Catalyst recycle methods
AssigneeNovomer, Inc.
InventorSadesh H. Sookraj
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Abstract
The present invention provides novel solutions to the problem of recycling carbonylation catalysts in epoxide carbonylation processes. The inventive methods are characterized in that the catalyst is recovered in a form other than as active catalyst. In some embodiments, catalyst components are removed selectively from the carbonylation product stream in two or more processing steps. One or more of these separated catalyst components are then utilized to regenerate active catalyst which is utilized during another time interval to feed a continuous carbonylation reactor.
Claims20
A method for the continuous reaction of an epoxide and carbon monoxide comprising:
- a) feeding a continuous carbonylation reactor during a first interval of time with a catalyst feed stream comprising a carbonylation catalyst, where within the reactor, the epoxide and the carbon monoxide react in the presence of the carbonylation catalyst to provide a reaction product stream comprising an epoxide carbonylation product and carbonylation catalyst
- b) treating the reaction product stream;
- c) separating at least a portion of the carbonylation catalyst from the reaction product stream, wherein the carbonylation catalyst comprises:
- a cationic Lewis acid and
- an anionic metal carbonyl;
- (d) accumulating the cationic Lewis acid separated in step (c) throughout the first interval of time to obtain a cationic Lewis acid batch, and
- (e) feeding a continuous carbonylation reactor during a second interval of time with a catalyst feed stream wherein at least a portion of the catalyst in the catalyst feed stream is derived from the cationic Lewis acid batch accumulated in step (d).
Dependencies are inferred from the claim text.