not shown).

(13) A reactive solution is formed in the solution tank (22) composed of the reactants supplied from the sources of reactants. In all cases the reactive solution comprises glycerol (1) and one or more additives including a triethyl orthoester (121), preferably triethyl orthoformate (TEOF), and/or carboxylic acid (2), preferably methanoic acid. The solution tank can be provided with a stirrer for enhancing homogeneity of the reactive solution. It may also be provided with heating means for heating the reactive solution, for example for lowering the viscosity of the reactive solution.

(14) The solution tank (22) is in fluid communication with a pump (23) for injecting under pressure the reactive solution into an inlet (32u) of a channel (32) extending from said inlet to an outlet (32d) located downstream from the inlet. For example, a HPLC pump can be used to inject the reactive solution into the channel (e.g., Thales Nano Micro-HPLC). Pressures of up to 75 bar (=1088 psi) can be used for the thermolysis of the reactive solution, but the microreactor of the present invention allows excellent yields at much lower pressures comprised between 10 and 25 bar (=145 to 363 psi), preferably between 14 to 20 bar (=203 to 290 psi), more preferably at a pressure of 17±2 bar (=250±29 psi).

(15) The channel (32) forms a capillary defined by a closed perimeter, P, and can be formed by a tube or by a recess in a plate. The reaction is carried out in a microreactor, and the channel has an inner hydraulic diameter, D=4 A/P, of not more than 1000 μm, wherein A is the area and P the perimeter of a cross-section of the channel. The inner hydraulic diameter of the channel can be lower than 1000 μm, such as not more than 750 μm, or not more than 500 μm, and even not more than 250 μm. A channel of inner hydraulic diameter, D, greater than 1000 μm significantly reduces the allyl conversion by thermolysis reaction. This is probably a consequence of temperature gradients across the section of the reactor channel. The channel can be equipped with a backpressure regulator (BPR) (24), which is inserted downstream to enable pressurized operation. Depending on the thermolysis temperature and type of heating module used, the channel can be made of stainless steel, preferably passivated stainless steel, aluminium, copper, PEEK, PEKK, PTFE, ceramics such as silicon carbide, and the like.

(16) The channel comprises a central portion comprised between the inlet and the outlet. If the channel is formed by a tube, the central portion preferably forms one or more coils. If it is formed by a recess in a plate, the recess may meander over the surface of the plate to form a serpentine. The inner walls of the channel can include specific structures, for instance to achieve high mixing. These configurations allow large linear lengths of channel to be housed in a small volume, thus saving space. The central portion of the channel is part of a thermolysis microreactor module (31) comprising a heating module arranged for heating the channel at a thermolysis temperature of at least 200° C. The heating module can be a furnace of any type known in the art allowing the heating of the channel at said temperature and enclosing the central portion of the channel. For example, the heating module can be a conventional electric or gas furnace, or can heat the channel by radiation, such as IR, by induction, by Joule effect, and the like. The heating module must be suitable for heating the interior of the channel to a temperature of at least 200° C., preferably comprised between 200 and 370° C., preferably between 220 and 320° C. If the reaction channel is formed by a recess in a plate, the heating module can also be integrated to the plate as a second recess independent of the channel (32), in which a thermofluid is circulated. The heating module can also be a heating cartridge hosted in the plate. Any heating means known in the art allowing the heating of the reaction mixture within a channel can be applied without affecting the present invention.

(17) By controlling the pressure (and back pressure) in the channel, and depending on the inner hydraulic diameter, D, of the channel the thermolysis time, t, can be controlled. The thermolysis time, t, is preferably comprised between 0.1 and 15 min, more preferably between 1 and 10 min, most preferably between 5 and 8 min. Longer thermolysis times do not significantly increase the yield in allyl compounds. In some cases, in particular at high temperatures, the yield drops with longer thermolysis times because of degradation of some of the components.

(18) In order to control and build up a pressure inside the channel, a backpressure regulator (BPR) (24) can be positioned downstream of the channel. The BPR can be a restriction in the channel cross-section, variable or not, or it can actively generate a counter-pressure. In the latter case, the back pressure, P.sub.24; generated by the BPR (24) must be lower than the pressure, P.sub.23, generated by the pump (23) (P.sub.24<P.sub.23), and both pressure and back pressure can be varied to allow the reactive solution to flow from the inlet to the outlet of the channel, at various pressures (P.sub.23+P.sub.24) and pressure differences (ΔP=P.sub.23−P.sub.24), the latter controlling the flowrate.

(19) The allyl production line can further comprise a cooling module (41) located directly downstream of the channel outlet (32d), for cooling the reaction products of the thermolysis reaction. Any cooling means known in the art allowing the cooling of the reaction products in a short time can be applied without affecting the present invention. A cooling module is not mandatory, but is advantageous in case an in-line analysis module (51), such as an IR spectrometer, and the like, is provided for identifying the components flowing out of the channel. Such in-line analysis modules may not be sufficiently temperature resistant to allow the reactants to flow through it without first being cooled.

(20) A separating module (61) located downstream of the outlet for separating at least one allyl compound (3a, 3b) from other thermolysis products such as CO.sub.2 and alcohols (cf. FIG. 4). The separating module can be in-line or off-line with respect of the channel (32). The separation step may comprise neutralization, liquid-liquid extraction, liquid-liquid separation, gas-liquid separation, filtration on silica gel, in-line distillation and the like. In some embodiments, liquid-liquid extraction requires the injection of a secondary phase, such as an aqueous phase. The aqueous phase may contain an inorganic salt such as sodium carbonate. Alternatively, in-line liquid-liquid or gas-liquid separation can be carried out with a membrane or a settling tank. In some embodiments, the liquid-liquid separation and the gas-liquid separation can be effected at the same time.

(21) Allyl Formation by Thermolysis of Glycerol and Carboxylic Acid

(22) An allyl production line as discussed supra can be used for carrying out a continuous flow process according to the present invention for the production of allyl compounds by deoxydehydration of glycerol. The continuous flow process comprises the following steps: (a) Forming a reactive solution in the solution tank (22) by mixing glycerol (1) with a carboxylic acid (2); (b) Feeding with the pump (23) the reactive solution to the inlet (32u) of the channel (32) of the thermolysis microreactor module discussed supra, (c) Exposing the reactive solution to thermolysis by driving a flow of the reactive solution along the channel from the inlet to the outlet (32d), for a thermolysis time, t, at a pressure, P, and at a thermolysis temperature, T, larger than 200° C., to form thermolysis products including at least one allyl compound; and (d) Recovering the thermolysis products at the outlet and separating the at least one allyl compound from the other thermolysis products

(23) The viscosity of the reaction solution is critical. Glycerol is quite viscous and, if used alone, would require a high pressure to flow through a capillary channel of a microreactor. By forming a reactive solution with a carboxylic acid, the viscosity is substantially reduced such that the reactive solution can flow easily through the channel. The reactive solution preferably has a viscosity, η, when it is fed to the inlet of the channel comprised between 0.003 and 1.1 Pa.Math.s, preferably between 0.006 and 0.5 Pa.Math.s. The viscosity is preferably lower than 0.5, more preferably lower than 0.3 Pa.Math.s, most preferably lower than 0.2 Pa.Math.s. The viscosity can be measured by strain-controlled rheology at a temperature of 20° C. and a shear rate of 99.8 s.sup.−1. A strain-controlled rheometer, Model: ARES G2 from TA instruments was used, capable of performing a temperature sweep from −80° C. to 350° C., a frequency sweep from 0.0001 to 100 rad/s, with steady state measurement between 0.01 s.sup.−1 and 2000 s.sup.−1. Glycerol alone has a dynamic viscosity at 20° C. of about 1.4 Pa.Math.s, which is too high to satisfactorily flow through capillary channels of diameter lower than 1000 μm. With a lower viscosity, the reaction solution can flow at a higher rate in the capillary channels requiring a lower pressure and temperature. A lower viscosity, however, may lead to a lower yield, as experienced by Sanchez et al. (Op. Cit.) by diluting glycerol in water to form a 35% aqueous solution of glycerol. Unlike Sanchez' aquesous solution, the reactive solution formed in the present invention does not reduce the yield of the reaction. This effect is unexpected and opens the door to cost-effective continuous production of allyl compounds using micro-/meso-fluidic.continuous flow reactors.

(24) The carboxylic acid preferably has 1 to 5 carbons and is typically methanoic acid (2m). Carboxylic acid is preferably present in the reactive solution in an amount comprised between 1 and 3 equivalents, more preferably between 1.5 and 2.5 equivalents. According to the reaction scheme illustrated in FIG. 2, the reaction formally consumes one equivalent of methanoic acid forming 4-(hydroxymethyl)-1,3-dioxolan-2-yl formate (R=H)(2a), that is decomposed into an allyl compound, water, and CO.sub.2 during the DODH process. A second equivalent is involved, but theoretically regenerated during the last irreversible step, leading to allyl alcohol (3a) and allyl formate (3b). It has been observed, however, that by adding carboxylic acid in amounts higher than the stoichiometric amount, the yield increased significantly. FIG. 5(a) compares the yield in allyl compounds obtained by thermolysis of a reaction solution composed of glycerol and methanoic acid, the latter being present in concentrations of 1.5 and 2.5 equivalents. The thermolysis conditions were T=315° C., P=17 bar (=250 psi) and t=6 min. It can be seen that by increasing the methanoic acid concentration from 1.5 to 2.5 equiv the yield jumped from 35 to 62%.

(25) As well known by a person of ordinary skill in the art of reaction stoichiometry, a concentration expressed in “equivalent” refers to the amount of one compound (e.g., methanoic acid) that reacts with one mole of another compound (here glycerol). “Equivalent” as used herein refers to a ratio for an amount of one compound relative to 1 mol of glycerol. For example, 2 equivalents mean twice as many moles of a component as moles of glycerol. Similarly, 0.1 equivalent means ten times less moles of a compound than moles of glycerol. It follows that for 1 mole of glycerol, 2 equivalents of methanoic acid correspond to 2 moles, and 0.1 equivalent of methanoic acid corresponds to 0.1 mole.

(26) Pressure, P, in the channel is controlled by the pressure, P.sub.23, developed by the pump (23) and the back-pressure, P.sub.24, developed by the backpressure regulator (BPR) (24). The pressure, P, preferably ranges between 10 and 75 bar (=145-1088 psi), preferably between 13 and 25 bar (=189 to 363 psi), more preferably between 14 to 20 bar (=203 to 290 psi), most preferably at a pressure of 17±2 bar (=250±29 psi). FIG. 5(b), illustrates the combined yield in allyl alcohol and allyl formate obtained by thermolysis of a reactive solution composed of glycerol and 1.5 equiv. methanoic acid, during a thermolysis time, t=6 min at pressures, P, of 17 and 69 bar at thermolysis temperatures, T, of 315° C. and 345° C. It can be seen that at the lower temperature, T=315° C., increasing the pressure, P, is detrimental to the conversion rate, whilst at the higher temperature, T=345° C., the opposite effect is observed.

(27) The pressure, P, has two counterbalancing effects on the reaction outcome, since both the DODH reaction and the thermal decomposition of methanoic acid have a large positive entropy of activation. At high operating pressure, both the desired DODH reaction and the undesired thermal decomposition of methanoic acid are hindered. A series of experiments at various pressures decreasing from 69 bar to 34 bar, and further down to 17 bar (1000, 500 and 250 psi), while keeping all other process parameters constant (T=345° C., 1.5 equiv. methanoic acid, and t=6 min), led to a decrease of the conversion from 46 to 38%. Decreasing the pressure had a beneficial effect, however, when combined with a decrease of the temperature: at 315° C. the combined yield increased from 23% at a pressure, P=69 bar (=1000 psi) to 35% at a pressure, P=17 bar (250 psi), (cf. FIG. 5(b)). The thermolysis time, t, is preferably comprised between 0.1 and 15 min, preferably between 5 and 8 min. Increasing the residence time up to 30 min had no significant effect on the conversion of glycerol.

(28) The thermolysis temperature, T, is preferably comprised between 200 and 370° C., more preferably between 200 and 350° C. FIG. 6 illustrates the allyl alcohol and allyl formate conversion by thermolysis of a reactive solution composed of glycerol and 1.5 equiv. methanoic acid, at a pressure of 69 bar (=1000 psi) and for a thermolysis time, t=6 min as a function of thermolysis temperature, T. Increasing the residence time higher than 15 min, e.g., up to 30 min, had no significant effect on the conversion of glycerol. The 3a/3b ratio defined as the relative content of allyl alcohol with respect to the total content of allyl compounds present in the thermolysis products (=allyl alcohol/(allyl alcohol+allyl formate)) depends on the temperature, and decreases as the temperature increases ranging from 60:40 at 300° C. to 96:4 at 360° C. The increasing 3a/3b ratio at higher temperature was correlated to the thermal instability of allyl formate, forming CO.sub.2 and propene above 350° C. With the thermolysis conditions used in the experiments illustrated in FIG. 6, the best conversion was obtained at a thermolysis temperature T=345° C. with a combined yield of allyl alcohol and allyl formate of 46%, and with a 3a/3b ratio of 96:4. Note that when ethanoic acid was used instead of methanoic acid, no allyl acetate was detected, therefore characterized by a 3a/3b ratio of 100:0.

(29) Although water is not involved in the irreversible thermolysis step (cf. FIG. 2), the moisture content definitively affects the preliminary reversible steps, especially in a closed system such as in microfluidic reactors. Since the thermal decomposition of methanoic acid releases water, it has a deleterious impact on the overall DODH process as well. Reducing the moisture contents of the reactants of the reactive solution is therefore advantageous for the conversion rate of the DODH.

(30) Allyl Formation by Thermolysis of Glycerol and a Triethyl Orthoester

(31) An allyl production line as discussed supra can be used for carrying out a continuous flow process according to the present invention for the production of allyl compounds by deoxydehydration of glycerol. The continuous flow process comprises the following steps: (a) forming a reactive solution in the solution tank (22) by mixing glycerol (1) with a triethyl orthoester (121), preferably triethyl orthoformate (TEOF), (b) feeding with the pump (23) the reactive solution to the inlet (32u) of the channel (32) of the thermolysis microreactor module discussed supra, (c) exposing the reactive solution to thermolysis by driving a flow of the reactive solution along the channel from the inlet to the outlet (32d), for a thermolysis time, t, at a pressure, P, and at a thermolysis temperature, T, larger than 200° C., to form thermolysis products including at least one allyl compound; and (d) recovering the thermolysis products at the outlet and separating the at least one allyl compound from the other thermolysis products

(32) As shown in FIG. 3, glycerol and triethyl orthoester (1 equiv.) form a homogeneous reactive solution as a consequence of the dynamic covalent exchange of orthoesters leading to a 9:1 mixture of (2-ethoxy-1,3-dioxolan-4-yl)methanol (R=H) (2b) (hereinafter referred to as dioxolane) and 2-ethoxy-1,3-dioxan-5-ol (R=H) (2c) (hereinafter referred to as dioxane), as well as ethanol (EtOH). Only dioxolane (2b) leads to allyl alcohol through CO.sub.2 extrusion. The same reactive solution could be utilized over several days without alteration of the results. The continuous-flow thermolysis of dioxolane (2b) in the reactive solution prepared by mixing glycerol (1) in the presence of triethyl orthoformate (21) undergoes a thermal concerted carbon dioxide elimination and hydrogen transfer to yield allyl alcohol (cf. FIG. 3).

(33) According to the reaction scheme illustrated in FIG. 3, the reaction with glycerol (1) formally consumes one equivalent of triethyl orthoformate (TEOF) (21) that forms dioxolane (2b) which is decomposed into allyl alcohol (3a) and possibly allyl formate (3b), CO.sub.2, and an alcohol, during the DODH process. It has been observed, however, that by adding triethyl orthoester (21) in amounts higher than the stoichiometric amount, the yield increased significantly. The triethyl orthoester is preferably present in the reactive solution in an amount comprised between 1 and 3 equivalents, more preferably between 1.5 and 2.5 equivalents.

(34) The release of ethanol significantly reduces the viscosity of the reactive solution, and pumping can be carried out without any issues with a standard HPLC pump without any solvent. As was the case with a reactive solution composed of glycerol and a carboxylic acid, discussed supra, the reactive solution preferably has a viscosity, when it is fed to the inlet of the channel comprised between 0.003 and 1.1 Pa.Math.s, measured as described supra

(35) Thermolysis of a reactive solution obtained by mixing glycerol and an orthoester, preferably TEOF, is preferably carried out with the following conditions. The pressure, P, is preferably comprised between 10-75 bar (=145-1088 psi), more preferably between 13 and 25 bar (=189 to 363 psi), more preferably between 14 to 20 bar (=203 to 290 psi), and most preferably at a pressure of 17±2 bar (=250±29 psi). The thermolysis time, t, is preferably comprised between 0.1 and 15 min, preferably between 5 and 8 min. Increasing the residence time up to 30 min had no significant effect on the conversion of glycerol. The thermolysis temperature, T, is preferably comprised between 200 and 370° C., preferably between 220 and 320° C.

(36) The absence of solvent, and the unique profile of the reagents and products enables convenient monitoring of the reaction course using in-line IR spectroscopy (51) (cf. FIG. 4). The appearance of allyl alcohol (3a) (νc=c at 1648 cm.sup.−1) and allyl formate (3b) (νc=c at 1656 cm.sup.−1 and νc=o at 1730 cm.sup.−1) was monitored through the evolution of the main characteristic vibration bands. In-line conversion of glycerol to (3a,3b) were obtained by combining in-line IR qualitative information and off-line quantitative NMR. The evolution of the intensity of the characteristic vibration band (νc=o at 2340 cm.sup.−1) of dissolved CO.sub.2 can be correlated to the conversion of glycerol. The white squares in FIG. 7(a) illustrate the yield of allyl compounds as a function of temperature for a reactive solution obtained by mixing glycerol (1) and 1 equivalent TEOF (21). The pressure, P, in the channel was 17 bar and the thermolysis time was 6 min. The reaction started at 175° C. and reached 5% after 6 min residence time. Rising the temperature up to 300° C. increased up to 27% the formation of allyl alcohol (3a). The conversion reached 55% at 350° C., but some clogging was observed. Allyl formate (3b) was not observed under these conditions.

(37) Allyl Formation by Thermolysis of Glycerol, a Carboxylic Acid, and a Triethyl Orthoester

(38) An allyl production line as discussed supra can be used for carrying out a continuous flow process according to the present invention for the production of allyl compounds by deoxydehydration of glycerol. The continuous flow process comprises the following steps: (a) Forming a reactive solution in the solution tank (22) by mixing: glycerol (1) with, carboxylic acid (2), and with, a triethyl orthoester (121), preferably triethyl orthoformate (TEOF), (b) feeding with the pump (23) the reactive solution to the inlet (32u) of the channel (32) of the thermolysis microreactor module discussed supra, (c) exposing the reactive solution to thermolysis by driving a flow of the reactive solution along the channel from the inlet to the outlet (32d), for a thermolysis time, t, at a pressure, P, and at a thermolysis temperature, T, larger than 200° C., to form thermolysis products including at least one allyl compound; and (d) recovering the thermolysis products at the outlet and separating the at least one allyl compound from the other thermolysis products

(39) As discussed supra in reference with FIG. 7(a), DODH of glycerol and triethyl orthoester, in particular TEOF, yields a moderate conversion rate into allyl alcohol of 27% at 315° C. Adding a carboxylic acid to the reactive solution of glycerol and TEOF, did not trigger any significant conversion rate differences at thermolysis temperatures of up to 200° C. As shown in FIG. 7(a), however, a huge difference was noticed at temperatures higher than 225° C. The black and white circles in FIG. 7(a) indicate the yield in allyl compounds by DODH of glycerol and TEOF with 0.1 equivalent of methanoic and ethanoic acid, respectively.

(40) The presence of a carboxylic acid, even in low amounts of between 10.sup.−3 to 10.sup.−1 equivalent (=0.1 to 10 mol % for 1 mol of glycerol) yielded a substantial increase of the yield in allyl compounds of up to nearly 90% at 250° C. No significant effect, however, of the nature of the carboxylic acid could be identified between methanoic acid (2m) and ethanoic acid (2e). With both acids, the yield decreased above 250° C. No allyl acetate was formed when ethanoic acid was used. As shown in FIG. 7(b), in the presence of a increasing amount of methanoic acid from 10.sup.−3 to 10.sup.−2, and to 10.sup.−equivalent (=0.1 to 1, and to 10 mol %), the yield at 250° C. and 6 min thermolysis time increased from 26% without carboxylic acid, to 48%, up to 77%, and to 86%, respectively. The system with 10.sup.−1 equivalent methanoic acid (black circles) at 250° C. yielded a 3a/3b ratio of 98:2 and was operated for 12 h in a row without any decrease in performance. Most importantly, it provided consistent results over various production campaigns even with aged glycerol samples.

(41) Thermolysis of a reactive solution obtained by mixing glycerol (1), a carboxylic acid (2), and a triethyl orthoester (21) is preferably carried out at a pressure, P, comprised between 10 and 75 bar (=145-1088 psi), more preferably between 13 and 25 bar (=189 to 363 psi), more preferably between 14 to 20 bar (=203 to 290 psi), and most preferably at a pressure of 17±2 bar (=250±29 psi). The thermolysis time, t, is preferably comprised between 0.1 and 15 min, preferably between 5 and 8 min. Increasing the residence time up to 30 min had no significant effect on the conversion of glycerol. The thermolysis temperature, T, is preferably comprised between 200 and 370° C., preferably between 220 and 320° C.

(42) According to the reaction scheme illustrated in FIG. 3, one equivalent of triethyl orthoformate (TEOF) (21) forming one equivalent of dioxolane (2b) suffices to form an allyl compound (3a, 3b). The triethyl orthoester is preferably present in the reactive solution in an amount comprised between 1 and 3 equivalents, more preferably between 1.5 and 2.5 equivalents, as it has been observed, that the yield increased with higher amounts of triethyl orthoester (21).

(43) The carboxylic acid (2) can be present in the reactive solution in an amount comprised between 0.001 and 1.5 equivalent, preferably between 0.01 and 1 equivalent. As discussed in continuation, the amount of carboxylic acid can be increased to 3 equivalents when used together with a triethyl orthoester.

(44) As discussed supra and illustrated in FIG. 7(b), a carboxylic acid can be present in small amounts, such as 10.sup.−3 to 10.sup.−1 equivalent (=0.1 to 10 mol % for 1 mol of glycerol) and increase the conversion rate of allyl compounds from 26% with no carboxylic acid to 47%, 77%, and up to 86% by addition of 10.sup.−3, 10.sup.−1, and 10.sup.−1 equivalent of methanoic acid, respectively. By further increasing the amount of carboxylic acid to 2.5 or 3 equivalents, yet higher conversion rates can be achieved. When used alone (i.e., in the absence of TEOF), it is preferred that the carboxylic acid be present in an amount higher than 2 equivalents. FIG. 8 illustrates the combined yield of allyl compounds (3a, 3b) obtained by thermolysis at a pressure, P=17 bar, for a thermolysis time, t=6 min; of a reactive solution obtained by mixing glycerol (1), 2.5 equivalents of carboxylic (methanoic) acid (2), and various amounts of TEOF ranging between 1 and 2.5 equivalents.

(45) It can be seen in FIG. 8 that for all temperatures, the conversion rate increases with higher amounts of TEOF. The highest conversion rate of 97% was obtained with 2.5 equivalents of methanoic acid and 2.5 equivalents of TEOF at a thermolysis temperature, T=300° C. Accordingly, in a preferred embodiment of the present invention, the reactive solution comprises both triethyl orthoformate (TEOF) and a carboxylic acid, present in amounts which do not differ from one another by more than ±20%, said amounts being preferably comprised between 2 and 3 equivalents, preferably between 2.3 and 2.7 equivalents, and wherein the thermolysis temperature is comprised between 200 and 370° C., preferably between 220 and 345° C., more preferably between 270 and 320° C.

(46) According to the reaction scheme illustrated in FIG. 3, the reaction between glycerol (1) and triethyl orthoformate (TEOF) (21) forms dioxolane (2b), dioxane (2c), and ethanol. The release of ethanol significantly reduces the viscosity of the reactive solution, and pumping can be carried out without any issues with a standard HPLC pump without any solvent. As was the case with a reactive solution composed of glycerol and a carboxylic acid, discussed supra, the reactive solution preferably has a viscosity, η, when it is fed to the inlet of the channel comprised between 0.003 and 1.1 Pa.Math.s, measured as described supra.

EXAMPLES

(47) The following Examples were carried out to illustrate the present invention. Table 1 summarizes the performances measured for Examples.

Example 1

Continuous-Flow DODH of Glycerol (1) with Methanoic Acid (2m)

(48) A dynamic reactive solution of glycerol was prepared by mixing glycerol (1) and 1.5 equiv. of methanoic acid (2m) (200 ml total volume), and connected to a HPLC pump (23) set at 0.12 ml min.sup.−1. The reactive feed solution was then thermolyzed at 345° C. at a pressure, P=69 bar (=1000 psi) of counter pressure in a production line as illustrated in FIG. 4. The outlet (32d) of the reaction coil was connected to a cooling SS capillary loop (41) (0.34 ml internal volume, 2.8 min residence time). The outlet of the second SS loop was connected to an in-line IR spectrometer (51), and a 17 bar (=250 psi) backpressure regulator (24) (BPR) was inserted downstream, for a thermolysis time, t=6 min. The reactor effluent was collected and analyzed by .sup.1H NMR yielding 46% combined yield, with a 96:4 3a/3b selectivity.

Example 2

Continuous-Flow DODH of Glycerol (1) with Methanoic Acid (2m)

(49) The same set up as described in Example 1 was used, pumping a dynamic reactive solution of glycerol (1) and 2.5 equiv. of methanoic acid (2m) (200 ml total volume). The reactive mixture was thermolyzed at T=315° C. at a pressure, P=17 bar (=250 psi) of counter pressure in a production line as illustrated in FIG. 4. The thermolysis time, t, was 13 min. The reactor effluent was collected and analyzed by .sup.1H NMR, yielding 62% combined yield with a 90:10 3a/3b selectivity.

Example 3

Continuous-Flow DODH with Triethyl Orthoformate

(50) The same set up as described in Example 1 was used, pumping a dynamic reactive solution of glycerol prepared by mixing glycerol (1) and 1 equiv. of triethyl orthoformate (21) (200 ml total volume). The HPLC pump used to deliver the dynamic reactive feed solution of glycerol was set at 0.26 ml min.sup.−1. The reactive mixture was thermolyzed at T=250° C. at a pressure, P=17 bar (=250 psi) of counter pressure in a production line as illustrated in FIG. 4. The thermolysis time, t, was 6 min. The reactor effluent was collected and analyzed by .sup.1H NMR yielding 26% combined yield with a 100:0 3a/3b ratio.

Example 4

Continuous-Flow DODH with Triethyl Orthoformate

(51) The same set up as described in Example 5 was used, pumping a dynamic reactive solution of glycerol prepared by mixing glycerol (1) and 1 equiv. of triethyl orthoformate (21) (200 ml total volume). The HPLC pump used to deliver the dynamic reactive feed solution of glycerol was set at 0.26 ml min.sup.−1. The reactive mixture was thermolyzed at T=350° C. at a pressure, P=17 bar (=250 psi) of counter pressure in a production line as illustrated in FIG. 4. The thermolysis time, t, was 6 min. The reactor effluent was collected and analyzed by .sup.1H NMR yielding 55% combined yield with a 100:0 3a/3b ratio. Some clogging was, however, observed.

Example 5

Continuous-Flow DODH with 1 eq. Triethyl Orthoformate (21) and 10.SUP.−3 .eq. Methanoic Acid (2m)

(52) The same set up as described in Example 1 was used, pumping a dynamic reactive solution of glycerol prepared by mixing glycerol (1), 1 equiv. of triethyl orthoformate (21) and 10.sup.−3 equivalent of methanoic acid (2m) (=0.1 mol %) (200 ml total volume). The HPLC pump used to deliver the dynamic reactive feed solution of glycerol was set at 0.26 ml min.sup.−1. The reactive mixture was thermolyzed at T=250° C. at a pressure, P=17 bar (=250 psi) of counter pressure in a production line as illustrated in FIG. 4. The thermolysis time, t, was 6 min. The reactor effluent was collected and analyzed by .sup.1H NMR yielding 48% combined yield with a 99:1 3a/3b ratio

Example 6

Continuous-Flow DODH with 1 eq. Triethyl Orthoformate (21) and 10.SUP.−2 .eq. Methanoic Acid (2m)

(53) The same set up as described in Example 1 was used, pumping a dynamic reactive solution of glycerol prepared by mixing glycerol (1), 1 equiv. of triethyl orthoformate (21) and 10.sup.−2 equivalent of methanoic acid (2m) (=1 mol %) (200 ml total volume). The HPLC pump used to deliver the dynamic reactive feed solution of glycerol was set at 0.26 ml min.sup.−1. The reactive mixture was thermolyzed at T=250° C. at a pressure, P=17 bar (=250 psi) of counter pressure in a production line as illustrated in FIG. 4. The thermolysis time, t, was 6 min. The reactor effluent was collected and analyzed by .sup.1H NMR yielding 77% combined yield with a 99:1 3a/3b ratio

Example 7

Continuous-Flow DODH with 1 eq. Triethyl Orthoformate (21) and 10.SUP.−1 .eq. Methanoic Acid (2m)

(54) The same set up as described in Example 1 was used, pumping a dynamic reactive solution of glycerol prepared by mixing glycerol (1), 1 equiv. of triethyl orthoformate (21) and 10.sup.−1 equivalent of methanoic acid (2m) (=10 mol %) (200 ml total volume). The HPLC pump used to deliver the dynamic reactive feed solution of glycerol was set at 0.26 ml min.sup.−1. The reactive mixture was thermolyzed at T=250° C. at a pressure, P=17 bar (=250 psi) of counter pressure in a production line as illustrated in FIG. 4. The thermolysis time, t, was 6 min. The reactor effluent was collected and analyzed by .sup.1H NMR yielding 86% combined yield with a 99:1 3a/3b ratio

Example 8

Continuous-Flow DODH with 1 eq. Triethyl Orthoformate (21) and 10.SUP.−1 .eq. Ethanoic Acid (2e)

(55) The same set up as described in Example 8 was used, pumping a dynamic reactive solution of glycerol prepared by mixing glycerol (1), 1 equiv. of triethyl orthoformate (21) and 10.sup.−1 equivalent of ethanoic acid (2e) (=10 mol %) (200 ml total volume). The HPLC pump used to deliver the dynamic reactive feed solution of glycerol was set at 0.26 ml min.sup.−1. The reactive mixture was thermolyzed at T=250° C. at a pressure, P=17 bar (=250 psi) of counter pressure in a production line as illustrated in FIG. 4. The thermolysis time, t, was 6 min. The reactor effluent was collected and analyzed by .sup.1H NMR yielding 84% combined yield with a 99:1 3a/3b ratio.

Example 9

Continuous-Flow DODH with 2.5 eq. Triethyl Orthoformate (21) and 2.5 eq. Methanoic Acid (2m)

(56) The same set up as described in Example 1 was used, pumping a dynamic reactive solution of glycerol prepared by mixing glycerol (1), 2.5 equiv. of methanoic acid (2m), and 2.5 equiv. of triethyl orthoformate (21) (200 ml total volume). The reactive mixture was thermolyzed at T=300° C. at a pressure, P=17 bar (=250 psi) of counter pressure in a production line as illustrated in FIG. 4. The thermolysis time, t, was 1 min. The reactor effluent was collected and analyzed by .sup.1H NMR, yielding 85% combined yield with a 90:10 3a/3b selectivity.

(57) TABLE-US-00001 methan. Glycerol ac. TEOF T P t yield 3a/3b mol eq. eq. ° C. Psi (bar) min % — Ex. 1 1 1.5 0 345 1000 (69.4) 6 46% 96/4 Ex. 2 1 2.5 0 315 250 (17.2) 13 62%  90/10 Ex. 3 1 0 1 250 250 (17.2) 6 26% 100/0  Ex. 4 1 0 1 350 250 (17.2) 6 55% 100/0  Ex. 5 1 0.001 1 250 250 (17.2) 6 48% 99/1 Ex. 6 1 0.01 1 250 250 (17.2) 6 77% 99/1 Ex. 7 1 0.1 1 250 250 (17.2) 6 86% 99/1 Ex. 8* 1 0.1 1 250 250 (17.2) 6 84% 99/1 Ex. 9 1 2.5 2.5 300 250 (17.2) 1 85%  90/10 Ex. 10 1 2.5 2.5 300 250 (17.2) 6 97%  80/20 *ethanoic acid was used instead of methanoic acid.

Example 10

Continuous-Flow DODH with 2.5 eq. Triethyl Orthoformate (21) and 2.5 eq. Methanoic Acid (2m)

(58) The same set up as described in Example 3 was used, pumping a dynamic reactive solution of glycerol prepared by mixing glycerol (1), 2.5 equiv. of methanoic acid (2m), and 2.5 equiv. of triethyl orthoformate (21) (200 ml total volume). The reactive mixture was thermolyzed at T=300° C. at a pressure, P=17 bar (=250 psi) of counter pressure in a production line as illustrated in FIG. 4. The thermolysis time, t, was 6 min. The reactor effluent was collected and analyzed by .sup.1H NMR yielding 97% combined yield with an 80:20 3a/3b ratio.

(59) The present invention implements the DODH reaction of glycerol under continuous-flow conditions in a microfluidic reactor setup. Dynamic reactive solutions are produced by mixing glycerol with a carboxylic acid (2), a triethyl orthoester (21), or a combination of both. Quick exposure to elevated temperatures under moderate pressure ensure short reaction times of less than 15 min, high yield of up to 97%, and excellent control of the selectivity. Triethyl orthoformate is a preferred triethyl orthoester. Best results are obtained when using triethyl orthoformate together with an amount of carboxylic acid for the DODH of glycerol, with shorter reaction times and lower reaction temperatures and high yields. The continuous flow process of the present invention is robust and gives reproducible results even with bio-sourced glycerol.

(60) TABLE-US-00002 # feature  1 glycerol  2 carboxylic acid  2a 4-(hydroxymethyl)-1,3-dioxolan-2-yl formate (R = H)  2b (2-ethoxy-1,3-dioxolan-4-yl)methanol (R = H) (=dioxolane)  2c ethoxy-1,3-dioxan-5-ol (R = H) (=dioxane)  2e ethanoic acid  2m methanoic acid  3a allyl alcohol  3b allyl formate  11 source of glycerol  12 source of carboxylic acid  21 triethyl orthoester (e.g., TEOF)  22 solution tank  23 pump  24 backpressure regulator (BPR)  31 thermolysis microreactor module  32 channel  32d channel outlet  32u channel inlet  41 cooling module  51 in-line analysis module  61 separating module 121 source of triethyl orthoester