Synthesis of guerbet alcohols

Abstract

A method and system for preparing a mixture of Guerbet alcohols where one or more primary alcohols of the formula RCH.sub.2CH.sub.2OH are provided, with R representing hydrogen or a straight or branched chain alkyl group of 1 to 14 carbon atoms. A base and a catalyst are provided, which are mixed with the primary alcohol(s). The resulting mixture is heated to a process temperature above the boiling point of water under reaction conditions and the water resulting from the thus obtained condensation and dehydration of the primary alcohols is then removed constantly. When the Guerbet reaction has reached a certain stage, at least part of the reaction mixture is removed, followed by a separation of the desired Guerbet alcohols from the removed part of the reaction mixture. The other alcohols are then returned to the reaction mixture for obtaining a higher amount of the desired Guerbet alcohols.

Claims

1. A method for preparing a mixture of Guerbet alcohols, the method comprising: providing a starting material comprising a blend of at least two different primary alcohols, each of the at least two different primary alcohols independently being of the formula RCH.sub.2CH.sub.2OH, where R is hydrogen or a straight or branched chain alkyl group of 1 to 14 carbon atoms; providing a base; providing a catalyst; mixing the starting material with the base and the catalyst in a reactor to form a reaction mixture; heating the reaction mixture to a process temperature above the boiling point of water and under reaction conditions to cause condensation and dehydration of the at least two primary alcohols of the blend and to evolve vapor including water vapor; removing the evolved vapor including water vapor from the reactor and feeding the removed vapor to a water separation unit, the water separation unit comprising a water outlet port; removing part of the reaction mixture from the reactor, to form a removed part, and feeding the removed part to a liquid-liquid mixer-settler, the removed part comprising a mixture of Guerbet alcohols having respective boiling points, and alcohols having lower boiling points than the boiling points of the Guerbet alcohols; feeding water from the water outlet port of the water separation unit, into the liquid-liquid mixer-settler to form a settler mixture; separating an organic fraction from an aqueous fraction in the liquid-liquid mixer-settler; feeding the organic fraction into an alcohols column; forming dried alcohols from the organic fraction in the alcohols column; separating the dried alcohols into a mixture of Guerbet alcohol products and the alcohols having lower boiling points than the boiling points of the Guerbet alcohols; returning the alcohols having lower boiling points than the boiling points of the Guerbet alcohols, to the reaction mixture in the reactor; and compensating for the removed part of the reaction mixture by adding appropriate amounts of new starting material comprising a blend of at least two different primary alcohols, base, and catalyst, to the reaction mixture in the reactor, for balancing the respective losses.

2. The method according to claim 1, wherein the starting material further contains primary alcohols in which a carbon atom in a beta-position is bonded to two or three alkyl groups, secondary alcohols, ketones, and aldehydes, and the method further comprises adding hydrogen gas (H.sub.2) to the reaction mixture or the removed part of the reaction mixture.

3. The method according to claim 1, wherein the blend of at least two different primary alcohols contains at least two primary alcohols selected from n-propanol, n-butanol, n-pentanol, and n-hexanol.

4. The method according to claim 1, wherein the base is selected from the group consisting of sodium tert-butoxide, potassium hydroxide, sodium hydroxide, and heterogeneous bases, which may optionally be doped.

5. The method according to claim 1, wherein the catalyst is a homogenous catalyst or a heterogeneous catalyst selected from the group consisting of Pd(OAc).sub.2, Pd/C, Pt/C, CuZnO, CuCrO, hydrotalcites and hydroxylapatites doped with metals, Raney Ni, and NiMgO/SiO.sub.2.

6. The method according to claim 5, wherein the catalyst is a solid heterogeneous catalyst provided in a fixed bed, or a slurry fluidized bed, or a mobile bed.

7. The method according to claim 1, wherein the process temperature corresponds to a boiling point of the starting material under reaction conditions.

8. The method according to claim 1, wherein the reaction conditions comprise a pressure in the range of from 1 to 20 bar.

9. The method according to claim 1, wherein the starting material is pretreated by a process comprising one or more of ion exchange, neutralization, and dehydration, to remove acidic components, ester components, water, or a combination thereof, before mixing the starting material with the base and the catalyst in the reactor.

10. The method of claim 1, further comprising adding the mixture of Guerbet alcohols to a gasoline, diesel fuel, aviation gasoline, jet fuel, or a combination thereof.

11. The method of claim 1, further comprising processing the mixture of Guerbet alcohols optionally with other components to form a surfactant, an alpha-olefin, an alpha-olefin polymer, an alpha-olefin oligomer, or a combination thereof.

12. The method of claim 1, wherein the step of compensating is performed simultaneously with the step of returning.

13. The method of claim 1, wherein the step of compensating is performed after the step of returning.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) A better understanding of the features and advantages of the present teachings can be achieved by reference to the accompanying drawings, which are intended to illustrate, not limit, the present teachings.

(2) FIG. 1 shows a simplified piping and instrumentation diagram of a process engineering system for a synthesis of Guerbet alcohols from a starting material comprising one or more primary alcohols.

(3) FIG. 2 shows a flow chart illustrating the basic steps of a method for synthesising Guerbet alcohols from a starting material comprising one or more primary alcohols with a system according to FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

(4) FIG. 1 shows a simplified piping and instrumentation diagram of a process engineering system 100 for a synthesis of Guerbet alcohols from one or more primary alcohols.

(5) The synthesis itself takes place in reactor 10 comprising a feed port 11 for introducing feedstock into the reactor 10, and a discharge port 12 for discharging material from the reactor 10. The reactor 10 is further provided with a vapour outlet port 13 and a reflux inlet port 14, both connected to a water separation unit 20. In preferred embodiments, the reactor further comprises a base inlet port 15 and catalyst inlet port 16 for enabling a separate feeding of a base and/or a catalyst into the reactor. The reactor may have further ports (not shown in the Figure) that may be used for other purposes like process control and addition of further reactants, e.g. hydrogen that may be added to the reactor at a later stage of the reaction for facilitating the hydrogenation step in the reaction sequence of Guerbet alcohol formation, or hydrogen capture agents, such as olefins, that may be added at an earlier stage of the reaction to facilitate the formation of the intermediate aldehydes.

(6) The reactor can be a stirred tank reactor, a fixed bed reactor, a mobile bed reactor, a fluidized bed reactor with a homogeneous or heterogeneous catalyst, where the base can be either homogeneous or heterogeneous, and in the latter case can eventually be used as catalyst or as the support phase of an active catalyst.

(7) As explained above, the Guerbet reaction requires a multi-functional catalytic system for enabling a dehydrogenation and a hydrogenation, which are both promoted by a metallic and/or basic function, an aldolisation and a dehydration, which are promoted by acidic-basic properties. Upon a start of operation, the reactor 10 is therefore filled up to a certain level with a starting material of primary alcohols, a base, and a catalyst, whereby the mixture is heated to a process temperature above the boiling point of water under reaction conditions. The synthesis process can be carried out at atmospheric pressure (1 bar) or higher pressures, like for instance up to 10 bar or even higher, for example 20 bar, whereby higher pressures usually allow higher process temperatures for example temperatures up to 200 C. and even higher, e.g. 250 C.

(8) Since the water formed during the reaction may have a negative effect on the further progress of the reaction, it is continuously removed from the reactor. To this end, vapours including steam, i.e. water vapour, evolving during the reaction process are removed from the reactor through vapour outlet port 13 and fed into the water separation unit 20 via the unit's vapour inlet port 21. The water separation unit 20 removes the water contained in the vapour received from the reactor 10. The water separation unit 20 is further configured to recycle part of the alcohols present in the vapour received and to return these via the unit's alcohol outlet port 22 and the reactor's reflux inlet port 14 back into the reaction mixture located inside the reactor 10. The separated water, usually still containing some of the light alcohols or other products originating from the reaction mixture, is discharged from the water separation unit through the water outlet port 23. Examples for water separation units 20 are water separation columns, Dean-Stark traps, molecular sieves, membranes, or the like. Preferred are distillation separation columns, including rotating packed bed units (HiGee), heat integrated distillation units (HiDic) and any alternative technology suited for the separation of close boiling point compounds.

(9) Between reactor 10 and water separation unit 20, or integrated in the water separation unit 20, a separator (not shown in the figure), e.g. flash, column or purge/splitter, can be optionally provided for removing some light components, to facilitate the operation of the water separation unit 20.

(10) In some embodiments, a stirrer (not shown in the Figure) is disposed within reactor 10 for stirring the reaction mixture and facilitating a separation between the liquid and the vapour phases in the reactor. The heating of the reaction can be accomplished using internal coils, a heating jacket, an external heat-exchanger with external recirculation, or any other suitable means.

(11) For separating the desired Guerbet alcohols, at least part of the reaction mixture is discharged from the reactor 10 via the discharge port 12. When applying a batchwise synthesis process, the reaction is performed until completed, which, since the production of water decreases towards the end of the process, can be determined by monitoring the water content of the vapour fed into the water separation unit 20. The end of the reaction is then determined when the production of water has sufficiently slowed down. Alternatively, the process will be ended when the desired reaction time has been reached, whereby the desired reaction time can be determined based on experiments and/or simulations. When applying a more continuous processing, part of the reaction mixture is removed from a certain stage of the reaction, and supplied to a separation system where the desired Guerbet alcohols are separated and the lighter alcohols returned to the reactor 10. Once started, the removal of part of the reaction mixture can be effected on a continuous or discontinuous basis. Returning the alcohols lighter than the desired long-chain Guerbet alcohols to the reactor 10 reintroduces these alcohols into the reaction process to thereby increase the process yield with respect to the amount of primary alcohols used.

(12) Prior to a separation of the desired Guerbet alcohols from the other alcohols, the discharged reaction mixture is preferably processed in a first after-treatment system 30 adapted to remove the catalyst, the base and possibly degradation products of the former, such as salts formed by neutralization of the base. The separation of the catalyst from the discharged reaction mixture depends on the respective catalyst's properties. When using e.g. palladium(II)-acetate (Pd(OAc).sub.2) as is preferred in some embodiments, the catalyst may be washed out with water allowing it to precipitate. The catalyst can then be filtered out, optionally dried, and returned to reactor 10 using catalyst inlet port 16 or can be eliminated from the process loop and regenerated into fresh catalyst. The homogeneous base may be removed using an acid, which may for example include an ion exchange resin or electrodialysis, and separating the resulting salt from the mixture. The resin may be regenerated by an acid wash. The first after-treatment system 30 may further also be configured to remove other solids from the discharged reaction mixture.

(13) Optionally an additional hydrogenation reactor (not shown in the figure) is provided downstream of the reactor 10, e.g. downstream of the first after-treatment system 30. The aim of this reactor is to complete the dehydration-hydrogenation of the reaction intermediates and to enrich the stream in Guerbet alcohols. Any conventional catalyst can be used for this step and preferably catalysts containing Ni, or a noble metal. A supplement of hydrogen (H.sub.2) is also fed to this reactor.

(14) When operating the system 100 in a continuous or stepwise continuous way, the amount of material discharged from the reactor is replaced in part by the lighter alcohols from the separation system 44 that are returned into the reactor, newly added feedstock, and the amounts of base and catalyst required for balancing the respective losses caused by the discharge of materials from the reactor 10. While the base replacement is advantageously effected using base inlet port 15, replenishment of the catalyst is preferably performed using catalyst inlet port 16.

(15) For the separation of the desired Guerbet alcohols and the recovery of the alcohols to be returned to the reaction chamber 10, a second after-treatment system 40 is used which comprises a liquid-liquid mixer-settler (or decanter) configuration 41, a water column 42, an alcohols column 43, and an alcohols splitter column 44.

(16) The liquid-liquid mixer-settler configuration 41 receives the output from the first after-treatment system 30 as well as the output from the water outlet port 23 of the water separation unit 20. The latter is necessary, because it is not always possible to obtain a pure aqueous stream at the water outlet port 23 due to the water forming azeotropes with the alcohols received from the reactor 10 and the water concentration being subazeotropic. The azeotropic composition from the water outlet port 23 of the water separation unit 20 and the output from the first after-treatment system 30 are initially introduced into the mixer where a phase separation is expected to occur.

(17) The organic fraction from the settler is fed into to the alcohols column 43, e.g. a stripping column, where the dried alcohols are obtained at the bottom while an azeotropic alcohol/water mixture is taken from the top, condensed, cooled and finally returned to the mixer. The operation of the alcohols column 43 is preferably effected under vacuum conditions (e.g. at 0.4 bar abs.) enabling a lowering of the working temperature of the reboilers.

(18) Optionally between the liquid-liquid mixer-settler 41 and the alcohols column 43, there is an additional separation unit (not shown in the figure), as e.g. flash, column or purge/splitter, to avoid building-up of some light components.

(19) The aqueous fraction from the settler is fed into the water column 42, e.g. a stripping column, where it is split into a water bottom stream representing the systems waste water and an azeotropic mixture on the top that is returned to the mixer after having been condensed and cooled. Also the water column 42 is preferably operated under vacuum conditions (e.g. at 0.4 bar abs.).

(20) The dried alcohols obtained at the bottom of the alcohols column 43 are separated by distillation in a single alcohols splitter column 44, based on their respective differences in volatility. The lighter alcohols are returned to the reactor while the heavier ones are obtained as product or are used for further processing like for instance hydrogenation and/or dehydration. The average size of the thus separated products can be controlled by setting the separation characteristics of the column 44.

(21) In the return loops described above, one or several systems can be provided to remove certain components which have the tendency to show ever increasing concentrations in this loop because they have no outlet and because they are not converted in the reactor, which have undesirable effects in the reactor or elsewhere in the loop, or which, through reaction, give rise to the formation of components having such undesirable effects. Such removal systems can be selective, e.g. distillation columns, or non-selective, i.e., simple purge streams.

(22) As feedstock starting materials composed of primary monofunctional alcohols are used. The starting materials can be of fossil origin or obtained from renewable resources. As materials from renewable resources, plant materials, materials of animal origin or materials resulting from recovered materials (recycled materials) may be used. Plant materials may be for example derived from sugar and/or starches containing plants, such as sugar cane, sugar beet, corn, wheat, potato, macro-algae and the like. The primary alcohols may be produced by fermentation from biomass using biocatalysts. The biocatalyst may be one or more microorganism (e.g. yeast, bacteria, fungi) capable of forming one or a mixture of two or more different alcohols. Fermentation methods and the respective microorganisms used for fermentation are known in the state of the art, and e.g. described in WO 2009/079213. Alcohols can also be mixed with ketones and aldehydes of biobased or fossil origin.

(23) When primary alcohols derived from biomass instead of petro-chemical origins are used, the carbon content of the resulting Guerbet alcohols originates from atmospheric carbon dioxide captured through photosynthesis, thus reducing the carbon dioxide impact on the environment caused by a consumption of the Guerbet alcohols. Alcohols derived from biomass conversion are called bio-alcohols. Bio-alcohols are thus identifiable by their .sup.14C content. Carbon taken from living organisms and in particular from plant matter used to manufacture bio-alcohols is a mixture of three isotopes, .sup.12C, .sup.13C, and .sup.14C, with the ratio of .sup.14C to .sup.12C being kept constant at 1.2.Math.10.sup.12 by the continuous exchange of the carbon with the environment. .sup.14C is radioactively unstable with its concentration therefore decreasing over time. With a half-life of 5,730 years, the .sup.14C content is, however, considered to be constant from the extraction of the plant matter up to the manufacture of bio-alcohols thereof and even up to the end of the bio alcohol's final use. An alcohol can be identified as bio-alcohol when the .sup.14C/.sup.12C ratio is strictly greater than zero and smaller than or equal to 1.2.Math.10.sup.12.

(24) The feedstock may contain acidic components, as it is for example known from bio-alcohols, compromising the performance of the Guerbet process through neutralisation of some of the alkaline components present in the reactor 10. The feedstock may further contain ester components, which are preferably removed prior to being supplied to the reactor. Preferred embodiments of the system 100 therefore provide for a preparatory treatment of the feedstock prior to supplying the feedstock to reactor 10. The preparatory treatment of the feedstock is performed in the pre-treatment facility 50 either by a process eliminating the presence of acids or esters by capture, e.g. ion exchange, or neutralisation, e.g. with an appropriate alkaline agent. Since water may be introduced into the feedstock through contact with an aqueous solution during an alkaline pre-treatment or may already have been part of the original feedstock, and since water is known to affect the Guerbet process, preferred embodiments of the pre-treatment facility 50 are further configured to remove water from the feedstock before it is fed into the reactor 10. When only water needs to be removed from the reactant, this step can be combined with the dehydration of reaction products and fresh reactants can be fed to the unit 43 or 42 or 41 depending on their water content. When acids need to be removed from the reactant, this step can be combined with the hydrogenationfinishing step included between unit 30 and 41, not shown on the figure.

(25) The Guerbet reaction enables a preparation of higher alcohols from light alcohols and in particular from bio-alcohols. The Guerbet reaction requires, however, a catalytic system providing a dehydrogenation, aldolisation, dehydration, and hydrogenation. The catalytic system is typically composed of a catalyst and a base.

(26) As catalysts homogeneous and heterogeneous metallic catalysts may be used. Homogenous catalysts have one catalytically active component while heterogeneous catalysts have more than one catalytically active component. An example for a homogeneous catalyst is Pd(Ac).sub.2. Examples for heterogeneous metallic catalysts are Pd(2%)/C, Pt/C, CuZnO, CuCrO, alkali or alkaline earth doped oxides, hydrotalcites and hydroxylapatites doped with metals as for example Ni, Pd, Cu, Raney Ni, NiMgO/SiO.sub.2. Although the effect of the catalyst on the Guerbet reaction cannot be assessed isolated from the alkaline component of the catalytic system, a tendency has been observed that heterogeneous catalysts promote a formation of a greater variety of reaction products, while homogeneous catalysts boost a formation of particular reaction products. Heterogeneous catalysts and particularly Ni/MgO/SiO.sub.2 are preferred for the production of higher molecular weight Guerbet alcohols. Furthermore, heterogeneous catalysts like Ni/MgO/SiO.sub.2 facilitate the product separation.

(27) It has been found that a strong base is beneficial for the Guerbet process, particularly when performed with relative low temperatures at atmospheric pressure. In preferred embodiments of synthesising Guerbet alcohols from primary alcohols with a system 100 as described above, sodium tert-butoxide (t-BuONa) is used as alkaline component of the catalytic system. The reaction process can be carried out at atmospheric pressure with a process temperature of above 104 C., whereby temperatures corresponding to the boiling temperature of the alcohol mixture fed into the reactor 10 are preferred. Using for example a feedstock containing 2.9 wt % 1-propanol, 57.8 wt % 1-butanol, 23.7 wt % 1-pentanol, and 15.3 wt % 1 hexanol, the process temperature at atmospheric pressure would be set to about 125 C. At higher pressures, the temperature would be raised accordingly. When carrying out the Guerbet reaction at higher temperatures and pressures, adequate conversion rates may also be achieved with weaker bases, like KOH or NaOH.

(28) The amount of the alkaline component in the reaction mixture is not critical. For sodium tert-butoxide rather similar Guerbet conversion rates were found in batch reactors at low temperature for amounts of the base ranging from 4 to 20 wt % of the primary alcohol starting mixture, whereby Pd(Ac).sub.2 has been used as catalyst in a concentration of 0.2 wt % with respect to the primary alcohol starting mixture. Lower catalyst concentrations have shown lower conversion rates. To achieve an adequate conversion rate with a proper base concentration throughout the process, a sodium tert-butoxide concentration of 8 wt % and a Pd(Ac).sub.2 concentration of 0.2 wt %, both with respect to the primary alcohol mixture to be converted, is used in some embodiments, whereby care is taken that any water evolving during the reaction process is removed from the mixture in order to avoid an inhibition of the reaction.

(29) One or more primary alcohols of the formula RCH.sub.2CH.sub.2OH, where R is hydrogen or a straight or branched chain alkyl of 1 to 14 carbon atoms, are used as starting material for the Guerbet alcohol production. For example, multiple alcohols of different chain length and including secondary alcohols can be reacted. The use of alcohols with a carbon number of 4 or more, as for example 1-butanol, 1-pentanol and/or 1-hexanol, as starting material is preferred, whereby small amounts (as for example less than 10% by weight and particularly less than 5%) of 1-propanol may also be used advantageously in combination with one or more other starting alcohols.

(30) The primary alcohol(s) may also contain secondary alcohols, ketones and aldehydes, since the latter would be intermediate reaction products when alcohols are the primary reactants. When aldehydes and ketones are added as reactants, a supplement of hydrogen is necessary to finally hydrogenate the reaction products to alcohols.

(31) The Guerbet alcohols produced according to the above are a mixture of Guerbet alcohols, comprising a different number of carbon atoms in the chain and comprising at least a branching at the carbon atom adjacent to the carbon atom carrying the hydroxyl group.

(32) The chain length of a Guerbet alcohol produced according to the Guerbet reaction as described above depends in principle on the primary alcohol(s) used as a starting material. When e.g. n-butanol is used as a starting material, 2-ethyl-1-hexanol is produced. A mixture of Guerbet alcohols is produced according to the different possible condensation reactions, using a mixture of starting alcohols differing from each other in the number of carbon atoms. When starting for example with 1-butanol (C.sub.4) and 1-pentanol (C.sub.5), the reaction results 2-ethyl-1-hexanol (C.sub.8), 2-ethyl-1-heptanol (C.sub.9), 2-propyl-1-hexanol (C.sub.9), and 2-propyl-1-heptanol (C.sub.10). With a feeding of a larger number of diverse alcohols, a greater variety of Guerbet alcohols is obtained. Furthermore, when starting with branched primary alcohols and/or reacting Guerbet alcohols already produced in the reaction mixture, multi-branched Guerbet alcohols are formed.

(33) According to an advantageous embodiment, one or more of the Guerbet alcohols in the final mixture comprise two or more branches, particularly if it is the product of two or more subsequent condensation reactions. This further increases the variety of the Guerbet alcohols.

(34) In the following tables, a non-exhaustive listing of examples is given for Guerbet alcohols obtained using one type or different types of primary alcohols as starting materials according to the following reaction scheme:
Alcohol 2.fwdarw.Aldehyde 2
Aldehyde 2+Alcohol 1.fwdarw.Guerbet alcohol
In the tables, the Guerbet alcohols are represented by the respective carbon number of the main chain and the kind and position of the substituent(s), the hydroxyl group of the alcohols being omitted in the table. The following abbreviations are used in the tables below: Me=methyl, diMe=dimethyl, triMe=trimethyl, Et=ethyl, Pr=propyl, iPr=CH(CH.sub.3).sub.2, Bu=butyl, iBu=CH.sub.2CH(CH.sub.3).sub.2, sBu=CH(CH.sub.3)CH.sub.2CH.sub.3, Pe=pentyl, A=amyl, iA=CH.sub.2CH.sub.2CH(CH.sub.3).sub.2, sA=CH(CH.sub.3)CH.sub.2CH.sub.2CH.sub.3, sA=CH.sub.2CH(CH.sub.3)CH.sub.2CH.sub.3, i=iso, s=sec, specifying the substituent's on the main chain of the Guerbet alcohol. The number preceding the substituent's gives the position of the substituent on the main chain. The number subsequent to C specifies the length of the main chain, i.e. stands for the number of carbon atoms in the main chain of the Guerbet alcohol with the hydroxyl group always in position 1 (primary alcohol). For example, 2MeC4 stands for 2-methyl-butanol, 2Et4MeC5 stands for 2-ethyl-4-methyl-1-pentanol, and 2iBu4MeC5 stands for 2-isobutyl-4-methyl-1-pentanol. X stands for a reaction which is either impossible or difficult.

(35) TABLE-US-00001 TABLE 2a Guerbet reactions Methanol Ethanol Propanol Butanol Isobutanol Alcohol 2 Alcohol 1 C1 C2 C3 C4 iC4 Methanol C1 x Propanol 2MeC3 2MeC4 x Ethanol C2 x Butanol 2MeC4 2EtC4 x Propanol C3 x Pentanol 2MeC5 2EtC5 x Butanol C4 x C6 2MeC6 2EtC6 x Isobutanol iC4 x 4MeC5 2,4diMeC5 2Et4MeC5 x Pentanol C5 x C7 2MeC7 2EtC7 x 2MethylBuOH 2MeC4 x 4MeC6 2,4diMeC6 2Et4MeC6 x 3MethylBuOH 3MeC4 x 5MeC6 2,5diMeC6 2Et5MeC6 x

(36) TABLE-US-00002 TABLE 2b Guerbet reactions Alcohol 1 Pentanol 2MethylBuOH 3MethylBuOH Alcohol2 C5 2MeC4 3MeC4 Methanol C1 2MeC5 x 2,3DiMeC4 Ethanol C2 2EtC5 x 2Et3MeC4 Propanol C3 2PrC5 x 2Pr3MeC4 Butanol C4 2PrC6 x 2iPrC6 Isobutanol iC4 2Pr4MeC5 x 2iPr4MeC5 Pentanol C5 2PrC7 x 2iPrC7 2MethylBuOH 2MeC4 2Pr4MeC6 x 2iPr4MeC6 3MethylBuOH 3MeC4 2Pr5MeC6 x 2iPr5MeC6

(37) TABLE-US-00003 TABLE 2c Guerbet reactions Hexanol Alcohol 2 Alcohol 1 C6 2MeC5 3MeC5 4MeC5 2,3DiMeC4 2EtC4 Methanol C1 2MeC6 x 2,3diMeC5 2,4diMeC5 x x Ethanol C2 2EtC6 x 2Et3MeC5 2Et4MeC5 x x Propanol C3 2PrC6 x 2Pr3MeC5 2Pr4MeC5 x x Butanol C4 2BuC6 x 2Bu3MeC5 2iBuC6 x x Isobutanol iC4 2Bu4MeC5 x 2iBu3MeC5 2iBu4MeC5 x x Pentanol C5 2BuC7 x 2Pe3MeC5 2Pe4MeC5 x x 2MethylBuOH 2MeC4 2Bu4MeC6 x 2sBu4MeC6 2iBu4MeC6 x x 3MethylBuOH 3MeC4 2Bu5MeC6 x 2sBu5MeC6 2iBu5MeC6 x x

(38) TABLE-US-00004 TABLE 2d Guerbet reactions Heptanol Alcohol 2 Alcohol 1 C7 2MeC6 3MeC6 4MeC6 5MeC6 Methanol C1 2MeC7 x 2,3DiMeC6 2,4DiMeC6 2,5DiMeC6 Ethanol C2 2EtC7 x 2Et3MeC6 2Et4MeC6 2Et5MeC6 Propanol C3 2PrC7 x 2Pr3MeC6 2Pr4MeC6 2Pr5MeC6 Butanol C4 2BuC7 x 2Bu3MeC6 2Bu4MeC6 2Bu5MeC6 Isobutanol iC4 2iBuC7 x 2iBu3MeC6 2iBu4MeC6 2iBu5MeC6 Pentanol C5 2PeC7 x 2sAC7 2sAC7 2iAC7 2MethylBuOH 2MeC4 2Pe4MeC6 x 2sA4MeC6 2sA4MeC6 2iA4MeC6 3MethylBuOH 3MeC4 2Pe5MeC6 x 2sA5MeC6 2sA5MeC6 2iA5MeC6

(39) TABLE-US-00005 TABLE 2e Guerbet reactions Heptanol Alcohol2 Alcohol 1 2,2diMeC5 2,3diMeC5 2,4diMeC5 3,3diMeC5 Methanol C1 x x x 2,3,3TriMeC5 Ethanol C2 x x x 2Et3,3diMeC5 Propanol C3 x x x 2Pr3,3diMeC5 Butanol C4 x x x 2Bu3,3diMeC5 Isobutanol iC4 x x x 2iBu3,3diMeC5 Pentanol C5 x x x 2Pe3,3diMeC5 2MethylBuOH 2MeC4 x x x 2sA3,3diMeC5 3MethylBuOH 3MeC4 x x x 2iA3,3diMeC5

(40) TABLE-US-00006 TABLE 2f Guerbet reactions Heptanol Alcohol2 Alcohol 1 3,4diMeC5 4,4diMeC5 2,2,3TriMeC4 2EtC5 Methanol C1 2,3,4TriMeC5 2,4,4TriMeC5 x x Ethanol C2 2Et3,4diMeC5 2Et4,4diMeC5 x x Propanol C3 2Pr3,4diMeC5 2Pr4,4diMeC5 x x Butanol C4 2Bu3,4diMeC5 2Bu4,4diMeC5 x x Isobutanol iC4 2iBu3,4diMeC5 2iBu4,4diMeC5 x x Pentanol C5 2Pe3,4diMeC5 2Pe4,4diMeC5 x x 2MethylBuOH 2MeC4 2sA3,4diMeC5 2sA4,4diMeC5 x x 3MethylBuOH 3MeC4 2iA3,4diMeC5 2iA4,4diMeC5 x x

(41) TABLE-US-00007 TABLE 2g Guerbet reactions Heptanol Alcohol2 Alcohol 1 3EtC5 2Et2MeC4 2Et3MeC4 Octanol C8 Methanol C1 2Me3EtC5 x x 2MeC8 Ethanol C2 2Et3EtC5 x x 2EtC7 Propanol C3 2Pr3EtC5 x x 2PrC8 Butanol C4 2Bu3EtC5 x x 2BuC8 Isobutanol iC4 2iBu3EtC5 x x 2iBuC8 Pentanol C5 2Pe3EtC5 x x 2PeC8 2MethylBuOH 2MeC4 2sA3EtC5 x x 2sAC8 3MethylBuOH 3MeC4 2iA3EtC5 x x 2sAC8

(42) The flow chart of FIG. 2 illustrates the basic steps of a method 200 for synthesising a mixture of Guerbet alcohols from a one or more primary alcohols as described above. The method starts in step S201 with the provision of one or more primary alcohols (e.g. a blend corresponding to the feedstock mentioned above) mixed with a base (e.g. sodium tert-butoxide) and a catalyst (e.g. a heterogeneous catalyst like Ni/MgO/SiO.sub.2 or a homogeneous catalyst like palladium(II)-acetate). The Guerbet conversion is enabled in step S202 by heating the mixture to a desired process temperature at the desired pressure (e.g. 125 C. at about 1 bar or 200 C. at about 9 bar) with the water evolving during the process being removed on a permanent basis. Either after a predetermined time or depending on the water content of the vapour transferred to the water separation unit 20when the process is preferably operated in a continuous mode the contact time in the reaction section is constant and determined by the reactant flow, part of the reaction mixture will be removed from the reactor 10 in step S203, with the mixture's alcohol components being separated from the base and catalyst components in the first after-treatment system in step S203 and transferred to the second after-treatment in step S204. In the second after-treatment system, the alcohol components are further processed in step 205 for obtaining dried alcohol components with the dried alcohols then being split into those desired and those lighter than the desired ones in step 206. The latter are in step S207 then returned to the Guerbet reaction taking place within reactor 10. The method may further comprise an optional step 208 compensating for the removed reaction mixture with appropriate amounts of new feedstock, base and catalyst, which may be performed simultaneously to one or more of the steps 203 to 207, or like these on a continuous basis, when a continuous process of manufacture is desired.

(43) The present invention enables a large scale production of multi-branched Guerbet alcohols where the final distribution of Guerbet alcohols can be controlled by splitting the desired reaction products from the lighter ones and returning the latter into the reaction chamber for further reaction processing. Respective Guerbet alcohols may be used as additives for fuels like diesel or jet fuels, where they increase the electric conductivity and thus decrease the probability of ignition by static electricity. The Guerbet alcohols may further be used as precursors of esters such as acrylates, methacrylates, phthalates or the like. The Guerbet alcohols may further also be hydrodeoxygenated and possibly further refined for obtaining gasoline, diesel fuel or aviation gasoline and jet fuel constituents. The Guerbet alcohols may also be dehydrated to alpha-olefins, which can then be polymerized or oligomerized. The Guerbet alcohols may also be used for producing surfactants that are e.g. suited for utilisation in petroleum industry operations.

(44) The present invention includes the following numbered aspects, embodiments, and features, in any order and/or in any combination:

(45) 1. A method for preparing a mixture of Guerbet alcohols, the method comprising:

(46) providing a starting material comprising one or more primary alcohols of the formula RCH.sub.2CH.sub.2OH, where R is hydrogen or a straight or branched chain alkyl of 1 to 14 carbon atoms;

(47) providing a base;

(48) providing a catalyst;

(49) mixing the starting material with the base and the catalyst and heating the thus obtained reaction mixture to a process temperature above the boiling point of water under reaction conditions while removing the water resulting from the thus obtained condensation and dehydration of the primary alcohols;

(50) removing at least part of the reaction mixture;

(51) separating the desired Guerbet alcohols from the removed part of the reaction mixture; and

(52) returning the other alcohols and optionally other intermediates from the removed part of the reaction mixture to the reaction mixture.

(53) 2. The method of any preceding or following embodiment/feature/aspect, wherein the starting material further contains primary alcohols in which the carbon atom in beta-position is bonded to two or three alkyl groups, secondary alcohols, ketones and aldehydes, and hydrogen is added to the reaction mixture or the removed part of the reaction mixture.

(54) 3. The method according to of any preceding or following embodiment/feature/aspect, wherein the starting material contains at least two primary alcohols selected from the group comprising n-propanol, n-butanol, n-pentanol, n-hexanol.

(55) 4. The method to of any preceding or following embodiment/feature/aspect, wherein the base is selected from the group consisting of sodium tert-butoxide, potassium hydroxide, sodium hydroxide, and heterogeneous bases, which may optionally be doped.

(56) 5. The method according to of any preceding or following embodiment/feature/aspect, wherein the catalyst is a homogenous catalyst or a heterogeneous catalyst selected from the group consisting of Pd(OAc).sub.2, Pd/C, Pt/C, CuZnO, CuCrO, hydrotalcites and hydroxylapatites doped with metals, Raney Ni, and NiMgO/SiO.sub.2

(57) 6. The method according to of any preceding or following embodiment/feature/aspect, wherein the catalyst is a solid heterogeneous catalyst provided in a fixed bed, or a slurry fluidized bed, or a mobile bed.

(58) 7. The method according to of any preceding or following embodiment/feature/aspect, wherein the alcohols returned to the reaction mixture have a lower boiling point than the desired Guerbet alcohols.

(59) 8. The method according to of any preceding or following embodiment/feature/aspect, wherein the process temperature corresponds to the boiling point of the starting material under reaction conditions.

(60) 9. The method according to of any preceding or following embodiment/feature/aspect, wherein the reaction process is performed at a pressure in the range of 1 to 20 bar.

(61) 10. The method according to of any preceding or following embodiment/feature/aspect, wherein the starting material is pre-treated with respect to removing acidic components, ester components, water, or a combination thereof, prior to being fed to mixing.

(62) 11. A system for synthesising Guerbet alcohols from a starting material according to the method of any preceding or following embodiment/feature/aspect, wherein the system comprising:

(63) a reactor adapted for receiving the starting material, a base, and a catalyst to form a reaction mixture, and for heating the reaction mixture to a temperature above the boiling point of water under reaction conditions to obtain a Guerbet condensation and dehydration process;

(64) a water separation unit connected to the reactor and adapted to receive from the reactor vapor evolving in the progress of the Guerbet condensation process, and to remove water from the vapor; and

(65) an after-treatment system connected to the reactor and adapted to receive from the reactor at least part of the reaction mixture, separating the desired Guerbet alcohols from the removed part of the reaction mixture, and returning the other alcohols and optionally other intermediates from the removed part of the reaction mixture to the reactor.

(66) 12. The system according to of any preceding or following embodiment/feature/aspect, wherein the reactor is one of a stirred tank reactor, a fixed bed reactor, a mobile bed reactor, and a fluidized bed reactor.

(67) 13. The system according to of any preceding or following embodiment/feature/aspect, wherein the after-treatment system comprises a first after-treatment system adapted to separate a catalytic component and an alkaline component from the part of the reaction mixture received from the reactor, and a second after-treatment system connected to the first after-treatment system and adapted to separate the desired Guerbet alcohols from the part of the reaction mixture treated by the first after-treatment system and to return the other alcohols from the part of the reaction mixture treated by the first after-treatment system, to the reactor.

(68) 14. The system according to of any preceding or following embodiment/feature/aspect, wherein wherein the second after-treatment system comprises a liquid-liquid mixer-settler configuration adapted to receive the reaction mixture treated by the first after-treatment system and to provide a phase separation of the components present in the mixture, an alcohols column adapted to receive the primarily alcohol components containing phase from the liquid-liquid mixer-settler configuration and to dry the alcohol components, and an alcohols splitter column connected to the alcohols column and the reactor, and being adapted to separate the desired Guerbet alcohols from the dried alcohol components and to return the remaining dried alcohols to the reactor.

(69) 15. The system according to of any preceding or following embodiment/feature/aspect, wherein the second after-treatment system further comprises a water column adapted to receive the primarily water containing phase from the liquid-liquid mixer-settler configuration, separate water from the primarily water containing phase, and return alcohols containing water to the liquid-liquid mixer-settler configuration.

(70) 16. The system according to of any preceding or following embodiment/feature/aspect, wherein the water separation unit is further adapted to return the vapor components different than the separated water, to the reactor, and to provide the still alcohols containing separated water to the liquid-liquid mixer-settler configuration.

(71) 17. The system according to of any preceding or following embodiment/feature/aspect, further comprising a pre-treatment facility adapted to remove acidic components, ester components, water, or a combination thereof, from the starting material prior to supplying the starting material to the reactor.

(72) 18. The method of of any preceding or following embodiment/feature/aspect, further comprising adding the mixture of Guerbet alcohols to a gasoline, diesel fuel, aviation gasoline, jet fuel, or a combination thereof.

(73) 19. The method of of any preceding or following embodiment/feature/aspect, further comprising processing the mixture of Guerbet alcohols optionally with other components to form a surfactant, an alpha-olefin, an alpha-olefin polymer, an alpha-olefin oligomer, or a combination thereof.

EXAMPLES

(74) The below examples have been obtained by simulations based on the system illustrated in the piping and instrumentation diagram shown in FIG. 1. The simulations have been carried out using the Aspen Plus chemical modelling system from Aspen Technology Inc., USA. The simulation results are summarised in the tables below, listing the process parameters together with the mass flow of several reactants, intermediate products, and products at different positions of the system illustrated in FIG. 1. The positions, which are referred to as checkpoints in the tables, are indicated in FIG. 1 by measurement point symbols a to h.

Example 1

(75) In this example, the simulation has the reactor operated at substantially atmospheric pressure and at a temperature of about 125 C. As starting material, a blend of primary alcohols is used, containing 2.9 wt % 1-propanol, 57.8 wt % 1-butanol, 23.7 wt % 1-pentanol, and 15.3 wt % 1-hexanol. The starting material is provided at an elevated pressure for facilitating the feeding of the reactor. Since the low temperature results in slow reaction kinetics, a stronger base was required; therefore sodium tert-butoxide has been used. The results for the simulation are shown below in the Table SL1.

(76) TABLE-US-00008 TABLE SL1 a b c d e f g h Checkpoint Temperature in C. 125 125 125 50 47 99 111 176 Pressure in bar 3 1.01 1.01 1.01 0.4 1.01 1.01 1.01 Mole Flow in kmol/h 137.6 312.4 160.3 160.3 67.7 189.2 110.7 78.6 Mass Flow in kg/h 11002 20773 15784 15784 1348 17981 8092 9889 Mass Flow in kg/h C2 alcohol 0.2 0.5 0.1 0.1 0.4 0.2 0.2 0 C3 alcohol 317 1891 382 382 41 1270 1269 1 C4 alcohol 6364 12343 4124 4124 101 5358 5331 27 C5 alcohol 2607 3582 2019 2019 2 2193 1274 919 C6 alcohol 1682 614 1047 1047 3 1047 52 995 C7 alcohol 0 76 250 250 0 250 1 250 C8 alcohol 0 646 4469 4469 1 4469 0 4469 C9 alcohol 0 113 1764 1764 0 1764 0 1764 C10 alcohol 0 59 1457 1457 0 1457 0 1457 Water 0 983 84 84 1176 9 9 0 2-Buten-1-ol 32.2 464.8 187.4 187.4 23.7 165 156.2 8.8
As can be seen from Table SL1, the reaction can be operated with recycling of the unconverted light compounds. The mass yield of the reaction reaches 90% looking at mass flow rate of product released in h versus mass flow rate of reactants in a. The product distribution contains a low amount of C4 alcohols but some C5 alcohols. The process could have been adjusted to recycle more C5 alcohols to the reactor and so the product would contain less C5 alcohols.

Example 2

(77) In this example, the simulation has the reactor operated at a pressure of substantially 9.0 bar abs. enabling an operation at a temperature of about 200 C. without excessive evaporation of the components present in the reaction medium. As starting material, again a blend of primary alcohols is used, containing 2.9 wt % 1-propanol, 57.8 wt % 1-butanol, 23.7 wt % 1-pentanol, and 15.3 wt % 1-hexanol. The starting material is provided at an elevated pressure for facilitating a feeding of the reactor. Since the higher temperature results in faster reaction kinetics, it was possible to use a weak base like NaOH or KOH. The results for the simulation are shown below in the Table SL2.

(78) TABLE-US-00009 TABLE SL2 a b c e f g h Checkpoint Temperature in C. 189 203 203 47 99 112 176 Pressure in bar 10 9 9 0.4 1.01 1.01 1.01 Mole Flow in kmol/h 137.6 349.4 179.3 68 202.7 124.1 78.6 Mass Flow in kg/h 11002 24280 16802 1357 19082 9196 9886 Mass Flow in kg/h C2 alcohol 0.2 0.3 0.3 0.5 0.3 0.3 0 C3 alcohol 317 2113 570 29 972 971 0 C4 alcohol 6364 13844 5151 118 6534 6502 33 C5 alcohol 2607 4805 1741 2 2428 1509 919 C6 alcohol 1682 752 1046 2 1045 52 993 C7 alcohol 0 94 238 0 238 0 238 C8 alcohol 0 1111 4481 1 4480 0 4480 C9 alcohol 0 205 1754 0 1754 0 1754 C10 alcohol 0 119 1460 0 1460 0 1460 Water 0 886 179 1181 10 10 0 2-Buten-1-ol 32.2 350.8 182.3 23 160.4 150.9 9.5
As can be seen from a comparison with Table SL1, in this configuration the reaction temperatures are higher but the downstream processing is done at the same temperature. This allows to have faster reactions and to reduce the size of the reactors accordingly, generating a capital cost advantage. In addition in this configuration, the mass yield is still around 90% and the product distribution remains unaffected. The overall process designed with its recycles and features allow to operate with a high yield.

Example 3

(79) In this example, the simulation has been carried out on a system modified with respect to that shown in FIG. 1. The modifications are designed to enable a system performing the Guerbet conversion with a starting material composed of a blend of primary alcohols as used in above examples 1 and 2 and a supplement of aldehydes. The addition of aldehydes is reflected in the simulation by an extra reaction butanol butyraldehyde. The modifications concern an added feed of ethylene for hydrogen capture to the reactor, a separator between the reactor 10 and the water column for removing the ethane from the vapour supplied to the water column 20, a post treatment unit (located with respect to FIG. 1 between the first after-treatment system 30 and checkpoint d) for hydrogenating the output from the first after-treatment system 30, and separators downstream of the alcohols column 43 and the alcohols splitter column 44 for removing by-products from the respective streams. The results for the simulation are shown below in the Table SL3.

(80) TABLE-US-00010 TABLE SL3 a b d e g h Checkpoint Temperature in C. 125 125 125 52.3 111.5 174.9 Pressure in bar 3 1.013 1.013 0.4 1.013 1.013 Mole Flow in kmol/h 137.6 324.0 164.1 64.8 115.0 78.7 Mass Flow in kg/h 11002 21624 16056 1262 8398 9884 Mass Flow in kg/h C2 alcohol 0.15 0.34 0.05 0.34 0.12 0 C3 alcohol 316.9 1824.9 345.7 32.9 1252.3 0.278 C4 alcohol 6363.8 12308.3 4119.5 77.7 5315.5 26.7 C5 alcohol 2607.1 3426.3 1999.4 2.1 1225.8 941.9 C6 alcohol 1681.9 632.4 1051.1 2.0 52.6 998.5 C7 alcohol 0 78.0 250.11 0.06 0.52 249.5 C8 alcohol 0 674.7 4452.4 0.46 0.18 4451.2 C9 alcohol 0 121.91 1755.4 0.02 0.001 1754.9 C10 alcohol 0 6; 1441.6 0.07 0 1441.2 C2H6 0 2.57 0.004 3.994 0 0 H2O 0 981.3 80.6 1133.4 9.14 0 ethylene 0 0 0 0 0 0 butanal 0 2.90 0 4.02 0.11 0 buten-1-ol 32.15 1506.4 558.4 5.89 541.6 18.6 2-ethyl hexenal 0 1.96 0.87 0.001 0.07 0.80 2-Ethyl hexanal 0 0.17 1.06 0.001 0.18 0.88
In this example, a reactor (additional finishing hydrogenation reactor) is included between points c and d. The conversion of butanal to butanol, 2-ethylhexenal to 2-ethylhexanal, and of the latter to 2-ethylhexanol have been assumed with partial conversion in some cases. Results show that the process can still be effective if aldehydes are present in the feedstock, injected for example within the loop or formed by the reaction. Aldehydes do not accumulate and are either reacted in the reactor or hydrogenated to alcohols. In this simulation light aldehydes, which are also fast reacting reaction intermediates, such as n-butanal present in stream g, are converted in reactor 10, where they have been fed, injected or formed. If not converted, these lighter aldehydes would tend to accumulate in the loop between liquid-liquid mixer-settler (or decanter) 41 and alcohols column 43. This could be prevented by partly or fully returning them back to the reactor upon their removal from the loop by separation or purging. Heavier aldehydes such as 2-ethyl hexenal and 2-ethyl hexanal would tend to leave the reactor by outlet 12. So in absence of a hydrogenation finishing reactor most of them leave the process by product stream h, thus contaminating it. When their concentration exceeds the tolerances, a finishing reactor has to be deployed to convert them into alcohols by a hydrogenation between point c and point d under sufficiently stringent conditions.

(81) It is apparent that variations and modifications to the present teachings are possible without departing from its scope and spirit. It is therefore to be understood that the appended claims are to be construed as encompassing all features of patentable novelty that reside in the present teachings, including all features that would be treated as equivalent thereof by those skilled in the art to which the present teachings pertain. All US, International, and foreign patents and publications, as well as non-patent literature, referred to herein are hereby incorporated herein by reference in their entireties. All publications, patents, and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference.

(82) While embodiments of the present teachings have been shown and described herein, it will be apparent to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the present teachings. It is to be understood that various alternatives to the embodiments of the disclosure described herein may be employed in practicing the present teachings. It is intended that the following claims define the scope of the present teachings and that methods and structures within the scope of these claims and their equivalents be covered thereby.

LIST OF REFERENCE SIGNS

(83) 100 process engineering system for a synthesis of Guerbet alcohols from a mixture of primary alcohols 10 reactor 11 feed port 12 discharge port 13 vapour outlet 14 reflux inlet 15 base inlet port 16 catalyst inlet port 20 water separation unit 21 vapour inlet port 22 alcohol outlet port 23 water outlet port 30 first after-treatment system 40 second after-treatment system 41 liquid-liquid mixer-settler configuration 42 water column 43 alcohols column 44 separation system/alcohols splitter column 50 pretreatment facility 200 simplified method for synthesising Guerbet alcohols from a mixture of primary alcohols S201-S208 basic process steps