Process to prepare higher ethylene amines and ethylene amine derivatives

Abstract

The present invention relates to a process to prepare ethyleneamines of the formula NH.sub.2—(C.sub.2H.sub.4—NH—).sub.pH wherein p is at least 2 wherein one or more units —NH—C.sub.2H.sub.4—NH— are present as a piperazine unit or precursors thereof wherein optionally one or more units —NH—C.sub.2H.sub.4—NH— are present as a cyclic ethylene urea unit or between two units —NH—C.sub.2H.sub.4—NH— a carbonyl moiety is present, by reacting an ethanolamine-functional compound, an amine-functional compound in the presence of a carbon oxide delivering agent, wherein at least one of the amine-functional compound or the ethanolamine-functional compound contains a piperazine unit, and the reaction is performed in a liquid that comprises water. ##STR00001##

Claims

1. A process for preparing a piperazine unit-containing ethyleneamine of the formula: ##STR00021## wherein R.sub.1 and R.sub.2 are independently selected form H and —(C.sub.2H.sub.4NH).sub.pH, wherein p is at least 1 and optionally i) one or more units —NH—C.sub.2H.sub.4—NH— are present as a piperazine unit: ##STR00022## or a cyclic ethylene urea unit: ##STR00023## or ii) a carbonyl moiety is present between two —NH—C.sub.2H.sub.4—NH— units; said process comprising reacting an ethanolamine-functional compound and an amine-functional compound in the presence of a carbon oxide delivering agent, in a liquid that comprises water, and at a temperature of at least 160° C. for a reaction time of between 5 minutes and 10 hours; wherein: the ethanolamine functional compound contains a hydroxyl group linked via an ethylene group to an amine group, or a linear or cyclic carbamate derivative thereof, or is UAEEA (the cyclic urea of aminoethylethanolamine) ##STR00024## the amine functional compound contains no alcohol groups, and contains one or more amine groups, or the amine functional compound is the cyclic urea of ethylenediamine (EU) ##STR00025## the carbon oxide delivering agent is carbon dioxide or an organic compound selected from urea, linear and cyclic alkylene ureas, mono- or di-substituted alkylene ureas, alkyl and dialkyl ureas, linear and cyclic carbamates, organic carbonates, and derivatives or precursors thereof selected from carbonate salts, bicarbonate salts and carbamic acids and their salts; wherein at least one of the amine-functional compound or the ethanolamine-functional compound contains a piperazine unit; and wherein the molar ratio of water to the amine-functional compound is greater than 0.2:1 and less than 4.8:1.

2. The process of claim 1, wherein the ethanolamine-functional compound is of the formula HO—(C.sub.2H.sub.4—NH—).sub.qH wherein q is at least 1; and the amine functional compound is of the formula NH.sub.2—(C.sub.2H.sub.4—NH—).sub.rH wherein r is at least 1 and one or more —NH—C.sub.2H.sub.4—NH— units are present as a piperazine unit; wherein optionally one or more —NH—C.sub.2H.sub.4—NH— units may be present as a cyclic ethylene urea unit; and wherein optionally one or more —O—C.sub.2H.sub.4—NH— units are present as a cyclic ethylene carbamate unit.

3. The process of claim 1, wherein the amine-functional compound is selected from the group consisting of (a) piperazine (PIP), (b) aminoethylpiperazine (AEP), (c) diaminoethylpiperazine (DAEP), (d) piperazinoethyl ethylenediamine (PEEDA), and a linear urea of any one of (a)-(d).

4. The process of claim 1, wherein the ethanolamine-functional compound is monoethanolamine (MEA) or a cyclic or linear carbamate thereof; or aminoethylethanolamine (AEEA) or a cyclic or linear carbamate or urea derivative thereof.

5. The process of claim 1, wherein the liquid comprises at least 75 wt-% of water based on a total weight of the liquid.

6. The process of claim 1, wherein the molar ratio of ethanolamine-functional compound to amine-functional compound is at least 0.7:1.

7. The process of claim 1, wherein the molar ratio of carbon oxide delivering agent to amine functional compound is at least 0.2:1.

8. The process of claim 1, wherein the molar ratio of ethanolamine-functional compound to amine-functional compound is between 0.8 and 5:1 and the molar ratio of carbon oxide delivering agent to amine functional compound is between 0.5:1 and 20:1.

9. The process of claim 1, wherein the molar ratio of ethanolamine-functional compound to amine-functional compound is between 0.7:1 and 2:1 and the molar ratio of carbon oxide delivering agent to amine-functional compound is between 0.7:1 and 3:1.

10. The process of claim 1, wherein the ethanolamine-functional compound and the carbon oxide delivering agent are at least partly added as one compound by using a carbamate adduct.

11. The process of claim 1, wherein the ethanolamine-functional compound is monoethanolamine (MEA), the cyclic carbamate of MEA (CMEA) or a mixture thereof and the amine-functional compound is PIP or a mixture of PIP, ethylenediamine (EDA) and the cyclic urea of EDA (EU), and wherein the molar ratio of MEA+CMEA to EDA+EU+PIP is higher than 2.

12. A process for producing an ethylene amine, said process comprising: (a) preparing an ethylene amine compound containing a cyclic ethylene urea moiety according to the process of claim 1; and (b) converting said ethylene amine compound containing a cyclic ethylene urea moiety into its corresponding ethylene amine.

13. The process of claim 1, wherein the molar ratio of water to the amine-functional compound is greater than 0.5:1.

14. The process of claim 1, wherein the molar ratio of water to the amine-functional compound is greater than 1:1.

15. The process of claim 11, wherein the molar ratio of MEA+CMEA to EDA+EU+PIP is higher than 3.

Description

EXAMPLES

(1) ##STR00015##

(2) Most preferred the amine-functional compound comprises piperazine (PIP), aminoethylpiperazine (AEP), diaminoethylpiperazine (DAEP), piperazinoethyl ethylenediamine (PEEDA) or a linear urea thereof

(3) Generally, the ethanolamine-functional compound is of the following formula

(4) ##STR00016##

(5) Where R in embodiments is a substituted or unsubstituted alkyl group which also can contain unsaturated moieties and heteroatoms, such as oxygen and nitrogen.

(6) Examples of Ethanolamine Functional Compounds Include

(7) ##STR00017##

(8) As to naming convention, MEA stands for monoethanolamine, AEEA stands for aminoethylethanolamine (also referred to as hydroxyethylethyleneamine), HE-DETA for hydroxyethyldiethylenetriamine, and from there on HE-TETA for hydroxyethyl triethylenetetramine etc. PE-MEA stands for piperazinoethylmonoethanolamine. By using the letter C it is indicated that a cyclic carbamate ring is present in the molecule.

(9) The ethanolamine-functional compound is preferably monoethanolamine (MEA) or aminethylethanolamine (AEEA) or a cyclic or linear carbamate or urea thereof.

(10) The carbon oxide delivering agent is a compound containing a carbonyl moiety that can be transferred to an ethanolamine functional compound leading to the formation of a cyclic carbamate, such as CMEA (2-oxazolidinone) or that can be transferred to an ethylene amine (EA) leading to the formation of the corresponding cyclic ethylene urea (UEA). Next to cyclic compounds linear carbamates and ureas may form as well.

(11) Carbon oxide delivering agents within the scope of the present invention include carbon dioxide, and organic compounds in which a carbonyl moiety is available for being transferred as described above. Organic compounds in which a carbonyl moiety is available include urea and derivatives thereof; linear and cyclic alkylene ureas, especially cyclic urea, mono or di-substituted alkylene ureas, alkyl and dialkyl ureas, linear and cyclic carbamates, organic carbonates and derivatives or precursors thereof. Such derivatives or precursors may for example include ionic compounds such as carbonate or bicarbonate salts, carbamic acids and associated salts, that can be converted, in some embodiments in situ in the process of the invention, into their non-ionic counterparts, for example into linear and cyclic carbamate or urea compounds. When such ionic compounds are used in the present invention, they are organic hydrocarbon-based carbonate bicarbonate or carbamate salts. Preferably the CO delivering agent is CO2 or an organic compound that is suitable for use as a carbon oxide delivering agent and wherein alkylene is ethylene, or urea or ethylene carbonate, more preferably the carbon oxide delivering agent is at least partly added as carbon dioxide or urea. The carbon oxide delivering agent can be present in the process in the same molecule as the amine functional or the ethanolamine functional compound by using the aforementioned urea or carbamate compounds.

(12) Examples of Carbon Oxide Delivering Agents Include

(13) ##STR00018## ##STR00019##

(14) In the above drawing CAEEA again stands for the carbamate of aminoethylethanolamine, UDETA for the urea of diethylene triamine, DAEU stands for diaminoethyl urea, AE AE carbamate stands for amino ethyl aminoethanol carbamate, CHE-DETA stands for the carbamate of hydroxyethyldiethylene triamine, U1TETA stands for the terminal urea of triethylene tetramine, and DUTETA stands for the 1,3-diurea of triethylene tetramine.

(15) The carbon oxide delivering agent is most preferably added to the reaction in the form of carbon dioxide, the carbamate derivative of the ethanolamine-functional compound or the urea derivative of the amine-functional compound, or a combination of these.

(16) In a preferred embodiment using at least 0.7 molar equivalents of ethanolamine-functional compound to amine-functional compound and at least 0.05 molar equivalents of carbon oxide delivering agent on amine-functional compound, the selectivity of the reaction towards specific higher ethylene amines can be further increased.

(17) In another preferred embodiment the molar ratio of carbon oxide delivering agent to amine functional compound is at least 0.2:1, even more preferably, the molar ratio of carbon oxide delivering agent to amine-functional compound is between 0.5:1 and 20:1

(18) More preferably, the molar ratio of ethanolamine-functional compound to amine functional compound is between 0.8 and 5:1 and the molar ratio of carbon oxide delivering agent to amine functional compound is between 0.5:1 and 20:1, even more preferably, the molar ratio of ethanolamine-functional compound to amine-functional compound is between 0.7:1 and 2:1 and the molar ratio of carbon oxide delivering agent to amine-functional compound is between 0.7:1 and 3:1.

(19) In yet another preferred embodiment piperazine can be reacted to give a disubstituted piperazine. It is to be understood that then the molar ratio of ethanolamine-functional compound to the amine-functional compound piperazine should be equal to, or even more preferred higher than, 2:1 as each equivalent of piperazine can be reacted with two equivalents of ethanolamine-functional compound.

(20) It should be noted that compounds exist that contain more than one carbonyl moiety that can be released from the molecule for transfer to the ethanolamine-functional compound. When determining the molar ratio for such compounds there should be an adjustment for the molar amount of carbon oxide they can release for transfer to the ethanolamine-functional compound or otherwise contribute to the process of the invention.

(21) Selecting the right molar amounts of the carbon oxide delivering agent on amine-functional compound was found to further improve selectivity and yield in the process of the invention.

(22) The molar amount of carbon oxide delivering agent on amine-functional compound is determined by the reactants in the process, independent of the dosing regime used for the reactants.

(23) The reaction mixture is characterized by containing as reactants ethanolamine-functional compound, amine-functional compound and carbon oxide delivering agent and can be roughly represented by below non-limiting scheme.

(24) Scheme 1: Amine Functional Compound is a Cyclic Secondary Amine

(25) ##STR00020## I Addition of CO to the ethanolamine to form the 2-oxazolidinone ring II Chain extension by ring opening by cyclic secondary amine III Removal of carbonyl group to form the ethylene amine V Hypothetical direct uncatalyzed amination

(26) A number of reactions take place simultaneously when heating a mixture of a carbonyl source, an ethanolamine-functional compound and an amine-functional compound.

(27) Without being bound to theory this can be summarized in two main reaction steps each composed of multiple sub steps: 1) the activation of the alcohol function (A) by the carbonyl group, the oxazolidinone (B) is assumed to be an intermediate, 2) the activated alcohol function is replaced by an amine (C) to give a chain extended primary addition product (D). In the presence of ammonia a conversion of the alcohol function to an amine function without giving a chain extension can take place as well. Optionally the CO groups can be removed leading to the formation of an ethylene amine (E).

(28) Hence, in an embodiment of the process of the invention where the product composition that is obtained contains ethylene urea compounds, a next step is performed to convert obtained ethylene urea compounds into their corresponding ethylene amines, for example by hydrolyzing them.

(29) Heating a suitable mixture of an ethanolamine, an amine that is not tertiary and a carbon oxide delivering agent to a relatively high temperature provides a way to produce a higher amine and CO containing derivative thereof that can serve as a carbon oxide delivering agent.

(30) In another preferred embodiment the ethanolamine-functional compound and the carbon oxide delivering agent are at least partly added as one compound by using a carbamate adduct and/or the amine-functional compound and the carbon oxide delivering agent are at least partly added as one compound by using an urea adduct.

(31) In a preferred embodiment the reactants are piperazine (PIP), and/or a mono or di aminoethyl-substituted piperazine (AEP or DAEP) as the amine-functional compound and monoethanolamine (MEA) and/or aminoethylethanolamine (AEEA) as the ethanolamine-functional compound wherein optionally one or more of these compounds may be present as a carbamate or urea derivative.

(32) In a more preferred embodiment the ethanolamine-functional compound is MEA, CMEA or a mixture thereof and the amine-functional compound is piperazine (PIP), or a combination of EDA, EU and PIP.

(33) Even more preferred the ratio of, the ratio MEA+CMEA to PIP, is higher than 2, yet more preferred higher than 3.

(34) In an embodiment of the process of the invention a next step is performed to convert possibly obtained cyclic ethylene urea into its corresponding ethylene amine, though in many embodiments this step is not necessary as the product will not be a cyclic ethylene urea which cannot form on a cyclic secondary amine function.

(35) The product mixture can be further processed or fractionated into several products that each independently are either pure compounds or mixture of compounds, some of which may be recycled.

(36) The process of the present invention is done in a liquid which is a polar liquid, such as an alcohol or water. Doing the process of the present invention in the presence of water as a liquid or without any additional liquid is preferred.

(37) The reactor employed can be any suitable reactor including continuously stirred tank reactor, pipeline reactor, tubular or multi-tubular reactor. The reactor may be adiabatic or equipped with external or internal heating devices. Feed may be single point or split into multiple points. It can consist of multiple stages with inter-stage heat exchange.

(38) The process is preferably performed at a temperature of at least 100° C. The temperature should preferably be lower than 400° C. More preferably the temperature is between 120 and 320° C. Even more preferably the temperature is between 150 and 280° C. Most preferably the temperature is between 190 and 230° C.

(39) In embodiments where the ethanolamine-functional compound is monoethanolamine the temperature is at least 100° C. The temperature should preferably be lower than 300° C. More preferably the temperature is between 120 and 280° C. Even more preferably the temperature is between 140 and 220° C. Most preferably the temperature is between 160 and 200° C.

(40) The reaction time during the process is in an embodiment between 5 minutes and 10 hours, preferably between 0.5 and 6 hours, more preferably between 1 and 4 hours.

(41) The process can be carried out in one or multiple batch reactors, possibly in fed-batch operation, and/or in a continuously operating system in one reactor or in a cascade of continuous flow reactors, optionally with multiple feeding points. The reaction and separation can be performed in separate steps or at least partially simultaneously. The reaction and separation can involve multiple reaction steps with separation steps in between.

(42) In the large-scale production of chemicals it is preferred to employ a continuous process. The continuous process may be, for example, a single-pass or a recycle process. In a single-pass process, one or more of the reagents pass through the process equipment once, and then the resulting effluent from the reactor is sent for purification or further processing.

(43) The person skilled in the art is capable of selecting the proper reactor and separation unit scheme by determining the overall yield, energy consumption and waste production.

Examples

Comparative Example A (Based on U.S. Pat. No. 5,262,534/Example 1)

(44) 25.48 g (1.18 mole) PIP and 21.78 g (1 mole) CMEA were charged to a 300 mL autoclave equipped with stirring and internal temperature monitoring. The reaction was then carried out for 2 h at 200° C. The resulting reaction mixture was analyzed using a GC-FID (gas chromatography using a flame ionization detector). The GC results are reported as area-%.

Examples 1-9 (Influence of Water on Product Yields for the Reaction PIP+CMEA after 30 min)

(45) PIP and CMEA—with a similar PIP to CMEA molar ratio as in the comparative Example A of 1.18 to 1—together with varying amounts of water—0.25 to 24 molar equivalent of water relative to the amount of PIP—were charged to a 300 mL autoclave equipped with stirring and internal temperature monitoring. The reaction was then carried out for 30 min at 200° C. The resulting reaction mixture was analyzed using GC-FID. The GC results are reported as area-% in below Table 1.

(46) TABLE-US-00002 TABLE 1 reaction of PIP and MEA at several water amounts Example A 1 2 3 4 5 6 7 8 9 H.sub.2O in molar equiv. 0 0.25 0.5 1 2.2 4.8 7.2 9.5 14.4 24 relative to n(PIP) MEA 7 7 7 7 6 6 6 5 6 6 PIP 52 51 49 42 40 34 35 38 32 31 AEP 26 27 32 38 40 42 42 41 43 42 CMEA 9 10 6 5 3 2 1 n.d. 1 n.d. DAEP 2 2 3 4 6 10 11 10 12 13 PEEDA n.d. n.d. n.d. n.d. n.d. 1 1 1 1 1 UAEEA 1 1 1 1 1 1 1 1 1 1 UPEEDA 2 2 2 2 3 3 3 2 3 3 UPEDETA n.d. n.d. n.d. n.d. n.d. 1 1 1 1 1 GC results in area-% n.d. = below detection limits

(47) Examples 1-9 clearly show that the addition of water of more than 0.2 mol-equiv. increases the conversion of PIP to AEP and DAEP compared to the reaction without water (Example A) without increasing the amount of other products formed.

Examples 10-15 (Influence of Water and Reaction Time on Product Yields for the Reaction PIP+CMEA at 200° C.)

(48) The same experimental setup as described for Examples 1-9 was used except that the reaction time at 200° C. was varied from 30 to 150 min. Reactions were performed without added water or with 0.5 molar equivalents of water relative to the molar amount of PIP. The resulting reaction mixture was analyzed using GC-FID. The GC results are reported as area-% in below Table 2.

(49) TABLE-US-00003 TABLE 2 the reaction of PIP and MEA at different reaction times with and without water Example A 10 11 12 1 13 14 15 with 0.5 mol.-equiv H2O without added H.sub.2O relative to n(PIP) reaction time in min 30 60 120 150 30 60 120 150 MEA  7  6  5  4  7  6  5  4 PIP 52 43  46  39 49 41  36  35 AEP 26 36  37  43 32 39  42  45 CMEA  9  5  2  3  6  4  1  2 DAEP  2  4  6  6  3  6  9  8 PEEDA n.d. n.d. n.d. n.d. n.d. n.d. n.d. n.d. UAEEA  1  1  1  1  1  1  1  1 UPEEDA  2  2  3  4  2  3  4  4 UPEDETA n.d. n.d.  1 n.d. n.d. n.d.  1  1 GC results in area-% n.d. = below detection limits

(50) It was shown that the addition of 0.5 moles of water per mole of PIP lead to higher AEP and DAEP yield compared to the reaction without water without increasing the amount of other products formed.

Examples 16-21 (Influence of Water and Reaction Temperature on Product Yields for the Reaction PIP+CMEA after 2 h Reaction Time)

(51) The same experimental setup as described for Examples 1-9 was used except that the reaction temperature was varied from 120 to 200° C. Reactions were performed without added water or with 4.8 molar equivalent of water relative to the amount of PIP. The reaction time was kept constant at 2 h. The resulting reaction mixture was analyzed using GC-FID. The GC results are reported as area-% in below Table 3.

(52) TABLE-US-00004 TABLE 3 the reaction of PIP and MEA at different temperatures with and without water Example 16 17 18 A 19 20 21 5 4.8 molar equiv. H.sub.2O without added H.sub.2O relative to n(PIP) temperature in ° C. 120 140 160 200 120 140 160 200 MEA n.d.  1  6  5 n.d.  4  6  6 PIP 66 67 59 46 57 50 44 34 AEP  5  7 16 37 16 28 37 42 CMEA 24 21 12  2 21 12  2  2 DAEP  1 n.d.  1  6  2  3  6 10 PEEDA n.d. n.d. n.d. n.d. n.d.  1  1  1 UAEEA n.d. n.d. n.d.  1 n.d. n.d. n.d.  1 UPEEDA n.d. n.d.  2  3 n.d.  1  2  3 UPEDETA n.d. n.d.  1  1 n.d. n.d.  1  1 GC results in area-% n.d. = below detection limits

(53) In agreement with Examples 10-15 the addition of water leads to an increase in AEP and DAEP yield at the same reaction temperature which also means that—compared to the reaction without water—similar AEP and DAEP yields can be obtained at lower reaction temperatures without increasing the amount of other products formed.

Examples 22-25 (Influence of Water on Product Yields for the Reaction AEP+CMEA)

(54) The same experimental setup as described for Examples 1-9 was used except that 1 mole AEP and 1 mole CMEA—were reacted at 200° C. for 1 h without added water or with 0.5, 1, or 2 molar equivalent of water relative to the amount of AEP. The resulting reaction mixture was analyzed using GC-FID. The GC results are reported as area-% in below Table 4.

(55) TABLE-US-00005 TABLE 4 reaction of AEP and MEA with different amounts of water Example 22 23 24 25 H.sub.2O in molar equiv. 0 0.5 1 2 relative to n(PIP) MEA 12 12 11 10 AEP 58 58 56 52 CMEA 5 4 3 2 DAEP 13 15 18 21 PEEDA n.d. n.d. n.d. n.d. UAEEA 2 2 2 2 UPEEDA 6 6 6 7 UTEPA 2 2 2 5 GC results in area-% n.d. = below detection limits

(56) The results show that the positive effect on the product yield of adding water is also observed when AEP is used as starting material.

Examples 26-27 (Influence of Water for Reaction PIP+UAEEA)

(57) The same experimental setup as described for Examples 1-9 was used except 1 mole PIP was reacted with 1 mole UAEEA at 200° C. for 30 min without added water or with 2.5 molar equivalent of water relative to the amount of PIP. The resulting reaction mixture was analyzed using GC-FID. The GC results are reported as area-% in below Table 5.

(58) TABLE-US-00006 TABLE 5 the reaction of PIP and AEEA with and without water Example 26 27 H.sub.2O in molar equiv. 0 2.5 relative to n(PIP) AEEA 4 12 PIP 34 27 UAEEA 48 26 PEEDA 1 8 UPEEDA 12 18 highers n.d. 1 GC results in area-% n.d. = below detection limits

(59) Adding water to PIP and UAEEA increases the conversion of PIP and results in higher yields of PEEDA and UPEEDA.