Esterification catalyst, polyester process and polyester article

A process for the production of a polyester comprising the reaction of a compound selected from the group consisting of terephthalic acid, dimethyl terephthalate, isophthalic acid, dimethyl isophthalate, dimethyl 2,6 naphthalate or naphthalene dicarboxylic acid with an alcohol selected from the group consisting of 1,2-ethanediol, 1,4-butanediol, 1,3 propane diol, 1,6-hexanediol, trimethylol-propane and pentaerythritol in the presence of a catalyst composition comprising:

• (a) a preformed metal-organic compound which is the product resulting from the reaction of
• (i) an orthoester or condensed orthoester of titanium, zirconium, or aluminum,
• (ii) an alcohol containing at least two hydroxyl groups,
• (iii) a 2-hydroxy carboxylic acid, and
• (iv) an organic base selected from the group consisting of quaternary ammonium hydroxide compounds;
• and
• (b) at least one compound of germanium, antimony or tin.

A process for the manufacture of a polyester article comprising:

• (i) reacting together a compound selected from the group consisting of terephthalic acid, dimethyl terephthalate, isophthalic acid, dimethyl isophthalate, dimethyl 2,6 naphthalate and naphthalene dicarboxylic acid with an alcohol selected from the group consisting of 1,2-ethanediol, 1,4-butanediol, 2,3-propanediol, 1,6-hexanediol, trimethylol-propane and pentaerythritol in the presence of a catalyst composition comprising:
• (a) a preformed metal-organic compound which is the product resulting from the reaction of an orthoester or condensed orthoester of titanium, zirconium;
• or aluminum, an alcohol containing at least two hydroxyl groups, a 2-hydroxy carboxylic acid, and an organic base selected from the group consisting of quaternary ammonium hydroxide compounds, and
• (b) at least one compound of germanium, antimony and tin,
• (ii) optionally subjecting the resulting polymer to a solid phase polymerisation reaction, to form a polyester material having an intrinsic viscosity of at least 0.5 dl/g, as measured by the method of ASTM D-4603, and
• (iii) forming said polyester article from said polymer in the melt phase and
• (iv) cooling.

A process for the manufacture of a polyester fiber comprising:

• (i) reacting together a compound selected from the group consisting of terephthalic acid, dimethyl terephthalate, isophthalic acid, dimethyl isophthalate, dimethyl 2,6 naphthalate and naphthalene dicarboxylic acid with an alcohol selected from the group consisting of 1,2-ethanediol, 1,4-butanediol 2,3-propanediol, 1,6-hexanediol, trimethylol-propane and pentaerythritol in the presence of a catalyst composition comprising:
• a preformed metal-organic compound which is the product resulting from the reaction of an orthoester or condensed orthoester of titanium, zirconium, or aluminum, an alcohol containing at least two hydroxyl groups, a 2-hydroxy carboxylic acid, and an organic base selected from the group consisting of quaternary ammonium hydroxide compounds, and
• (ii) optionally subjecting the resulting polymer to a solid phase polymerisation reaction, to form a polyester material having an intrinsic viscosity of at least 0.5 dl/g, as measured by the method of ASTM D-4603, and
• (iii) forming said polyester fiber from said polymer in the melt phase and
• (iv) cooling.

A polyester material containing residues of a catalyst composition comprising a metal-organic compound consisting essentially of the product resulting from the reaction of:

• (a) an orthoester or condensed orthoester of titanium, zirconium, or aluminium;
• (b) an alcohol containing at least two hydroxyl groups;
• (c) a 2-hydroxy carboxylic acid;
• and
• (d) an organic base selected from the group consisting of tetraethyl ammonium hydroxide or benzyltrimethyl ammonium hydroxide.

A catalyst composition consisting essentially of a metal-organic compound which is the product resulting from the reaction of:

• (a) an orthoester or condensed orthoester of titanium, zirconium, or aluminium;
• (b) an alcohol containing at least two hydroxyl groups;
• (c) a 2-hydroxy carboxylic acid;
• and
• (d) an organic base selected from the group consisting of tetraethyl ammonium hydroxide or benzyltrimethyl ammonium hydroxide.

A catalyst composition consisting of a metal-organic compound which is the product resulting from the reaction of:

• (a) an orthoester or condensed orthoester of titanium, zirconium, or aluminium;
• (b) an alcohol containing at least two hydroxyl groups;
• (c) a 2-hydroxy carboxylic acid;
• and
• (d) an organic base selected from the group consisting of tetraethyl ammonium hydroxide or benzyltrimethyl ammonium hydroxide.