Process for the production of dialkyl terephthalate

Abstract

A process for preparing dialkyl terephalate comprising the following steps:—i) providing furan-2,5-dicarboxylate; ii) esterifying the furan-2,5-dicarboxylate with alcohol to form furan-2,5-carboxylic acid dialkyl ester; iii) reacting the furan-2,5-carboxylic acid dialkyl ester with ethylene under Diels Alder conditions, elevated temperature and pressure and in the presence of a catalyst such that dialkyl terephthalate is produced; wherein the Diels-Alder reaction is free from solvent; wherein the catalyst comprises a clay comprising metal ions and having Lewis acidity.

Claims

1. A process for preparing dialkyl terephthalate comprising: esterifying furan-2,5-dicarboxylate with an alcohol to form furan-2,5-carboxylic acid dialkyl ester; and reacting the furan-2,5-carboxylic acid dialkyl ester with ethylene under Diels Alder conditions, elevated temperature and pressure and in the presence of a catalyst such that dialkyl terephthalate is produced; wherein the Diels-Alder reaction is free from solvent; and wherein the catalyst comprises a clay comprising metal ions and having Lewis acidity.

2. The process as claimed in claim 1 further comprising converting the dialkyl terephthalate into a product selected from the group consisting of a) terephthalate polyesters, b) poly(butyleneterphthalate-co-butyleneadipate and c) terephthalate plasticizers, which are terephthalate diesters where the alkyl groups are longer carbon chains selected from straight and branched.

3. The process as claimed in claim 1, wherein the dialkyl terephthalate is diethyl terephthalate.

4. The process as claimed in claim 2, comprising converting the dialkyl terephthalate into polyalkylene terephthalate.

5. The process as claimed in claim 1, wherein the alcohol is a bioalcohol.

6. The process as claimed in claim 1, wherein the alcohol is selected from an aliphatic alcohol, a benzyl alcohol and a phenolic alcohol.

7. The process as claimed in claim 1, wherein the alcohol is selected from the group consisting of bio-methanol, bio-ethanol, bio-propanol, and mixtures thereof.

8. The process as claimed in claim 1, wherein an intermediate is formed during the Diels-Alder reaction, which is a bi-cyclic oxo-adduct.

9. The process as claimed in claim 1, wherein the clay is a smectite clay selected from the classes of the montmorillonites, hectorites, volchonskoites, nontronites, saponites, beidelites and sauconites.

10. The process as claimed in claim 1, wherein the catalyst is selected from cation-exchanged clays and pillared clays.

11. The process as claimed in claim 10, wherein the cation is selected from the group consisting of aluminium, zirconium, titanium and copper.

12. The process as claimed in claim 10, wherein the pillared clay is selected from the group consisting of aluminium pillared clay, zirconium pillared clay, titanium pillared clay and copper pillared clay.

13. The process as claimed in claim 1, wherein the furan-2,5-carboxylic acid dialkyl ester is pre-adsorbed onto the clay catalyst.

14. The process as claimed in claim 1, which is a batch process.

15. The process as claimed in claim 2, comprising converting the dialkyl terephthalate into polyethylene terephthalate.

16. The process as claimed in claim 7, wherein the alcohol is bio-ethanol.

17. The process as claimed in claim 9, wherein the clay is a montmorillonite clay.

18. The process as claimed in claim 10, wherein the catalyst is pillared clays.

19. The process as claimed in claim 11, wherein the cation is aluminium.

20. The process as claimed in claim 12, wherein the pillared clay is aluminium pillared clay.

21. The process as claimed in claim 13, wherein pre-adsorbing the furan-2,5-carboxylic acid dialkyl ester onto the clay catalyst comprises: dissolving the furan-2,5-carboxylic acid dialkyl ester in a solvent; adding the clay catalyst; and removing the solvent using a vacuum and heating.

22. The process as claimed in claim 21, wherein the solvent is selected from ethanol, ethyl acetate or a mixture thereof.

Description

DETAILED DESCRIPTION OF THE INVENTION

(1) The term “bio-based,” as used in the context of the presence invention, preferably indicates the inclusion of some component that derives from at least one bio-based material. For example, a “bio-based PET polymer” would be a PET polymer that comprises at least one component that partially or totally derives from at least one bio-based material.

The furan-2,5-dicarboxylate

(2) The furan-2,5-dicarboxylate for use in the process of the invention is preferably waste derived, for example, from carbohydrate, cellulose or lignocellulosic waste.

The Alcohol and the Esterification Reaction

(3) The furan-2,5-dicarboxylate is esterified using an alcohol, preferably a bioalcohol to form furan-2,5-carboxylic acid alkyl ester.

(4) The furan-2,5-carboxylic acid dialkyl ester is preferably furan-2,5-carboxylic acid diethyl ester.

(5) A bioalcohol is an alcohol that is produced through contemporary biological processes, such as agriculture and anaerobic digestion, rather than from fossil fuels, such as coal and petroleum. For example, bioethanol is made by fermentation, mostly from carbohydrates produced in sugar or starch crops such as corn, sugarcane, or sweet sorghum. Cellulosic biomass, derived from non-food sources, such as trees and grasses, is also being developed as a feedstock for bioethanol production.

(6) Preferably the alcohol has 1 to 9 carbon atoms, more preferably from 1 to 4 carbon atoms, most preferably from 1 to 3 carbon atoms.

(7) The alcohol may be aliphatic, benzyl or phenolic in nature, preferably aliphatic.

(8) The alcohol may be straight chain or branched, preferably straight.

(9) More preferably the alcohol is straight chain aliphatic of 1 to 4 carbon atoms, preferably 1 to 3 carbon atoms.

(10) Preferably the alcohol has a boiling point of up to 200° C., more preferably less than 120° C., most preferably up to 100° C.

(11) Preferably the alcohol is selected from the group consisting of bio-methanol, bio-ethanol, bio-propanol, and mixtures thereof. The most preferred alcohol is bio-ethanol.

(12) The esterification reaction is preferably carried out in the presence of an acid catalyst, and excess alcohol. The acid catalyst is preferably selected from sulphuric acid, toluene sulphonic acid and sulphonic acid resin polymer, preferably sulphuric acid. The sulphonic acid resin polymer is environmentally advantageous because it is solid, recoverable and reusable.

Diels-Alder Addition of furan-2,5-carboxylic acid dialkyl ester to ethylene

(13) The product of step ii) (furan-2,5-carboxylic acid dialkyl ester) is reacted with ethylene to form dialkyl terephthalate under Diels Alder conditions, in the presence of a catalyst such that dialkyl terephthalate is produced.

(14) Where the product of step ii) is furan-2,5-carboxylic acid dethyl ester, it is reacted with ethylene to form diethylalkyl terephthalate under Diels Alder conditions, in the presence of a catalyst such that diethyl terephthalate is produced.

(15) The reaction is pressurized, for example using a high-pressure reactor. The filling pressure is preferably from 20 to 300 bar, more preferably from 30 to 250 bar, even more preferably from 30 to 200 bar, most preferably from 40 to 100 bar.

(16) In addition, a temperature of from 50 to 400° C., more preferably from 100 to 300° C., most preferably from 120 to 280° C. is utilized. Both temperature and pressure should be selected according to the exact nature of the catalyst, as different catalysts work at different temperatures and pressures.

(17) An intermediate is formed during the Diels-Alder reaction. The first step of the Diels-Alder reaction forms a bi-cyclic oxo-adduct, which auto-aromatises via dehydration under the high temperature acidic conditions of the reaction, thus forming the desired dialkyl terephthalate, which is preferably diethyl terephthalate.

(18) The Diels-Alder reaction may suitably be carried out below the critical point of ethene, for example, at a pressure of from 20 to 40 bar. If necessary, dissolution of the furan-2,5-carboxylic acid dialkyl ester may be required to prevent sublimation.

(19) The Diels-Alder reaction of the process of the invention is carried out in a solvent-free environment. The use of a solvent-free reaction resulted in high yields of diethyl terephthalate.

(20) Attempts to use solvents, for example ethanol and water, were found to be unsuccessful with no formation of terephthalate or the oxo-adduct observed.

The Ethylene

(21) The process of the invention utilises ethylene. The ethylene is preferably bioderived from biomass feedstock. Bioethylene is produced from bioethanol.

The Catalyst

(22) The process of the invention utilises a heterogeneous catalyst that comprises a clay. Heterogeneous catalysts are advantageous because they are recoverable and reusable.

(23) The clay may be a natural, synthetic or chemically modified clay. It is preferably a smectite clay. The term smectite clay as used herein includes clays in which aluminium oxide is present in a silicate lattice as well as clays in which magnesium oxide is present in a silicate lattice.

(24) Specific examples of suitable smectite clays include those selected from the classes of the montmorillonites, hectorites, volchonskoites, nontronites, saponites, beidelites and sauconites. Preferably, the clay is a montmorillonite.

(25) Preferred chemically modified clays are selected from cation-exchanged clays and pillared clays, preferably pillared clays. Cation-exchanged clays are clays in which cations, typically metal Lewis acid cations, have been introduced into the interlamellar spaces of the layered structure of the clay, typically by ion-exchange. Pillared clays are treated such that large metal polycations are introduced into the layered structure of the clay, forming a porous structure that, once calcined, is thermally stable. A commercially available example of an aluminium pillared clay is available from Sigma-Aldrich.

(26) The clay catalyst exhibits inherent Lewis acidity. Other metal ions may be exchanged into the clay in order to tailor the level of catalytic Lewis acidity.

(27) A preferred catalyst is a pillared clay, preferably an aluminium pillared clay, that has been treated with metal cations, for example, with aluminium nitrate.

(28) Preferred metals for use in exchange and pillaring are selected from the group consisting of aluminium, zirconium, titanium and copper; and is most preferably aluminium.

(29) Preferably, the furan-2,5-carboxylic acid dialkyl ester (preferably furan-2,5-carboxylic acid diethyl ester) is first pre-adsorbed onto the clay catalyst. This is advantageous because it was found to minimise sublimation of the furan-2,5-carboxylic acid dialkyl ester.

(30) A preferred method of pre-adsorbing the furan-2,5-carboxylic acid dialkyl ester onto the clay comprises the steps of dissolving the furan-2,5-carboxylic acid dialkyl ester in a solvent (preferably ethanol), adding the clay catalyst, then removing the ethanol solvent using a vacuum and heating.

Conversion to PET

(31) Preferably the process further comprises the step of converting the dialkyl terephthalate into a further product, preferably selected from the group consisting of terephthalate polyesters (most preferably polyethylene terephthalate), poly(butyleneterphalate-co-butyleneadipate (PBAT), and terephthalate plasticizers (which are terephthalate diesters where the alkyl groups are longer carbon chains selected from straight and branched). Preferably, diethyl terephthalate is converted into polyethylene terephthalate.

(32) Other ingredients may be added to the PET polymer. Those of ordinary skill in the art would readily be able to select the suitable ingredient(s) to add to the PET polymer to improve the desired properties, which may depend on the type of application intended. In a particular embodiment, the PET polymer may further comprise a supplemental component selected from at least one colouring agent, at least one fast re-heat additive, at least one gas barrier additive, at least one UV blocking additive, and a combination thereof.

(33) The PET polymers may be used to form resins, which may be further processed into containers using methods including, but not limited to, injection moulding and stretch blow moulding.

(34) Embodiments of the invention will now be illustrated by the following examples.

EXAMPLES

Example 1: Preparation of Catalysts CAT1-CAT5 for Use in a Process in Accordance with the Invention and Comparative Catalysts CATA and CATB

(35) The following catalysts were prepared:

(36) CAT1-CAT5: in accordance with the invention

(37) CATA and CATB: comparative examples

(38) CAT1 was an Aluminium exchanged clay, prepared using Al nitrate and “Monmorillonite” clay obtained from Sigma Aldrich.

(39) CAT2 was an Aluminium pillared clay, obtained from Sigma Aldrich.

(40) CAT3 was the Aluminium pillared clay (CAT2), treated with aluminium nitrate.

(41) CAT4 was the Aluminium pillared clay, pre-treated with furan-2,5-carboxylic acid diethyl ester.

(42) CAT5 was CAT1 with pre-adsorbed reagent.

(43) CATA was Zeolite Y (obtained from Sigma Aldrich).

(44) CATB was CATA with pre-adsorbed reagent.

Process for Preparing Cation Exchanged Clays

(45) Montmorillonite clay and Aluminium pillared clay were exchanged with metal ions as follows:

(46) 1.86 mmol of the desired metal nitrate (e.g. aluminium nitrate) was dissolved in 60 ml of distilled water. To this metal nitrate solution 1 g of montmorillonite clay or Al pillared clay was added and the suspension heated to 60° C. for 18 hours. The suspension was subsequently centrifuged and the liquor decanted off leaving the exchanged clay catalyst. The catalyst was washed several times with distilled water and centrifuged again before being dried in a vacuum oven at 80° C. for 5 hours.

Process for Pre-Adsorbing furan-2,5-carboxylic acid diethyl ester onto catalyst

(47) Typically 1 g of furan-2,5-carboxylic acid diethyl ester was dissolved in 20 ml of ethyl acetate and then 1 g of catalyst (CAT1, CAT2, CAT3 or CAT4) added. The suspension was then placed on a rotary evaporator and rotated without vacuum or heat for 30 minutes. After 30 minutes of rotation both heat (50° C.) and vacuum (25 mbar) were applied to remove the ethyl acetate, whilst rotation was increased to maximum speed. Once all the solvent was removed the sample was placed under high vacuum (1 mbar) overnight. Finally, the collected solid was ground with a pestle and mortar to ensure homogeneity.

(48) The level of pre-adsorption was varied from 50:50 to 60:40 by weight of FDEE:catalyst.

(49) Pressurised reactions of furan-2,5-carboxylic acid diethyl ester with ethene were performed as follows:

(50) Catalyst and furan-2,5-carboxylic acid diethyl ester were added to a high-pressure reactor, which was then purged with nitrogen. Ethene was then added to the reactor (40 bar fill pressure, 20° C.).

(51) Amount of catalyst was varied between 0.15-0.5 g

(52) Amount of ethene was varied between 80-100 ml.

(53) Amount of furan-2,5-carboxylic acid diethyl ester was 0.5 g

(54) Reaction temperature was varied between 150° C.-250° C.; and the

(55) Reaction time was 24-48 hours.

(56) After the allotted reaction time, the reactor was slowly vented. All solid and liquid material was washed from the reactor using ethyl acetate and the catalyst filtered from the resulting suspension. The ethyl acetate was removed in vacuo to typically yield a yellow oil.

(57) The effect of reaction conditions, pre-adsorption of reagent and catalyst on the conversion, yield and selectivity of the process was determined. The results are given in the following examples.

Example 2: Conversion, Yield and Selectivity Using Catalyst CAT5 (Aluminium Exchanged Clay with Pre-Absorbed furan-2,5-carboxylic acid diethyl ester)

(58) TABLE-US-00001 TABLE 1 Conversion, yield and selectivity using CAT 5 - a process in accordance with the invention Pre-ads Temp Pressure.sub.f/Pressure.sub.r Time Conversion/Yield/ Catalyst loading ° C. (bar) (h) Selectivity (%)*.sup.∞ CAT 5 50:50 150 80/230 24 18/17/94 50:50 150 80/150 48 48/36/75 50:50 150 60/140 48  34/34/100 50:50 200 60/130 24 56/37/66 50:50 200 60/140 48 66/44/66 60:40 200 60/160 48 96/61/63 60:40 250 60/230 48 65/28/43 Pressure.sub.f = fill pressure; Pressure.sub.r = reaction pressure

(59) It will be seen that excellent yields are obtained with the CAT5 catalyst, in a process in accordance with the invention.

Example 3: Conversion, Yield and Selectivity Using Catalysts CATA (Aluminium-Y-Zeolite) and CATB (with Pre-Adsorbed Reagent)

(60) TABLE-US-00002 TABLE 2 Conversion, yield and selectivity using CATA and CATB - a comparative process. Pre-ads Temp Pressure.sub.f/Pressure.sub.r Time Conversion/Yield/ Catalyst loading ° C. (bar) (h) Selectivity (%)*.sup.∞ CATA 0 200 60/130 24 0/0/0 CATB 50:50 200 60/130 24 0/0/0 CATA 0 250 60/140 24  6/6/100 Pressure.sub.f = fill pressure; Pressure.sub.r = reaction pressure

(61) It will be seen that the zeolite comparative produces very poor conversion and yield, even with pre-adsorption of the reagent.

(62) Example 4: Conversion, Yield and Selectivity Using Catalyst CAT3 (Aluminium-Pillared Clay with Preadsorbed Reagent

(63) TABLE-US-00003 TABLE 3 Conversion, yield and selectivity using CAT3 - process in accordance with the invention. Pre-ads Temp Pressure.sub.f/Pressure.sub.r Time Conversion/Yield/ Catalyst loading ° C. (bar) (h) Selectivity (%)*.sup.∞ CAT3 50:50 150 60/120 48 0/0/0 50:50 200 60/160 48 19/17/88 50:50 200 70/160 48 8/5/63 50:50 250 60/150 6 23/20/87 50:50 250 60/230 48 68/50/74 50:50 250 70/170 48 51/48/94 60:40 200 60/160 48 18/17/97 60:40 250 60/250 24 66/59/88 60:40 250 60/250 48 81/51/63 Pressure.sub.f = fill pressure; Pressure.sub.r = reaction pressure

(64) It will be seen that excellent yields are obtained with the CAT3 catalyst, in a process in accordance with the invention. The CAT3 catalyst required a temperature of over 150° C. to function.

Example 5: Conversion, Yield and Selectivity During Re-Use of Catalyst CAT2 (Aluminium-Pillared Clay)

(65) Catalyst CAT2 was reused in the reaction of furan-2,5-carboxylic acid diethyl ester with ethene, under batch conditions, in accordance with the invention.

(66) TABLE-US-00004 TABLE 4 Conversion, yield and selectivity on reuse of CAT2 in a process in accordance with the invention. Conversion Yield Selectivity No. of use cycles (%) (%) (%) First use 52 42 81 Second use 26 25 96 Third use 23 15 67

(67) It will be seen that the catalyst performs well when re-used and displays excellent selectivity. Improved results would be expected under flow conditions.