Patent Application
20230338248
The present disclosure relates to a 1,3-butylene glycol product. The present application claims priority from the Japanese Patent Application No. 2019-239974, Japanese Patent Application No. 2019-239975, Japanese Patent Application No. 2019-239976, Japanese Patent Application No. 2019-239977, Japanese Patent
Application No. 2019-239978, and Japanese Patent Application No. 2019-239979, all filed in Japan on Dec. 28, 2019, the Japanese Patent Application No. 2020-006660 filed in Japan on Jan. 20, 2020, and the Japanese Patent Application No. 2020-018910 filed in Japan on Feb. 6, 2020, the entire contents of which are incorporated herein by reference.
1,3-Butylene glycol is a colorless, transparent, and odorless liquid and has properties, such as low volatility, low toxicity, and high hygroscopicity, and has excellent chemical stability. 1,3-butylene glycol has a wide range of applications, including raw materials for various synthetic resins and surfactants, as well as materials for cosmetics, hygroscopic agents, high boiling point solvents, and antifreezes, etc. Particularly in recent years, 1,3-butylene glycol has been attracting attention for having excellent properties as a moisturizer, and demand is growing in the cosmetic industry.
1,3-Butylene glycol produced by a known production method has had a problem of acid concentration (acidity) increase when the 1,3-butylene glycol is left for a long period of time in a state containing water. The cause of the acid concentration increase has been uncertain but thought to be related to by-products contained in crude 1,3-butylene glycol. Cosmetics typically contain water and require a long period of time from production to actual use by general consumers. In addition, from the viewpoint, such as storage stability of cosmetics, liquidity is strictly controlled. When 1,3-butylene glycol produced by a known method is used in cosmetics, an acid concentration increase can disrupt the liquidity balance of the cosmetics, and this can lead to a loss of the intended effect. In addition, the acid concentration increase of cosmetics can cause rough skin or the like of the users. Furthermore, there was a case where cosmetics containing no water also have absorbed water during use or storage, and this has also increased the acid concentration accordingly. Thus, removing by-products from crude 1,3-butylene glycol to yield high-purity 1,3-butylene glycol has been required.
Also, 1,3-butylene glycol produced by a known production method have sometimes had an odor due to effects from by-products. In addition, 1,3-butylene glycol transparent immediately after production may be colored over time, which is a problem in storing for a long period of time. For example, during use and/or storage after use of a cosmetic, the cosmetic is exposed to air. In addition, in production of cosmetics, the production is usually performed in air atmosphere, and the product may be heated for the purposes of, for example, sterilization. When 1,3-butylene glycol produced by a known method is used in cosmetics, sometimes coloration occurs due to the presence of air or effects of heating. To solve such problems, removing by-products from crude 1,3-butylene glycol to yield high-purity 1,3-butylene glycol has been required.
For a method to produce high-purity 1,3-butylene glycol, a method including adding sodium hydroxide to crude 1,3-butylene glycol produced by hydrogen reduction of acetaldols and performing distillation has been proposed. In addition, other methods have been proposed, including a method in which an alkali metal base is added to crude 1,3-butylene glycol from which a high boiling point substance has been removed, the mixture is heat-treated, then 1,3-butylene glycol is distilled, and the alkali metal compound and a high boiling point substance are separated as residues, and subsequently a low boiling point substance is distilled off from the 1,3-butylene glycol distillate (Patent Documents 1 to 6). Various methods for purifying 1,3-butylene glycol have been thus proposed to produce high-purity 1,3-butylene glycol.
Patent Document 1: JP 07-258129 A
Patent Document 2: WO 00/07969
Patent Document 3: JP 2001-213822 A
Patent Document 4: JP 2001-213824 A
Patent Document 5: JP 2001-213825 A
Patent Document 6: JP 2001-213828 A
However, 1,3-butylene glycol products produced from these purification methods still contain by-products and have a problem of having an odor, a problem of causing odor over time even when having no odor immediately after manufacture, a problem of an increase in acid concentration over time when the 1,3-butylene glycol product contains water, a problem of coloration, and a problem of an increase in coloration over time.
1,3-Butylene glycol is produced, for example, by a method of (1) reduction (hydrogenation) of acetaldols, (2) hydrolysis of 1,3-butylene oxide, (3) selective hydrocracking of erythritol, (4) selective hydration of butadiene, (5) hydrogen addition to n-butanol-3-one, (6) hydrogen addition to 1-butanol-3-one, (7) hydrogen addition to 3-hydroxy-1-butanoic acid, (8) hydrogen addition to β-butyrolactone, or (9) hydrogen addition to diketene.
Of the production methods, the method of (1) reduction (hydrogenation) of acetaldols to yield 1,3 butylene glycol is preferable. Among them, the method of reduction of acetaldols in a liquid phase is preferable in terms of yield. The reasons for this are that acetaldols have a high boiling point, that acetaldols are unstable to heat and readily undergo a dehydration reaction at high temperatures to form crotonaldehyde or the like, and furthermore, that a reaction rate of the dehydration reaction is greater than that of the reduction reaction (hydrogenation reaction) at high temperatures. That is, when acetaldols are subjected to vapor-phase reduction, the temperature inside the reaction system needs to be increased to high temperature, but subjecting the acetaldols to high temperature causes a dehydration reaction to produce crotonaldehyde or the like, and the subsequent reduction reaction produces by-products, such as butanol. Thus, this results in relatively reduced yield of the target 1,3-butylene glycol. Thus, to produce a high-purity 1,3-butylene glycol product, a liquid phase reduction rather than a gas phase reduction is preferably performed.
In production of 1,3-butylene glycol, by-products are generally produced in the production process. For example, in production of 1,3-butylene glycol by hydrogen reduction of an acetaldol, a low boiling point substance (low boiling point compound) having an unsaturated bond, such as acetaldehyde, butylaldehyde, crotonaldehyde, acetone, and methyl vinyl ketone; a condensate of these (e.g., a trimer of acetaldehyde); a hydride of the above condensate; a condensate of 1,3-butylene glycol and the above low boiling point substance (e.g., an acetal of 1,3-butylene glycol and acetaldol); or the like is produced as a by-product. In addition, an acetal of crotonaldehyde and 1,3-butylene glycol; an acetal of acetaldehyde and 1,3-butylene glycol; an acetal of a hydride of a trimer of acetaldol, acetaldehyde, and acetaldehyde; or the like is produced as a by-product. Furthermore, in addition to the above, acetic acid may be present as an impurity in an acetaldol used as a raw material or is used to neutralize sodium hydroxide used in producing an acetaldol, and a condensate of the acetic acid and 1,3-butylene glycol (ester of acetic acid and 1,3-butylene glycol) is formed as a by-product. Moreover, these by-products may have properties as a substance that causes coloration, a substance that causes odor or a substance that causes acidity.
Whether the acetal is a substance that causes coloration, a substance that causes odor or a substance that causes acidity is uncertain, and the acetal is also considered to have all the properties but is considered to have strong properties as a substance that causes odor. Specifically, the acetal itself is unlikely to be a substance that causes odor but can form a substance that causes odor by a change over time or heating. Furthermore, the acetal may be hydrolyzed to form acetaldol, which is a substance that causes odor and has an oxidation (coloration) promoting effect. Thus, the acetal can also be said to be a substance that causes coloration. Here, the substance that causes coloration is defined as including not only a substance actually having a hue itself but also a substance changing over time into a substance having a hue. The substance that causes odor is defined as including not only a substance actually emitting an odor itself but also a substance changing over time into a substance emitting an odor. The substance that causes acidity is defined as a substance increasing acid concentration over time when containing water.
Whether the ester is a substance that causes coloration, a substance that causes odor or a substance that causes acidity is uncertain, and the ester is also considered to have all the properties but is considered to have strong properties as both a substance that causes odor and a substance that causes acidity. This is because when the ester is hydrolyzed by water, acetic acid is produced.
In production of 1,3-butylene glycol, it is considered that by-products in the production process may include, in addition to the acetal and ester, a wide variety of by-products corresponding to a substance that causes coloration, a substance that causes odor, or a substance that causes acidity. For example, the hydride of a trimer of acetaldehyde described above is considered to possibly correspond to any of a substance that causes coloration, a substance that causes odor or a substance that causes acidity.
The by-products described above are difficult to completely remove even using a purification means, such as distillation known in the art. This is considered to be because crude 1,3-butylene glycol is subjected to high temperature conditions and alkali treatment in the purification stage of the crude 1,3-butylene glycol, and new by-products are produced accordingly. For these reasons, as described above, the 1,3-butylene glycol products of Patent Documents 1 to 6 contain a wide variety of by-products, thus have an odor and are colored over time, and furthermore, increase acid concentration over time in a state containing water.
Thus, an object of the present disclosure is to provide a high-purity 1,3-butylene glycol product that is colorless and odorless (or almost colorless and odorless), and hardly causes or increases odor over time.
Another object of the present disclosure is to provide a high-purity 1,3-butylene glycol product that is colorless and odorless (or almost colorless and odorless), hardly causes or increases coloration and odor over time, and/or is unlikely to cause an acid concentration increase over time even in a state containing water.
Still another object of the present disclosure is to provide a moisturizer and a cosmetic product that have excellent moisturizing performance and can retain high quality for a long period of time.
As a result of diligent research to achieve the purpose, the inventors of the present disclosure have found that: storage of a 1,3-butylene glycol product for a long period of time causes deteriorations in qualities such as increase in coloration, increase in odor over time, decrease in initial boiling point, rise in dry point, and decrease in potassium permanganate test value over time; and that increase in contents of specific impurities in the 1,3-butylene glycol product to certain values or greater not only deteriorates qualities (coloration, odor, initial boiling point, dry point, potassium permanganate test value, acid concentration, etc.) of the 1,3-butylene glycol product, but also further deteriorates the qualities during storage of the product for a long period of time. Also, the present inventors have found a method for producing 1,3-butylene glycol in which the contents of the specific impurities can be reduced as much as possible. The present disclosure has been completed by further studying based on these findings.
Specifically, the present disclosure provides a 1,3-butylene glycol product containing 1,3-butylene glycol, wherein a sum of contents of acetaldehyde, crotonaldehyde, methyl vinyl ketone, acetone, formaldehyde, butylaldehyde, acetaldol, 1-hydroxy-3-butanone, 2-butanol, a compound represented by Formula (1) below, a compound represented by Formula (2) below, a compound represented by Formula (3) below, a compound represented by Formula (4) below, a compound represented by Formula (5) below, a compound represented by Formula (6) below, a compound represented by Formula (7) below, a compound represented by Formula (8) below, a compound represented by Formula (9) below, and a compound represented by Formula (10) below is less than 65 ppm.
In the 1,3-butylene glycol product, the sum of the contents of acetaldehyde, crotonaldehyde, methyl vinyl ketone, acetone, formaldehyde, butylaldehyde, acetaldol, 1-hydroxy-3-butanone, 2-butanol, the compound represented by Formula (1) above, the compound represented by Formula (2) above, the compound represented by Formula (3) above, the compound represented by Formula (4) above, the compound represented by Formula (5) above, the compound represented by Formula (6) above, the compound represented by Formula (7) above, the compound represented by Formula (8) above, the compound represented by Formula (9) above, and the compound represented by Formula (10) above is preferably less than 70 ppm, after the 1,3-butylene glycol product has been kept at 180° C. for 3 hours in air atmosphere.
In the 1,3-butylene glycol product, a sum of the contents of the compound represented by Formula (1) above, the compound represented by Formula (2) above, the compound represented by Formula (3) above, the compound represented by Formula (4) above, the compound represented by Formula (5) above, the compound represented by Formula (6) above, and the compound represented by Formula (7) above is preferably less than 28 ppm.
Further, in the 1,3-butylene glycol product, the sum of the contents of the compound represented by Formula (1) above, the compound represented by Formula (2) above, the compound represented by Formula (3) above, the compound represented by Formula (4) above, the compound represented by Formula (5) above, the compound represented by Formula (6) above, and the compound represented by Formula (7) above is preferably less than 40 ppm, after the 1,3-butylene glycol product has been kept at 180° C. for 3 hours in air atmosphere.
In addition, the present disclosure also provides a moisturizer containing the 1,3-butylene glycol product.
Furthermore, the present disclosure also provides a cosmetic product containing the moisturizer.
In the present disclosure, “1,3-butylene glycol product” means a composition in which 1,3-butylene glycol occupies a majority of the components (e.g., a 1,3-butylene glycol content is 95 wt. % or greater, preferably 98 wt. % or greater).
The present disclosure provides a high-purity 1,3-butylene glycol product that is colorless and odorless (or almost colorless and odorless), and hardly causes or increases odor over time.
The present disclosure also provides a high-purity 1,3-butylene glycol product that is colorless and odorless (or almost colorless and odorless), hardly causes or increases coloration and odor over time, and/or is unlikely to cause an acid concentration increase over time also in a state containing water.
Furthermore, the present disclosure provides a moisturizer and a cosmetic product that have excellent moisturizing performance and can retain high quality for a long period of time.
1,3-Butylene glycol product
The 1,3-butylene glycol product according to the present disclosure is a 1, 3-butylene glycol product containing 1,3-butylene glycol, wherein a sum of contents of acetaldehyde, crotonaldehyde, methyl vinyl ketone, acetone, formaldehyde, butylaldehyde, acetaldol, 1-hydroxy-3-butanone, 2-butanol, a compound represented by Formula (1) below, a compound represented by Formula (2) below, a compound represented by Formula (3) below, a compound represented by Formula (4) below, a compound represented by Formula (5) below, a compound represented by Formula (6) below, a compound represented by Formula (7) below, a compound represented by Formula (8) below, a compound represented by Formula (9) below, and a compound represented by Formula (10) below is less than 65 ppm.
The compounds represented by Formulas (1) to (7) above are cyclic acetal compounds, and the compounds represented by Formulas (8) to (10) are 3-hydroxybutyl carboxylate compounds. These compounds are also present as impurities during production of 1,3-butylene glycol, but are impurities whose content increases over time, when the 1,3-butylene glycol product is stored for a long period of time. The cyclic acetal compounds are hydrolyzed in the presence of water to produce corresponding carbonyl compounds. The thus-produced carbonyl compound is itself a reducing substance, not only diminishes the potassium permanganate test value, but also is highly reactive and likely to produce a variety of complex compounds by heat or oxygen, and may become a substance that causes coloration, a substance that causes odor or a substance that causes acidity. Also, the 3-hydroxybutyl carboxylate compounds are hydrolyzed in the presence of water to produce corresponding carboxylic acids. The thus-produced carboxylic acid may be a substance that causes odor or a substance that causes acidity.
Acetaldehyde, crotonaldehyde, methyl vinyl ketone, acetone, formaldehyde, acetaldol, and 1-hydroxy-3-butanone are precursors of the cyclic acetal compounds or 3-hydroxybutyl carboxylate compounds. Butylaldehyde can also be precursors of the cyclic acetal compounds considering its structure. In addition, these compounds are carbonyl compounds, and are prone to produce various complex compounds by heat or oxygen, and may be a substance that causes coloration, a substance that causes odor or a substance that causes acidity.
In a 1,3-butylene glycol product, having high contents of acetaldehyde, crotonaldehyde, methyl vinyl ketone, acetone, formaldehyde, butylaldehyde, acetaldol, 1-hydroxy-3-butanone, 2-butanol, and the compounds represented by Formulas (1) to (10) below, odor increases over time. Even when it is odorless at the time of manufacture, odor is likely to be caused by long-term storage, for example. Thus, in the 1,3-butylene glycol product of the present disclosure, a sum of contents of acetaldehyde, crotonaldehyde, methyl vinyl ketone, acetone, formaldehyde, butylaldehyde, acetaldol, 1-hydroxy-3-butanone, 2-butanol, and the compounds represented by or Formulas (1) to (10) is less than 65 ppm, preferably 50 ppm or less, more preferably 45 ppm or less, 40 ppm or less, 35 ppm or less, 30 ppm or less, 25 ppm or less, or 20 ppm or less, and even more preferably 15 ppm or less, 13 ppm or less, 10 ppm or less, 8 ppm or less, 5 ppm or less, 4 ppm or less, 3 ppm or less, or 2 ppm or less.
In addition, in the 1,3-butylene glycol product of the present disclosure, a sum of the contents of the compounds (cyclic acetal compounds) represented by Formulas (1) to (7) above is preferably less than 28 ppm, more preferably 25 ppm or less, 20 ppm or less, or 15 ppm or less, and even more preferably 12 ppm or less, 10 ppm or less, 8 ppm or less, 6 ppm or less, 4 ppm or less, 2 ppm or less, or 1.4 ppm or less.
In addition, in the 1,3-butylene glycol product of the present disclosure, a sum of the contents of the compounds (3-hydroxybutyl carboxylate compounds) represented by Formulas (8) to (10) above is preferably less than 6 ppm, more preferably 5 ppm or less, and still more preferably 4 ppm or less, 3 ppm or less, 2 ppm or less, 1 ppm or less, 0.8 ppm or less, or 0.6 ppm or less.
Also, the 1,3-butylene glycol product of the present disclosure preferably has a sum of the contents of the compounds represented by Formulas (1) to (10) above of preferably less than 34 ppm, more preferably 30 ppm or less, and still more preferably ppm or less, 20 ppm or less, 18 ppm or less, 16 ppm or less, 14 ppm or less, 12 ppm or less, 10 ppm or less, 8 ppm or less, 7 ppm or less, 6 ppm or less, 5 ppm or less, 4 ppm or less, 3 ppm or less, or 2 ppm or less.
In addition, in the 1,3-butylene glycol product of the present disclosure, the content of acetaldehyde is preferably less than 1.6 ppm, and more preferably 1.5 ppm or less, 1.4 ppm or less, 1.2 ppm or less, 1.0 ppm or less, 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, or 0.2 ppm or less. The content of the crotonaldehyde is preferably less than 1 ppm, and more preferably 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, or 0.2 ppm or less. The content of methyl vinyl ketone is preferably less than 6 ppm, and more preferably 5 ppm or less, 4 ppm or less, 3 ppm or less, 2 ppm or less, 1 ppm or less, 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, or 0.2 ppm or less. The content of acetone is preferably less than 5 ppm, and more preferably 4 ppm or less, 3 ppm or less, 2 ppm or less, 1 ppm or less, 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, or 0.2 ppm or less. The content of formaldehyde is preferably less than 1 ppm, and more preferably 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, 0.3 ppm or less, or 0.2 ppm or less. The content of butylaldehyde is preferably less than 5 ppm, and more preferably 4 ppm or less, 3 ppm or less, 2 ppm or less, 1 ppm or less, 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, or 0.2 ppm or less. The content of acetaldol is preferably 6 ppm or less, and more preferably 5 ppm or less, 4 ppm or less, 3 ppm or less, 2 ppm or less, 1 ppm or less, 0.8 ppm or less, 0.4 ppm or less, or 0.2 ppm or less. The content of 1-hydroxy-3-butanone is preferably less than 6 ppm, and more preferably 5 ppm or less, 4 ppm or less, 3 ppm or less, 2 ppm or less, 1 ppm or less, 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, or 0.2 ppm or less. The content of 2-butanol is preferably 0.3 ppm or less, and more preferably less than 0.2 ppm. The content of the compound represented by Formula (1) is preferably less than 2 ppm, and more preferably 1.8 ppm or less, 1.6 ppm or less, 1.4 ppm or less, 1.2 ppm or less, 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, or 0.2 ppm or less. The content of the compound represented by Formula (2) is preferably less than 1 ppm, and more preferably 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, 0.3 ppm or less, or 0.2 ppm or less. The content of the compound represented by Formula (3) is preferably less than 4 ppm, and more preferably 3 ppm or less, 2 ppm or less, 1 ppm or less, 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, or 0.2 ppm or less. The content of the compound represented by Formula (4) is preferably less than 3 ppm, and more preferably 2 ppm or less, 1 ppm or less, 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, 0.3 ppm or less, or 0.2 ppm or less. The content of the compound represented by Formula (5) is preferably less than 6 ppm, and more preferably 5 ppm or less, 4 ppm or less, 3 ppm or less, 2 ppm or less, 1 ppm or less, 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, or 0.2 ppm or less. The content of the compound represented by Formula (6) is preferably less than 5 ppm, and more preferably 4 ppm or less, 3 ppm or less, 2 ppm or less, 1 ppm or less, 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, or 0.2 ppm or less. The content of the compound represented by Formula (7) is preferably less than 7 ppm, and more preferably 6 ppm or less, 5 ppm or less, 4 ppm or less, 3 ppm or less, 2 ppm or less, 1 ppm or less, 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, or 0.2 ppm or less. The content of the compound represented by Formula (8) is preferably less than 1 ppm, and more preferably 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, 0.3 ppm or less, or 0.2 ppm or less. The content of the compound represented by Formula (9) is preferably less than 4 ppm, and more preferably 3 ppm or less, 2 ppm or less, 1 ppm or less, 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, or 0.2 ppm or less. The content of the compound represented by Formula (10) is preferably less than 1 ppm, and more preferably 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, 0.3 ppm or less, or 0.2 ppm or less.
Each of the contents of acetaldehyde, crotonaldehyde, methyl vinyl ketone, acetone, formaldehyde, butylaldehyde, acetaldol, 1-hydroxy-3-butanone, 2-butanol, and the compounds represented by the following formulas (1) to (10) can be quantified by GC-MS analysis under the conditions described above. In GC-MS analysis, even very small peaks are all subjected to mass spectrometry, and each component is quantified. Since the analysis is performed for a specific mass, a substance different in mass is not detected even when another impurity overlaps the peak. Therefore, the analysis is more sensitive than GC analysis which will be described below. In the present specification, the unit “ppm” of the content of each component by GC-MS analysis means “ppm by weight”.
Conditions for GC-MS analysis
Analytical Column: a column with dimethylpolysiloxane as a stationary phase, having a length of 30 m, an inner diameter of 0.25 mm, and a film thickness of 1.0 μm
Heating conditions: heating from 80° C. to 120° C. at 5° C./min, then heating again to 160° C. at 2° C./min and maintaining for 2 minutes, and further heating to 230° C. at 10° C./min and maintaining at 230° C. for 18 minutes
Sample Introduction Temperature: 250° C.
Carrier Gas: helium
Column Gas Flow Rate: 1 mL/min
Ion source temperature: EI 230° C., CI 250° C.
Q Pole temperature: 150° C.
Sample: subjected to analysis as it is
In the above analytical conditions, the retention time of a peak of 1,3-butylene glycol is usually from 5.5 minutes to 7 minutes. When a relative retention time of the peak of 1,3-butylene glycol under the above analysis conditions is defined as 1.0, a relative retention time of the peak of acetaldehyde is from 0.3 to 0.5, a relative retention time of the peak of crotonaldehyde is from 0.3 to 0.5, a relative retention time of the peak of methyl vinyl ketone is from 0.3 to 0.5, a relative retention time of the peak of acetone is from 0.3 to 0.5, a relative retention time of the peak of formaldehyde is from 0.3 to 0.5, a relative retention time of the peak of butylaldehyde is from 0.3 to 0.5, and a relative retention time of the peak of acetaldol is from 0.4 to 0.6, a relative retention time of the peak of 1-hydroxy-3-butanone is from 0.4 to 0.6, and a relative retention time of the peak of 2-butanol is from 0.3 to 0.5, a relative retention time of the peak of the compound represented by Formula (1) above is from 1.3 to 1.7, a relative retention time of the peak of the compound represented by Formula (2) is from 1.6 to 2.0, a relative retention time of the peak of the compound represented by Formula (3) is from 0.7 to 1.0, a relative retention time of the peak of the compound represented by Formula (4) is from 0.4 to 0.6, a relative retention time of the peak of the compound represented by Formula (5) is from 1.3 to 1.7, a relative retention time of the peak of the compound represented by Formula (6) is from 1.6 to 2.0, a relative retention time of the peak of the compound represented by Formula (7) is from 0.6 to 0.8, a relative retention time of the peak of the compound represented by Formula (8) is from 1.6 to 2.0, and a relative retention time of the peak of the compound represented by Formula (9) is from 1.0 to 1.2, and a relative retention time of the peak of the compound represented by Formula (10) is from 1.6 to 2.0.
Note that the compound represented by Formula (1) is a compound produced by a reaction (an acetalization reaction) of methyl vinyl ketone with 1,3-butylene glycol. Methyl vinyl ketone is produced by a dehydration reaction of 1-hydroxy-3-butanone. 1-hydroxy-3-butanone is produced by oxidation of 1,3-butylene glycol. The compound represented by Formula (2) is a compound produced by a reaction (an acetalization reaction) of 1-hydroxy-3-butanone with 1,3-butylene glycol. The compound represented by Formula (3) is a compound produced by a reaction (an acetalization reaction) of acetone with 1,3-butylene glycol. The compound represented by Formula (4) is a compound produced by a reaction (an acetalization reaction) of formaldehyde with 1,3-butylene glycol. Acetone and formaldehyde are produced by decomposition of 1-hydroxy-3-butanone. The compound represented by Formula (5) is a compound produced by a reaction (an acetalization reaction) of crotonaldehyde with 1,3-butylene glycol. Crotonaldehyde is produced by a dehydration reaction of acetaldol. Acetaldol is produced by oxidation of 1,3-butylene glycol. Acetaldol is also produced by dimerization of acetaldehyde. The compound represented by Formula (6) is produced by a reaction (an acetalization reaction) of acetaldol with 1,3-butylene glycol. The compound represented by Formula (7) is produced by a reaction (an acetalization reaction) of acetaldehyde with 1,3-butylene glycol. Acetaldehyde is produced by decomposition of acetaldol. The compound represented by Formula (8) is produced by a reaction (an esterification reaction) of crotonic acid with 1,3-butylene glycol. Crotonic acid is produced by oxidation of crotonaldehyde. The compound represented by Formula (9) is produced by a reaction (an esterification reaction) of acetic acid with 1,3-butylene glycol. Acetic acid is produced by oxidation of acetaldehyde. The compound represented by Formula (10) is produced by a reaction (an esterification reaction) of 3-hydroxybutanoic acid with 1,3-butylene glycol. 3-hydroxybutanoic acid is produced by oxidation of acetaldol. In addition, the oxidation of formaldehyde produces formic acid, and a reaction between the formic acid and 1,3-butylene glycol (an esterification reaction) produces 2-hydroxypropyl formate. Decarbonation of the 2-hydroxypropyl formate produces 2-butanol. An estimated formation pathway for each compound (impurity) (sometimes referred to as “impurity formation pathway diagram”) is illustrated below. In the following formula, “1,3 BG” represents 1,3-butylene glycol.
As described above, acetaldehyde, crotonaldehyde, methyl vinyl ketone, acetone, formaldehyde, butylaldehyde, acetaldol, and 1-hydroxy-3-butanone are precursors of the cyclic acetal compounds or 3-hydroxybutyl carboxylate compounds. In particular, 1-hydroxy-3-butanone and acetaldol are precursors of various impurities. Therefore, these impurities are present desirably as little as possible in the 1,3-butylene glycol product of the present disclosure. From such a perspective, in the 1,3-butylene glycol product of the present disclosure, a total content of acetaldehyde, crotonaldehyde, methyl vinyl ketone, acetone, formaldehyde, butylaldehyde, acetaldol, and 1-hydroxy-3-butanone is desirably 31 ppm or less (preferably, 30 ppm or less, 25 ppm or less, 20 ppm or less, 18 ppm or less, 16 ppm or less, 14 ppm or less, 13 ppm or less, 12 ppm or less, 11 pm or less, 10 ppm or less, 9 ppm or less, 8 ppm or less, 7 ppm or less, 6 ppm or less, 5 ppm or less, 4 ppm or less, 3 ppm or less, 2 ppm or less, or 1.5 ppm or less). In the 1,3-butylene glycol product of the present disclosure, a content of acetaldol and 1-hydroxy-3-butanone is less than 12 ppm (preferably, 10 ppm or less, 9 ppm or less, 8 ppm or less, 7 ppm or less, 6 ppm or less, 5 ppm or less, 4 ppm or less, 3 ppm or less, 2 ppm or less, 1 ppm or less, 0.5 ppm or less, or 0.4 ppm or less).
Furthermore, in the 1,3-butylene glycol product of the present disclosure, an acid concentration (in terms of acetic acid) is less than 6 ppm (e.g., 5 ppm or less, preferably 4 ppm or less, more preferably 3 ppm or less, even more preferably 2 ppm or less, and particularly preferably 1 ppm or less). Lowering the acid concentration in the 1,3-butylene glycol product can suppress increases, over time, of 3-hydroxybutyl carboxylate compounds such as the compounds represented by Formulas (8) to (10) above. The 3-hydroxybutyl carboxylate compounds are hydrolyzed in the presence of water to produce corresponding carboxylic acids. The thus-produced carboxylic acid may be a substance that causes odor or a substance that causes acidity.
The 1,3-butylene glycol product of the present disclosure preferably has an acid concentration (in terms of acetic acid) of preferably less than 9 ppm (for example, 8 ppm or less, preferably 7 ppm or less, more preferably 6 ppm or less, still more preferably 5 ppm or less, and particularly preferably 4 ppm or less, 3 ppm or less, 2 ppm or less, or 1 ppm or less), after a 90 wt. % aqueous solution thereof has been kept at 100° C. for 1 week. The 90 wt. % aqueous solution means an aqueous solution prepared by mixing the 1,3-butylene glycol product and water (e.g., pure water) to adjust the 1,3-butylene glycol product to 90 wt. %. Reduction in the concentrations of acid precursors in the 1,3-butylene glycol product can suppress increases, over time, of 3-hydroxybutyl carboxylate compounds such as the compounds represented by Formulas (8) to (10) above.
For the acid concentration (in terms of acetic acid) of the 90 wt. % aqueous solution of the 1,3-butylene glycol product according to the present disclosure, a ratio of the acid concentration after keeping the aqueous solution at 100° C. for 1 week to the acid concentration before keeping the solution at 100° C. for 1 week, [(acid concentration after keeping the solution at 100° C. for 1 week)/(acid concentration before keeping the solution at 100° C. for 1 week) x 100 (%)], is preferably 150% or less, more preferably 120% or less, and even more preferably 110% or less.
The 1,3-butylene glycol product of the present disclosure has an APHA (Hazen color number) of, for example, 3 or less (preferably 2 or less, and more preferably 1 or less). Furthermore, an APHA, after the 1,3-butylene glycol product has been kept at 100° C. for 75 days in air atmosphere, is 11 or less (preferably 10 or less, more preferably 8 or less, 7 or less, 6 or less, and even more preferably 5 or less, 4 or less, 3 or less, or 2 or less).
For the APHA of the 1,3-butylene glycol product according to the present disclosure, a ratio of the APHA after the 1,3-butylene glycol product has been kept at 100° C. for 75 days to the APHA before the 1,3-butylene glycol product has been kept at 100° C. for 75 days, [(APHA after the 1,3-butylene glycol product has been kept at 100° C. for 75 days)/(APHA before the 1,3-butylene glycol product has been kept at 100° C. for 75 days)], is not particularly limited, but is preferably less than 3, more preferably 2.5 or less, even more preferably 2 or less, and particularly preferably 1.5 or less (for example, 1.2 or less).
Additionally, the 1,3-butylene glycol product according to the present disclosure preferably has an initial boiling point of 204° C. or higher. The initial boiling point is preferably 204.5° C. or higher, more preferably 205° C. or higher, even more preferably 206° C. or higher or 207° C., and particularly preferably 208° C. or higher.
In addition, the 1,3-butylene glycol product of the present disclosure preferably has a dry point of lower than 209° C. (e.g., 208.8° C. or lower).
The 1,3-butylene glycol product of the present disclosure preferably has a potassium permanganate test value (PMT) of 36 minutes or longer. The potassium permanganate test value (PMT) is more preferably 38 minutes or longer, even more preferably 40 minutes or longer, and particularly preferably 50 minutes or longer (especially 60 minutes or longer).
The 1,3-butylene glycol product of the present disclosure has a content of 1,3-butylene glycol of, for example, 99.3% or greater. The content of the 1,3-butylene glycol corresponds to an area ratio (GC area ratio) of the peak of 1,3-butylene glycol, in the gas chromatographic analysis (GC analysis) performed under the following conditions.
The conditions for the gas chromatographic analysis are as follows:
In the present disclosure, the “(peak) area ratio” means a ratio of the area of a specific peak relative to the sum of the areas of all peaks appearing in the chromatogram. In addition, all peaks mean, for example, all of the peaks appearing in the analysis continued until and discontinued at a relative retention time of 7.8, provided that the relative retention time of 1,3-butylene glycol is 1.0. The content of 1,3-butylene glycol in the 1,3-butylene glycol product is, for example, 98.6% or greater, and thus basic properties inherent in 1,3-butylene glycol are guaranteed.
The content (GC area ratio) of the 1,3-butylene glycol is preferably 99.4% or greater, more preferably 99.5% or greater, even more preferably 99.6% or greater, and particularly preferably 99.7% or greater, and especially 99.8% or greater.
In the GC analysis, a total area ratio of peaks shorter in retention time than a peak of 1,3-butylene glycol is preferably 0.09% or less, more preferably 0.08% or less, even more preferably 0.07% or less, 0.04% or less, 0.03% or less, 0.02% or less, 0.01% or less, 0.007% or less, and particularly preferably 0.005% or less (e.g., 0.003% or less).
In the GC analysis, a total area ratio of peaks longer in retention time than the peak of 1,3-butylene glycol is preferably 0.7% or less, more preferably 0.6% or less, even more preferably 0.5% or less, 0.4% or less, 0.3% or less, or 0.2% or less, and particularly preferably 0.1% or less.
In the 1,3-butylene glycol product according to the present disclosure, a content of water is preferably 0.2 wt. % or less. The content of water is preferably 0.15 wt. % or less, more preferably 0.1 wt. % or less, even more preferably 0.07 wt. % or less, 0.05 wt. % or less, 0.03 wt. % or less, 0.02 wt. % or less, or 0.01 wt. % or less, and particularly preferably 0.005 wt. % or less. Note that the content of water can be quantified by a Karl Fischer water content measurement instrument.
The 1,3-butylene glycol product of the present disclosure has no or very little coloration or odor even after storage for a long period of time. In addition, the 1,3-butylene glycol product of the present disclosure has extremely low contents of impurities that may serve as a substance that causes coloration or a substance that causes odor even after storage for a long period of time. For example, even after an acceleration test assuming long-term storage of the 1,3-butylene glycol product (test in which the 1,3-butylene glycol product has been kept at 180° C. for 3 hours in air atmosphere), the contents of impurities that may serve as a substance that causes coloration or a substance that causes odor in the product are extremely low.
In the 1,3-butylene glycol product of the present disclosure, a total content of acetaldehyde, crotonaldehyde, methyl vinyl ketone, acetone, formaldehyde, butylaldehyde, acetaldol, 1-hydroxy-3-butanone, 2-butanol and the compounds represented by Formulas (1) to (10) is, for example, less than 70 ppm, preferably 65 ppm or less, 60 ppm or less, 55 ppm or less, 50 ppm or less, 45 ppm or less, 40 ppm or less, 35 ppm or less, 30 ppm or less, 25 ppm or less, or 20 ppm or less, and even more preferably 18 ppm or less, 15 ppm or less, 13 ppm or less, 10 ppm or less, 8 ppm or less, 5 ppm or less, 4 ppm or less, or 3.5 ppm or less, after the 1,3-butylene glycol product has been kept at 180° C. for 3 hours in air atmosphere.
Also, the 1,3-butylene glycol product of the present disclosure preferably has a sum of the contents of the compounds represented by Formulas (1) to (7) above (cyclic acetal compounds) of, for example, less than 40 ppm, preferably 35 ppm or less, and more preferably 30 ppm or less, 25 ppm or less, 20 ppm or less, 15 ppm or less, 12 ppm or less, 10 ppm or less, 8 ppm or less, 6 ppm or less, 5 ppm or less, 4 ppm or less, 3 ppm or less, 2 ppm or less, or 1.4 ppm or less, after the product has been kept at 180° C. for 3 hours in air atmosphere.
Also, the 1,3-butylene glycol product of the present disclosure has a sum of the contents of the compounds represented by Formulas (8) to (10) above (3-hydroxybutyl carboxylate compounds) of, for example, less than 18 ppm, preferably 16 ppm or less, more preferably 14 ppm or less, 13 ppm or less, 12 ppm or less, 11 pm or less, 10 ppm or less, 9 ppm or less, 8 ppm or less, 7 ppm or less, 6 ppm or less, 5 ppm or less, 4 ppm or less, 3 ppm or less, 2 ppm or less, 1 ppm or less, or 0.6 ppm or less, after the product has been kept at 180° C. for 3 hours in air atmosphere.
Further, the 1,3-butylene glycol product of the present disclosure preferably has a sum of the contents of the compounds represented by Formulas (1) to (10) above of, for example, less than 59 ppm, preferably 55 ppm or less, more preferably 50 ppm or less, 40 ppm or less, 30 ppm or less, 20 ppm or less, 18 ppm or less, 16 ppm or less, 14 ppm or less, 12 ppm or less, 10 ppm or less, 8 ppm or less, 7 ppm or less, 6 ppm or less, 5 ppm or less, 4 ppm or less, 3 ppm or less, or 2 ppm or less, after the product has been kept at 180° C. for 3 hours in air atmosphere.
In addition, in the 1,3-butylene glycol product of the present disclosure, the content of acetaldehyde is preferably less than 1 ppm, and more preferably 0.9 ppm or less, 0.8 ppm or less, 0.7 ppm or less, 0.6 ppm or less, 0.5 ppm or less, 0.4 ppm or less, 0.3 ppm or less, or 0.2 ppm or less, after the 1,3-butylene glycol product has been kept at 180° C. for 3 hours in air atmosphere. The content of the crotonaldehyde is preferably less than 0.5 ppm, and more preferably 0.4 ppm or less, 0.3 ppm or less, 0.2 ppm or less, or 0.1 ppm or less. The content of methyl vinyl ketone is preferably less than 4 ppm, and more preferably 3 ppm or less, 2 ppm or less, 1 ppm or less, 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, 0.3 ppm or less, or 0.2 ppm or less. The content of acetone is preferably less than 2 ppm, and more preferably 1 ppm or less, 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, 0.3 ppm or less, or 0.2 ppm or less. The content of formaldehyde is preferably less than 0.5 ppm, and more preferably 0.4 ppm or less, 0.3 ppm or less, or 0.2 ppm or less. The content of butylaldehyde is preferably less than 3 ppm, and more preferably 2 ppm or less, 1 ppm or less, 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, 0.3 ppm or less, or 0.2 ppm or less. The content of acetaldol is preferably less than 0.5 ppm, and more preferably 0.4 ppm or less, 0.3 ppm or less, or 0.2 ppm or less. The content of 1-hydroxy-3-butanone is preferably less than 0.5 ppm, and more preferably 0.4 ppm or less, 0.3 ppm or less, or 0.2 ppm or less. The content of 2-butanol is preferably less than 0.2 ppm. The content of the compound represented by Formula (1) is preferably less than 6 ppm, and more preferably 5 ppm or less, 4 ppm or less, 3 ppm or less, 2 ppm or less, 1 ppm or less, 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, 0.3 ppm or less, or 0.2 ppm or less. The content of the compound represented by Formula (2) is preferably less than 5 ppm, and more preferably 4 ppm or less, 3 ppm or less, 2 ppm or less, 1 ppm or less, 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, 0.3 ppm or less, or 0.2 ppm or less. The content of the compound represented by Formula (3) is preferably less than 4 ppm, and more preferably 3 ppm or less, 2 ppm or less, 1 ppm or less, 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, 0.3 ppm or less, or 0.2 ppm or less. The content of the compound represented by Formula (4) is preferably less than 5 ppm, and more preferably 4 ppm or less, 3 ppm or less, 2 ppm or less, 1 ppm or less, 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, 0.3 ppm or less, or 0.2 ppm or less. The content of the compound represented by Formula (5) is preferably less than 7 ppm, and more preferably 6 ppm or less, 5 ppm or less, 4 ppm or less, 3 ppm or less, 2 ppm or less, 1 ppm or less, 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, 0.3 ppm or less, or 0.2 ppm or less. The content of the compound represented by Formula (6) is preferably less than 6 ppm, and more preferably 5 ppm or less, 4 ppm or less, 3 ppm or less, 2 ppm or less, 1 ppm or less, 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, 0.3 ppm or less, or 0.2 ppm or less. The content of the compound represented by Formula (7) is preferably less than 8 ppm, and more preferably 7 ppm or less, 6 ppm or less, 5 ppm or less, 4 ppm or less, 3 ppm or less, 2 ppm or less, 1 ppm or less, 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, 0.3 ppm or less, or 0.2 ppm or less. The content of the compound represented by Formula (8) is preferably less than 6 ppm, and more preferably 5 ppm or less, 4 ppm or less, 3 ppm or less, 2 ppm or less, 1 ppm or less, 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, 0.3 ppm or less, or 0.2 ppm or less. The content of the compound represented by Formula (9) is preferably less than 5 ppm, and more preferably 4 ppm or less, 3 ppm or less, 2 ppm or less, 1 ppm or less, 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, 0.3 ppm or less, or 0.2 ppm or less. The content of the compound represented by Formula (10) is preferably less than 7 ppm, and more preferably 6 ppm or less, 5 ppm or less, 4 ppm or less, 3 ppm or less, 2 ppm or less, 1 ppm or less, 0.8 ppm or less, 0.6 ppm or less, 0.4 ppm or less, 0.3 ppm or less, or 0.2 ppm or less.
In the 1,3-butylene glycol product, a sum of the contents of acetaldehyde, crotonaldehyde, methyl vinyl ketone, acetone, formaldehyde, butylaldehyde, acetaldol, and 1-hydroxy-3-butanone is, for example, less than 12 ppm, preferably 10 ppm or less, and more preferably 8 ppm or less, 7 ppm or less, 6 ppm or less, 5 ppm or less, 4 ppm or less, 3 ppm or less, 2 ppm or less, or 1.6 ppm or less, after the 1,3-butylene glycol product has been kept at 180° C. for 3 hours in air atmosphere.
In addition, in the 1,3-butylene glycol product of the present disclosure, a sum of the contents of acetaldol and 1-hydroxy-3-butanone is, for example, less than 1 ppm, preferably 0.9 ppm or less, and more preferably 0.8 ppm or less, 0.7 ppm or less, 0.6 ppm or less, 0.5 ppm or less, or 0.4 ppm or less, after the 1,3-butylene glycol product has been kept at 180° C. for 3 hours in air atmosphere.
Furthermore, in the 1,3-butylene glycol product according to the present disclosure, an APHA is less than 25 (preferably 20 or less, and more preferably 18 or less, 15 or less, 14 or less, 13 or less, 12 or less, 11 or less, 10 or less, 9 or less, 8 or less, or 7 or less), after the 1,3-butylene glycol product has been kept at 180° C. for 3 hours in air atmosphere.
Also, the 1,3-butylene glycol product according to the present disclosure preferably has an initial boiling point of 204° C. or greater and preferably has a dry point of less than 209° C., after the 1,3-butylene glycol product has been kept at 180° C. for 3 hours in air atmosphere. The initial boiling point is preferably 205° C. or greater, more preferably 206° C. or greater, and even more preferably 207° C. or greater.
The 1,3-butylene glycol product according to the present disclosure preferably has a potassium permanganate test value (PMT) of longer than 30 minutes, after the 1,3-butylene glycol product has been kept at 180° C. for 3 hours in air atmosphere. The potassium permanganate test value is more preferably longer than 32 minutes or longer, even more preferably 35 minutes or longer (e.g., 40 minutes or longer), and particularly preferably 50 minutes or longer (especially, 60 minutes or longer).
The 1,3-butylene glycol product according to the present disclosure preferably has an acid concentration (in terms of acetic acid) of less than 8 ppm, after the 1,3-butylene glycol product has been kept at 180° C. for 3 hours in air atmosphere. The acid concentration (in terms of acetic acid) is more preferably 7 ppm or less, even more preferably 6 ppm or less, 5 ppm or less, 4 ppm or less, 3 ppm or less, 2 ppm or less, or 1 ppm or less.
A 1,3-butylene glycol product having a content of 1,3-butylene glycol of a specific value or greater and a content of a specific substance after the heating test under the specific conditions has high purity and high quality, and is hardly deteriorated in quality over time. In particular, the 1,3-butylene glycol product according to the present disclosure is colorless and odorless (or almost colorless and odorless), and hardly causes or increases odor over time. Therefore, it can be suitably used as a raw material for moisturizers or cosmetic products.
A moisturizer of the present disclosure contains the 1,3-butylene glycol product described above. Therefore, the moisturizer has excellent moisturizing performance. The moisturizer of the present disclosure may contain a component besides the 1,3-butylene glycol product described above, such as a moisturizer component besides the 1,3-butylene glycol product described above. In the moisturizer of the present disclosure, the content of the 1,3-butylene glycol product described above is, for example, 10 wt. % or greater, preferably 30 wt. % or greater, more preferably 50 wt. % or greater, even more preferably 80 wt. % or greater, and particularly preferably 90 wt. % or greater, and the moisturizer may be composed of only the 1,3-butylene glycol product described above.
A cosmetic of the present disclosure contains the moisturizer described above. The blending amount of the 1,3-butylene glycol product in the cosmetic product of the present disclosure is any amount in which the moisturizing performance can be exhibited according to the type and form of cosmetic. The blending amount of the 1,3-butylene glycol product in the cosmetic product of the present disclosure is, for example, from 0.01 to 40 wt. %, preferably from 0.1 to 30 wt. %, more preferably from 0.2 to 20 wt. %, even more preferably from 0.5 to 15 wt. %, and particularly preferably from 1 to 10 wt. %.
The cosmetic product of the present disclosure may contain, in addition to the 1,3-butylene glycol product, for example, another moisturizer; an oil, such as a vegetable oil, a hydrocarbon oil, a greater fatty acid, a greater alcohol, or a silicone; a surfactant, such as an anionic surfactant, a cationic surfactant, an amphoteric surfactant, or a nonionic surfactant; a preservative, a sequestrant, a thickener, a powder, an ultraviolet absorber, an ultraviolet blocker, a fragrance, or a pH adjuster; or a medicinal ingredient or bioactive component, such as a vitamin preparation, a skin activator, a blood circulation promoter, a skin-lightening preparation, an antibacterial agent, or an anti-inflammatory agent.
The cosmetic product of the present disclosure can be a skin cosmetic product, such as a lotion, an emulsion, a cream, a gel, a pack, or a mask; or a hair cosmetic product, such as a shampoo, a rinse, or a hair restorer. In addition, the cosmetic product may be a sunscreen cosmetic product, a make-up cosmetic product or the like. Furthermore, the cosmetic product can be a pharmaceutical product or quasi drug containing a medical component.
The cosmetic product of the present disclosure can be produced by utilizing a method known per se.
The 1,3-butylene glycol product of the present disclosure can be produced, for example, by a method 1 of producing 1,3-butylene glycol which will be described below, or a method 2 of producing 1,3-butylene glycol which will be described below.
A method for producing 1,3-butylene glycol to yield purified 1,3-butylene glycol from a reaction crude liquid containing 1,3-butylene glycol,
The conditions for the gas chromatographic analysis are as follows:
A method for producing 1,3-butylene glycol to yield purified 1,3-butylene glycol from a reaction crude liquid containing 1,3-butylene glycol,
The conditions for the gas chromatographic analysis are as follows:
The method 1 for producing 1,3-butylene glycol described above (hereinafter, sometimes simply referred to as “production method 1”) is a method for producing 1,3-butylene glycol to yield purified 1,3-butylene glycol from a reaction crude liquid containing 1,3-butylene glycol (1,3 BG) (hereinafter, sometimes referred to as “crude 1,3-butylene glycol”), the method including: performing dehydration including removing water by distillation, removing a high boiling point component including removing a high boiling point component by distillation, and performing product distillation to yield purified 1,3-butylene glycol. Then, in the product column for use in the performing product distillation, a 1,3-butylene glycol charged liquid having a content of acetaldehyde of 500 ppm or less, a content of crotonaldehyde of 200 ppm or less, a content of water of 0.7 wt. % or less, and a concentration of 1,3-butylene glycol of 97.6 area % by gas chromatographic analysis under the above conditions is subjected to distillation under a condition that a reflux ratio is 0.3 or greater, a liquid with a concentrated low boiling point component is distilled from above a charging plate, and 1,3-butylene glycol is extracted from below the charging plate. The thus-obtained 1,3-butylene glycol is colorless and odorless (or almost colorless and odorless), unlikely to cause or increase coloration and odor over time, and, in addition, unlikely to cause an acid concentration increase over time also in a state containing water, and thus can constitute a 1,3-butylene glycol product.
The method 2 for producing 1,3-butylene glycol (hereinafter, sometimes simply referred to as “production method 2”) is a method for producing 1,3-butylene glycol to yield purified 1,3-butylene glycol from a reaction crude liquid containing 1,3-butylene glycol, the method including: performing dehydration including removing water by distillation and removing a high boiling point component including removing a high boiling point component by distillation. In a high boiling point component removal column for use in the removing a high boiling point component, a charged liquid containing 1,3-butylene glycol, which has a content of acetaldehyde of 500 ppm or less, a content of crotonaldehyde of 200 ppm or less, a content of water of 3 wt. % or less, and a concentration of 1,3-butylene glycol of 96.7 area % or greater by gas chromatographic analysis under the conditions above is subjected to distillation under a condition that a reflux ratio is 0.03 or greater, 1,3-butylene glycol having improved purity is distilled from above the charging plate, and a liquid in which a high boiling point component is concentrated is extracted from below the charging plate. The thus-obtained 1,3-butylene glycol is colorless and odorless (or almost colorless and odorless), unlikely to cause or increase coloration and odor over time, and, in addition, unlikely to cause an acid concentration increase over time also in a state containing water, and thus can constitute a 1,3-butylene glycol product.
Examples of the crude 1,3-butylene glycol include (1) a reaction crude liquid produced by reduction (hydrogenation) of an acetaldol, (2) a reaction crude liquid produced by hydrolysis of 1,3-butylene oxide, (3) a reaction crude liquid produced by selective hydrocracking of erythritol, (4) a reaction crude liquid produced by selective hydration to butadiene, (5) a reaction crude liquid produced by hydrogen addition to n-butanal-3-one, (6) a reaction crude liquid produced by hydrogen addition to 1-butanol-3-one, (7) a reaction crude liquid produced by hydrogen addition to 3-hydroxy-1-butanoic acid, (8) a reaction crude liquid produced by hydrogen addition to β-butyrolactone, and (9) a reaction crude liquid produced by hydrogen addition to diketene. In the present disclosure, the crude 1,3-butylene glycol may be one type or a mixture of two or more types of the above (1) to (9). The crude 1,3-butylene glycol is preferably (1) the reaction crude liquid produced by reduction (in particular, liquid phase reduction) of an acetaldol.
Hereinafter, a case where the reaction crude liquid produced by reduction (hydrogenation) of an acetaldol is used as the crude 1,3-butylene glycol will be mainly described. Note that the reduction (hydrogenation) of an acetaldol is sometimes referred to as “hydrogenation”.
The acetaldol used as a raw material in the hydrogenation is not particularly limited as long as it is a compound that becomes 1,3-butylene glycol by hydrogen reduction. Examples of the raw material acetaldols include acetaldol; its cyclic dimer paraldol; aldoxane as a cyclic trimer of acetaldehyde; and mixtures of these.
The method of producing the acetaldol (e.g., acetaldol or paraldol) is not particularly limited, but the acetaldol may be, for example, those produced by an aldol condensation reaction of acetaldehyde in the presence of a basic catalyst or those produced by pyrolysis or the like of aldoxane. Note that the production of the acetaldol is sometimes referred to as “acetaldol production” or “acetaldehyde polymerization”.
A reaction crude liquid produced by the reaction described above and containing an acetaldol may be neutralized with an acid and used in the production of 1,3-butylene glycol. Such a reaction crude liquid may contain, in addition to an acetaldol, acetaldehyde (AD), crotonaldehyde (CR), another aldehyde component; a low boiling point substance; a high boiling point substance, such as an aldehyde dimer or trimer; water; a salt; and the like. In the present specification, a compound with a lower boiling point than that of 1,3-butylene glycol may be referred to as a “low boiling point substance” or “low boiling substance”, and a compound with a higher boiling point than that of 1,3-butylene glycol may be referred to as a “high boiling point substance” or “high boiling substance”.
The reaction crude liquid containing an acetaldol may be subjected to a pretreatment, such as dealcoholization distillation, dehydration distillation, desalting, alkaline treatment and dealkalization treatment, or impurity removal, as necessary, and a product produced by removing by-products, such as unreacted acetaldehyde and crotonaldehyde, may be used. Examples of the pretreatment method include distillation, adsorption, ion exchange, conversion to a high boiling point substance by heating, and decomposition. For the distillation, a distillation method of various types, such as reduced pressure, normal pressure, increased pressure, azeotropic, extraction, or reaction, can be used. In particular, it is preferred that the reaction crude liquid containing an acetaldol is subjected to simple evaporation, distillation, or hydrogen addition to remove aldehydes such as acetaldehyde and crotonaldehyde, followed by the hydrogenation.
The content of the acetaldol in the raw material for hydrogenation is not particularly limited but is, for example, preferably 30 wt. % or greater (e.g., from 30 to 99 wt. %), more preferably 40 wt. % or greater (for example, from 40 to 98 wt. %), 50 wt. % or greater (for example, from 50 to 97 wt. %) or 60 wt. % or greater (for example, from 60 to 95 wt. %), and even more preferably from 65 to 90 wt. %, particularly preferably from 70 to 90 wt. %, and most preferably from 75 to 90 wt. %. With the content of the acetaldol within the above ranges, impurities contained in the reaction crude liquid containing 1,3-butylene glycol (crude 1,3-butylene glycol) tend to be reduced.
The raw material for hydrogenation may or may not contain water but preferably contains water from the viewpoint of the purity of 1,3-butylene glycol product. The water content in the raw material for hydrogenation is not particularly limited but is, for example, preferably 2 wt. % or greater, more preferably 5 wt. % or greater, even more preferably 10 wt. % or greater, and particularly preferably 15 wt. % or greater. The upper limit may be, for example, 90 wt. %, 80 wt. %, 70 wt. %, 60 wt. %, 50 wt. %, 40 wt. %, 30 wt. % or 20 wt. %. With the water content within the above ranges, the acetal of 1,3-butylene glycol and acetaldol contained in the resulting crude 1,3-butylene glycol is decreased, and thus this tends to increase the purity of the 1,3-butylene glycol product finally produced. This is because the raw material for hydrogenation contains water to a certain extent, and the acetal is hydrolyzed into 1,3-butylene glycol accordingly as well as coexisting acetaldol is reduced into 1,3-butylene glycol.
Examples of the hydrogenation catalyst include Raney nickel. The hydrogenation catalyst can also be used in a suspended state, and can also be filled in a reaction vessel and used. The amount of the hydrogenation catalyst to be used is not particularly limited but is, for example, preferably from 1 to 30 parts by weight, more preferably from 4 to 25 parts by weight, even more preferably from 8 to 20 parts by weight, and particularly preferably from 12 to 18 parts by weight relative to 100 parts by weight of the raw material for hydrogenation. The amount of hydrogen to be used in the reduction reaction is not particularly limited but is, for example, preferably from 0.5 to 40 parts by weight, more preferably from 1 to 30 parts by weight, even more preferably from 4 to 20 parts by weight, and particularly preferably from 8 to 12 parts by weight relative to 100 parts by weight of the raw material for hydrogenation. A pressure (total pressure; gauge pressure) in a reaction system in the reduction reaction is not particularly limited but is, for example, preferably from 9 to 70 MPa and more preferably from 10 to 40 MPa. A hydrogen pressure (partial pressure of hydrogen) in the reaction system is not particularly limited, but is, for example, from 7 to 60 MPa, and preferably from 10 to 30 MPa. Note that, from the perspective of reducing the amount of the reducing materials such as acetaldehyde and crotonaldehyde, it is better to increase the hydrogen pressure in the reaction system, and the hydrogen pressure is preferably 10 MPa or greater, and may be 100 MPa. A reaction temperature in the reduction reaction is not particularly limited but is, for example, from 40 to 150° C., preferably from 50 to 140° C., and more preferably from 60 to 130° C. A reaction time (residence time) in the reduction reaction is not particularly limited but is, for example, from 10 to 500 minutes, preferably from 20 to 400 minutes, more preferably from 30 to 300 minutes, even more preferably from 50 to 280 minutes, and particularly preferably from 80 to 250 minutes. The present reaction can be carried out in any of a batch, semi-batch, or continuous manner.
For example, the thus-produced crude 1,3-butylene glycol contains a low boiling point substance (low boiling point compound) having an unsaturated bond, such as acetaldehyde (AD), butylaldehyde, crotonaldehyde (CR), acetone, and methyl vinyl ketone; a condensate of these; a condensate of 1,3-butylene glycol and the above low boiling point substance (e.g., an acetal of 1,3-butylene glycol and acetaldol); an alcohol such as ethanol, isopropyl alcohol, or butanol; water (for example, solvent), a salt produced by neutralization or the like, a catalyst (when used in suspension) or the like. These impurities are removed in the purification, and a 1,3-butylene glycol product (purified 1,3-butylene glycol) can be produced.
The production method 1 according to the present disclosure includes, at least, performing dehydration including removing water by distillation, removing a high boiling point component including removing a high boiling point component by distillation (high boiling point component removal distillation), and performing product distillation to yield purified 1,3-butylene glycol. In the production method 2 of the present disclosure, at least dehydration for removing water by distillation and high boiling point component removal for removing a high boiling point component by distillation (high boiling point component removal distillation).
In the production method of the present disclosure, the order of the performing dehydration and the removing a high boiling point component does not matter. In the production method 1, both the performing dehydration and the removing a high boiling point component are provided prior to the performing product distillation. The production method according to the present disclosure may include, in addition to these steps, desalting, alkaline reaction (alkaline treatment), and dealkalization. Additionally, prior to the dehydration, catalyst separation, neutralization by alkali, dealcoholization (low boiling point component removal), and the like can be provided. These steps may be performed in the order described above, but the order of the steps may be changed as appropriate except that the dealkalization is provided after the alkaline reaction. For example, the dealcoholization (low boiling point component removal), the desalting, the alkaline reaction, and the dealkalization can be provided at appropriate locations, but are usually provided after the hydrogenation. Note that, among the above-described steps, the catalyst separation, the neutralization by alkali, the dealcoholization (low boiling point component removal), the desalting, the alkaline reaction, and the dealkalization may be provided as necessary, and do not necessarily have to be provided.
Crude 1,3-butylene glycol (corresponding to “X-1”) produced by hydrogen reduction of a raw material for hydrogenation is fed to the dehydration column A. Note that the crude 1,3-butylene glycol (corresponding to “X-1”) may be fed to the dehydration column A after undergoing the dealcoholization (distillation by a dealcoholization column) for removing an alcohol such as ethanol and a low boiling point substance.
In the production method of the present disclosure, in the dehydration column A used in the dehydration, for example, a charged liquid containing 1,3-butylene glycol and water is subjected to distillation, and a liquid having a concentrated low boiling point component containing water is distilled from above the charging plate (preferably, the top of the column) (corresponding to “X-2” in
The dehydration column A and any other distillation column for separating 1,3-butylene glycol can be, for example, perforated-plate columns, bubble columns, and the like, but are more preferably packed columns with a low pressure loss, filled with Sulzer Packing, Melapack (trade names of Sumitomo Heavy Industries, Ltd.). This is because 1,3-butylene glycol and trace impurities would be thermally decomposed at a high temperature (e.g., 150° C. or greater) and form a low boiling point substance, which is a coloring component, and thus the distillation temperature is to be lowered. In addition, this is also because a long thermal history (residence time) for 1,3-butylene glycol would also have a similar effect. Thus, the reboiler employed is preferably one with a short residence time of the process side fluid, for example, a thin-film evaporator, such as a natural downward flow thin-film evaporator or a forced-stirring thin-film evaporator.
A theoretical number of plates of the dehydration column A is, for example, from 1 to 100 plates, preferably from 2 to 80 plates, from 3 to 80 plates, from 4 to 60 plates, from 5 to 40 plates, from 6 to 30 plates or from 7 to 20 plates, and more preferably from 8 to 15 plates. A feed position for the charged liquid is, for example, from 10 to 90%, preferably from 20 to 80%, and more preferably from 30 to 70%, and even more preferably from 40 to 60% of a height of the column downward from the top of the column. In the distillation in the dehydration column A, the pressure (absolute pressure) of the top of the column is, for example, 101 kPa or less, preferably from 0.1 to 90 kPa, more preferably from 0.5 to 70 kPa, and even more preferably from 1 to 50 kPa, from 2 to 30 kPa or from 3 to 20 kPa, and particularly preferably from 4 to 10 kPa. Note that the distillation in the dehydration column A may be performed under increased pressure, in which case the pressure (gauge pressure) at the top of the column may be, for example, 0.2 MPaG or less, or 0.1 MPaG or less.
A concentration of 1,3-butylene glycol in the charged liquid into the dehydration column A is, for example, 9 wt. % or greater, preferably 10 wt. % or greater, more preferably 15 wt. % or greater, even more preferably 20 wt. % or greater, 25 wt. % or greater, 30 wt. % or greater, 35 wt. % or greater, 40 wt. % or greater, 45 wt. % or greater, 50 wt. % or greater, 55 wt. % or greater, or 60 wt. % or greater, and particularly preferably 70% or greater. An upper limit of the concentration of 1,3-l butylene glycol in the charged liquid into the dehydration column A is, for example, 90 wt. %, 85 wt. %, or 80 wt. %. However, in consideration of the hydrogen addition reaction and the like in the step prior to the dehydration, the concentration of water in the charged liquid into the dehydration column A is preferably greater in some cases. Taken together, the concentration of 1,3-butylene glycol in the charged liquid into the dehydration column A may be, for example, 1 wt. % or greater, 5 wt. % or greater, 10 wt. % or greater, 15 wt. % or greater, 20 wt. % or greater, 25 wt. % or greater, 30 wt. % or greater, 35 wt. % or greater, 40 wt. % or greater, 50 wt. % or greater, 60 wt. % or greater, 70 wt. % or greater, 80 wt. % or greater, or 90 wt. % or greater. Furthermore, the concentration of 1,3-butylene glycol in charged liquid into the dehydration column A may be, for example, 99 wt. % or less, 95 wt. % or greater, 90 wt. % or less, 85 wt. % or less, 80 wt. % or less, 75 wt. % or less, 70 wt. % or less, 65 wt. % or less, 60 wt. % or less, 55 wt. % or less, 50 wt. % or less, or 45 wt. % or less. The concentration of 1,3-butylene glycol in the charged liquid into the dehydration column A can be, for example, in the range described above by adjusting the reaction conditions in the hydrogenation (for example, the concentration of an acetaldol used as a raw material) and the distillation conditions of the dealcoholization column (low boiling point component removal column) provided before the dehydration column as needed.
The concentration (wt. %) of 1,3-butylene glycol is a value determined according to the following formula by determining an area proportion (GC area %) of the peak of 1,3-butylene glycol relative to a total peak area in the gas chromatographic analysis under the following conditions. Note that the concentration (wt. %) of water in the charged liquid into the dehydration column A is a value measured by the method which will be described below (Karl Fischer method).
Concentration (wt. %) of 1,3-butylene glycol in charged liquid into dehydration column A =[1−(concentration (wt. %) of water in charged liquid into dehydration column A)/100]×(GC area % of 1,3-butylene glycol described above)
The conditions for the gas chromatographic analysis are as follows:
In the production method of the present disclosure, a content of acetaldehyde in the charged liquid into the dehydration column A is, for example, 1000 ppm or less, preferably 900 ppm or less, more preferably 800 ppm or less, 700 ppm or less, 600 ppm or less, or 500 ppm or less, even more preferably 400 ppm or less, 300 ppm or less, 200 ppm or less, 155 ppm or less, or 140 ppm or less, and may be 100 ppm or less, 90 ppm or less, 80 ppm or less, 70 ppm or less, 60 ppm or less, 50 ppm or less, 40 ppm or less, or 30 ppm or less, 20 ppm or less, 10 ppm or less, 5 ppm or less, 3 ppm or less, 2 ppm or less, or 1 ppm or less.
The content of crotonaldehyde in charged liquid into the dehydration column A may be, for example, 400 ppm or less, preferably 300 ppm or less, more preferably 200 ppm or less, even more preferably 150 ppm or less, 130 ppm or less, 117 ppm or less, or 100 ppm or less, and may be 90 ppm or less, 80 ppm or less, 70 ppm or less, 60 ppm or less, 50 ppm or less, 40 ppm or less, 30 ppm or less, 20 ppm or less, 10 ppm or less, 5 ppm or less, 3 ppm or less, 2 ppm or less, or 1 ppm or less.
The acetaldehyde content and the crotonaldehyde content in the charged liquid into the dehydration column A can be reduced, for example, by providing a dealcoholization column (low boiling point component removal column) upstream of the dehydration column A, and adjusting the distillation conditions of the dealcoholization column (low boiling point component removal column). For example, increasing the reflux ratio and the number of plates, and the distillation ratio of the dealcoholization column (low boiling point component removal column) can reduce the acetaldehyde content and the crotonaldehyde content of the charged liquid into the dehydration column A. Furthermore, the contents can be adjusted according to the conditions for the hydrogen addition reaction in the hydrogenation, and when hydrogen addition is completely performed, the concentrations of acetaldehyde and crotonaldehyde can be reduced to below the detection limit, but there are disadvantages of a high reaction pressure, an increase in size of the reaction tank and the like.
Note that the acetaldehyde content and the crotonaldehyde content of the charged liquid into the dehydration column A can be quantified by GC-MS analysis (gas mass spectrometry).
In the production method of the present disclosure, the content of water in the charged liquid into the dehydration column A is, for example, 90 wt. % or less, 85 wt. % or less, 80 wt. % or less, 70 wt. % or less, 60 wt. % or less, 50 wt. % or less, or 40 wt. % or less, and preferably 35 wt. % or less, more preferably 30 wt. % or less, and even more preferably 25 wt. % or less. A lower limit of the water content of the charged liquid into the dehydration column A is, for example, 10 wt. % or 15 wt. %. Note that, when the hydrogen addition reaction in the hydrogenation is taken into consideration, the greater the water concentration and the smaller the viscosity, the greater the solubility and dispersity of hydrogen in the liquid, which is advantageous for the hydrogen addition reaction. The water content of the charged liquid into the dehydration column A can be reduced, for example, by providing a dealcoholization column (low boiling point component removal column) upstream of the dehydration column A, and adjusting the distillation conditions of the dealcoholization column (low boiling point component removal column). For example, increasing the reflux ratio and the number of plates, and the distillation ratio of the dealcoholization column (low boiling point component removal column) can reduce the water content of the charged liquid into the dehydration column A. Note that the water content of the charged liquid into the dehydration column A can be quantified by the Karl Fischer water content measurement instrument.
In the production method of the present disclosure, the content of the low boiling point component (excluding water) in the charged liquid into the dehydration column A is, for example, 20% or less, preferably 10% or less, more preferably 8% or less, even more preferably 5% or less, and particularly preferably 3% or less or 2% or less, and may be 1% or less, 0.5% or less, or 0.1% or less. The content of the low boiling point component (also referred to as “low boiling point substance” or “low boiling substance”) excluding water in the charged liquid into the dehydration column A is a total area proportion (area %) of peaks of shorter in retention time than the peak of 1,3-butylene glycol relative to the total peak area in the gas chromatographic analysis under the above conditions. The content of the low boiling point component (excluding water) in the charged liquid into the dehydration column A can be reduced, for example, by providing a dealcoholization column (low boiling point component removal column) upstream of the dehydration column A, and adjusting the distillation conditions of the dealcoholization column (low boiling point component removal column). For example, increasing the reflux ratio and the number of plates, and the distillation ratio of the dealcoholization column (low boiling point component removal column) can reduce the content of the low boiling point component (excluding water) in the charged liquid into the dehydration column A. Furthermore, the concentration of the low boiling point component (excluding water) in the charged liquid into the dehydration column A can be reduced, for example, by reaction conditions (e.g., reaction temperature) in the hydrogenation.
The content of the high boiling point component in the charged liquid into the dehydration column A is, for example, 20% or less, preferably 10% or less, more preferably 7% or less, 4% or less, 3% or less, or 2% or greater, even more preferably 1% or less, 0.5% or less, 0.4% or less, 0.3% or less, 0.2% or less, 0.1% or less, or 0.05% or less, and particularly preferably 0.01% or less. The content of the high boiling point component in the charged liquid into the dehydration column A can be adjusted, for example, by reaction conditions (e.g., reaction temperature) in the hydrogenation. The content of the high boiling point component in the charged liquid into the dehydration column A is a total area proportion (area %) of peaks longer in retention time than the peak of 1,3 BG to the total peak area in the gas chromatographic analysis under the above conditions. (area %).
In the production method of the present disclosure, the reflux ratio [dehydration column reflux amount/dehydration column distilled amount (discharge amount to outside of distillation column)] in the dehydration column A is, for example, greater than 0.3, preferably 0.4 or greater, 0.5 or greater, 0.6 or greater, or 0.7 or greater, 0.8 or greater, 0.9 or greater, 1 or greater, 1.1 or greater, 1.2 or greater, 1.3 or greater, 1.4 or greater, 1.5 or greater, 1.6 or greater, 1.7 or greater, 1.8 or greater, 1.9 or greater, 2 or greater, 3 or greater, 4 or greater, 5 or greater, 6 or greater, 7 or greater, 8 or greater, 9 or greater, 10 or greater, 15 or greater, 20 or greater or 25 or greater, and more preferably 30 or greater (for example, 40 or greater) from the perspective of reducing the content of the low boiling point substance (including water) in the crude 1,3-butylene glycol stream containing 1,3-butylene glycol taken out from below the charging plate of the dehydration column A (preferably, the bottom of the column). In particular, in the production method 2 of the present disclosure, the reflux ratio in the dehydration column A is preferably 10 or greater, more preferably 20 or greater, even more preferably 30 or greater, and particularly preferably 50 or greater. An upper limit of the reflux ratio is, for example, 100, preferably 50 from the point of energy cost. In a case where the theoretical number of plates of the dehydration column A is sufficiently large, sufficient separation can be performed, for example, if the reflux ratio is 0.03 or greater. Note that, in the reflux to the dehydration column A, a condensate of dehydration column top vapor is ordinarily refluxed to the dehydration column. But some or all of the refluxes may be replaced with the charge of the water-containing liquid (e.g., pure water) into the dehydration column. In this case, the “dehydration column reflux amount” refers to a sum of the amount of reflux of the condensate of the dehydration column top vapor to the dehydration column, and the amount of the water-containing liquid (e.g., pure water) charged into the dehydration column.
In the production method of the present disclosure, the distillation ratio in the dehydration column A can be appropriately set in accordance with the concentration of water in the charged liquid into the dehydration column A. Desirably, the distillation ratio is a sufficient distillation ratio for the total amount of water in the charged liquid to be distilled. For example, in a case where the concentration of water in the charged liquid into the dehydration column A is X wt. %, the distillation ratio in the dehydration column A is preferably X wt. % or greater. Therefore, the distillation ratio in the dehydration column A is, for example, 95 wt. % or less, 90 wt. % or less, 85 wt. % or less, 80 wt. % or less, 75 wt. % or less, 70 wt. % or less, 65 wt. % or less, 60 wt. % or less, 55 wt. % or less, 50 wt. % or less, 45 wt. % or less, 40 wt. % or less, 35 wt. % or less, 30 wt. % or less, 25 wt. % or less, 20 wt. % or less, 15 wt. % or less, 10 wt. % or less, or 5 wt. % or less. The distillation ratio refers to a proportion (wt. %) of an amount of liquid extracted from above the charging plate of the dehydration column A (e.g., the top of the column) to the outside of the distillation column with respect to a charged amount into the dehydration column A.
In the production method of the present disclosure, the 1,3 BG recovery ratio in the dehydration column A is, for example, 99.3% or greater. Note that, in the present specification, the 1,3 BG recovery ratio in the dehydration column A is a value (%) determined by the following formula.
{1−[concentration (wt. %) of 1,3 BG in distillate×(distilled amount (part)−recycled amount (part))]/(concentration (wt. %) of 1,3 BG in charged liquid×charged amount (part))}×100
Note that the low boiling point substance and the high boiling point substance may be hydrolyzed by water to produce 1,3 BG, while the high boiling point substance may be formed by polymerization of 1,3 BG. Further, trace impurities may be formed or disappear. Thus, the mass balance in the dehydration column may not always be retained. This applies to the dealcoholization column (low boiling point component removal column), the high boiling point component removal column, the product column, and other distillation columns.
Next, the crude 1,3-butylene glycol stream containing 1,3-butylene glycol taken out from below the charging plate of the dehydration column A (preferably, the bottom of the column) is fed to the desalting column B. In the desalting column B, the crude 1,3-butylene glycol stream after the desalting is produced from the top of the column, and a salt, a high boiling point substance, or the like is discharged from the bottom of the column. The bottom ratio (%) of the desalting column B [(desalting column bottom amount (part)/desalting column charge amount (part) x 100] is, for example, from 0.1 to 40 wt. %, preferably from 1 to 35 wt. %, more preferably from 2 to 30 wt. %, even more preferably from 3 to 25 wt. %, and particularly preferably from 5 to 20 wt. %, and may be from 7 to 15 wt. %. At least a portion of the bottom in the desalting column may be recycled to the step prior to the desalting.
The crude 1,3-butylene glycol stream after the desalting described above is fed to the high boiling point component removal column C. In the high boiling point component removal column C, the high boiling point component (high boiling point substance) is discharged from below the charging plate (preferably, from the bottom of the column). On the other hand, the crude 1,3-butylene glycol stream after high boiling point substance removal (1,3-butylene glycol with improved purity) is produced from above the charging plate.
The high boiling point component removal column C can be, for example, a perforated-plate column, a bubble column, or the like, but is more preferably a packed column with a low pressure loss, filled with Sulzer Packing, Melapack (trade names of Sumitomo Heavy Industries, Ltd.). This is because 1,3-butylene glycol and trace impurities would be thermally decomposed at a high temperature (e.g., 150° C. or greater) and form a low boiling point substance, which is a coloring component, and thus the distillation temperature is to be lowered. In addition, this is also because a long thermal history (residence time) for 1,3-butylene glycol would also have a similar effect. Thus, the reboiler employed is preferably one with a short residence time of the process side fluid, for example, a thin-film evaporator, such as a natural downward flow thin-film evaporator or a forced-stirring thin-film evaporator.
A theoretical number of plates of the high boiling point component removal column C is, for example, from 1 to 100 plates, preferably from 2 to 90 plates, more preferably from 3 to 80 plates, more preferably from 4 to 70 plates, from 5 to 60 plates, from 8 to 50 plates, or from 10 to 40 plates, and particularly preferably from 15 to 30 plates. A feed position for the charged liquid is, for example, from 10 to 90%, preferably from 20 to 80%, and more preferably from 30 to 70 plates, and even more preferably from 40 to 60% of a height of the column downward from the top of the high boiling point component removal column. In the distillation in the high boiling point component removal column C, a pressure (absolute pressure) at the top of the column is, for example, from 0.01 to 50 kPa, preferably from 0.1 to 30 kPa, more preferably from 0.3 to 20 kPa, and even more preferably from 0.5 to 10 kPa.
In the production method 1 of the present disclosure, a concentration of 1,3 BG in the charged liquid into the high boiling point component removal column C is, for example, 95% or greater, preferably 96% or greater (for example, 96.7% or greater), more preferably 97% or greater, even more preferably 98% or greater, and particularly preferably 99% or greater. In the production method 2 of the present disclosure, the concentration of 1,3 BG in the charged liquid into the high boiling point component removal column C is 96.7% or greater, preferably 97% or greater, more preferably 98% or greater, and even more preferably 99% or greater. The concentration of 1,3 BG into the charged liquid into the high boiling point component removal column C can be improved by adjusting the distillation conditions of the dehydration column A and the desalting column B. For example, increasing the reflux ratio of the dehydration column A or increasing the bottom ratio of the desalting column B can increase the concentration of 1,3 BG in the charged liquid into the high boiling point component removal column C. Note that the concentration of the 1,3 BG described above is an area proportion (area %) of a 1, 3 BG peak relative to a total peak area in a gas chromatographic analysis (GC analysis) under the following conditions.
The conditions for the gas chromatographic analysis are as follows:
A content of the high boiling point component in the charged liquid into the high boiling point component removal column C is, for example, 4% or less, preferably 3% or less, more preferably 2% or less, even more preferably 1% or less, 0.5% or less, 0.4% or less, 0.3% or less, 0.2% or less, 0.1% or less, or 0.05% or less, and particularly preferably 0.01% or less. In particular, in the production method 2 of the present disclosure, a content of the high boiling point component in the charged liquid into the high boiling point component removal column C is preferably 3% or less, more preferably 2% or less, even more preferably 1.5% or less, 1% or less, 0.5% or less, 0.4% or less, 0.3% or less, 0.2% or less, 0.1% or less, or 0.05% or less, and particularly preferably 0.01% or less. The content of the high boiling point component in the charged liquid into the high boiling point component removal column C can be reduced by adjusting the distillation conditions of the desalting column B. For example, increasing the bottom ratio of the desalting column B can reduce the content of the high boiling point component in the charged liquid into the high boiling point component removal column C. Note that the content of the high boiling point component in the charged liquid into the high boiling point component removal column C is a total area proportion (area %) of peaks longer in retention time than the 1,3 BG peaks relative to the total peak area in the gas chromatographic analysis under the above conditions.
In the production method of the present disclosure, the content of acetaldehyde in charged liquid into the high boiling point component removal column C is, for example, 500 ppm or less, preferably 205 ppm or less (e.g., 200 ppm or less), more preferably 100 ppm or less, even more preferably 90 ppm or less, 80 ppm or less, 70 ppm or less, 60 ppm or less, 50 ppm or less, 40 ppm or less, 30 ppm or less, 20 ppm, or less or 10 ppm or less, and particularly preferably 5 ppm or less, and may be less than 2 ppm, or less than 1 ppm. The content of crotonaldehyde in the charged liquid into the high boiling point component removal column C is, for example, 200 ppm or less, preferably 110 ppm or less, more preferably 100 ppm or less, even more preferably 80 ppm or less, 70 ppm or less, 60 ppm or less, 50 ppm or less, 40 ppm or less, 30 ppm or less, 20 ppm or less, 10 ppm or less, 5 ppm or less, or 3 ppm or less, and particularly preferably 2 ppm or less, and may be less than 1 ppm. The acetaldehyde content and the crotonaldehyde content in the charged liquid into the high boiling point component removal column C can be reduced, for example, by providing a dealcoholization column (low boiling point component removal column) and a dehydration column upstream of the high boiling point component removal column C, and adjusting the distillation conditions of the dealcoholization column (low boiling point component removal column) and the dehydration column. For example, increasing the reflux ratio and the number of plates, and the distillation ratio of the dealcoholization column (low boiling point component removal column) and the dehydration column can reduce the acetaldehyde content and the crotonaldehyde content of the charged liquid into the high boiling point component removal column C. Note that the acetaldehyde content and the crotonaldehyde content of the charged liquid into the high boiling point component removal column C can be quantified by GC-MS analysis (gas mass spectrometry).
In the production method of the present disclosure, the content of water in charged liquid into the high boiling point component removal column C is, for example, 3 wt. % or less, preferably 2 wt. % or less, more preferably 1.2 wt. % or less, more preferably 1.1 wt. % or less, 1.0 wt. % or less, 0.95 wt. % or less, 0.9 wt. % or less, 0.8 wt. % or less, 0.7 wt. % or less, 0.6 wt. % or less, 0.5 wt. % or less, 0.4 wt. % or less, 0.3 wt. % or less, or 0.2 wt. % or less, and particularly preferably 0.1 wt. % or less. The content of water in the charged liquid into the high boiling point component removal column C can be reduced by adjusting the distillation conditions of the dehydration column A. For example, increasing the reflux ratio and the number of plates, and the distillation ratio of the dehydration column A can reduce the concentration of water in the charged liquid into the high boiling point component removal column C. Note that the water content of the charged liquid into the high boiling point component removal column CF can be quantified by the Karl Fischer water content measurement instrument. In the production method 2 of the present disclosure, the content of water in the charged liquid into the high boiling point component removal column C is 3 wt. % or less, preferably 2 wt. % or less, 1.2 wt. % or less, 0.4 wt. % or less, 0.3 wt. % or less, or 0.2 wt. % or less, and particularly preferably 0.1 wt. % or less, 0.05 wt. % or less, or 0.03 wt. % or less.
In the production method of the present disclosure, the content of the low boiling point component (excluding water) in the charged liquid into the high boiling point component removal column C is, for example, 1.8% or less, preferably 1.6% or less, more preferably 1.4% or less, more preferably 1.2% or less, 1.1% or less, 1% or less, 0.9% or less, 0.8% or less, 0.7% or less, 0.6% or less, 0.5% or less, 0.4% or less, 0.3% or less, or 0.2% or less, and particularly preferably 0.1% or less. The content of the low boiling point component (also referred to as “low boiling point substance” or “low boiling substance”) excluding water in the charged liquid into the high boiling point component removal column C is a total area proportion (area %) of peaks of shorter in retention time than the peak of 1,3-butylene glycol relative to the total peak area in the gas chromatographic analysis under the above conditions. The content of the low boiling point component (excluding water) in the charged liquid into the high boiling point component removal column C can be reduced, for example, by providing a dealcoholization column (low boiling point component removal column) upstream of the high boiling point component removal column C, and adjusting the distillation conditions of the dealcoholization column (low boiling point component removal column). For example, increasing the reflux ratio and the number of plates, and the distillation ratio of the dealcoholization column (low boiling point component removal column) can reduce the content of the low boiling point component (excluding water) in the charged liquid into the high boiling point component removal column C.
In the production method of the present disclosure, the reflux ratio [(high boiling point component removal column reflux amount)/(high boiling point component removal column distilled amount (discharge amount to outside of distillation column))] in the high boiling point component removal column C is 0.03 or greater, preferably 0.05 or greater, more preferably 0.1 or greater, even more preferably 0.2 or greater, 0.3 or greater, 0.4 or greater, 0.5 or greater, 0.6 or greater, 0.7 or greater, 0.8 or greater, 0.9 or greater, 1 or greater, 1.2 or greater, 1.5 or greater, 2 or greater, 3 or greater, 4 or greater, 5 or greater, or 10 or greater, and particularly preferably 20 or greater, from the perspective of reducing the dry point of the 1,3-butylene glycol product. In particular, in the production method 2 of the present disclosure, the reflux ratio in the high boiling point component removal column C is preferably 0.1 or greater, more preferably 0.2 or greater, 0.3 or greater, 0.4 or greater, 0.5 or greater, 0.6 or greater, 0.7 or greater, 0.8 or greater, 0.9 or greater, 1 or greater, 1.2 or greater, 1.5 or greater, 2 or greater, 3 or greater, 4 or greater, 5 or greater, or 10 or greater, and particularly preferably 20 or greater. An upper limit of the reflux ratio is, for example, 100, preferably 50 from the point of energy cost. In a case where the theoretical number of plates of the high boiling point component removal column C is large, sufficient separation can be performed, even when the reflux ratio in the high boiling point component removal column C is about 1 or less.
In the production method of the present disclosure, the reflux ratio in the high boiling point component removal column C is within the range described above, and thus highly pure 1,3 BG having a very low content of the high boiling point component and a low dry point can be produced with a high recovery ratio.
In the production method of the present disclosure, the bottom ratio of the high boiling point component removal column C is, for example, less than 30 wt. %. Note that it is not limited to the value when the bottom of the high boiling point component removal column is distilled in a further distillation column and a high boiling point substance is removed therefrom, and 1,3 BG is yielded as the product. When an extracted amount of the material containing a high boiling point substance to the outside of the system is reduced to less than 30 wt. % with respect to the charged amount into the high boiling point component removal column C, it is possible to obtain 1,3 BG in a high yield. Note that the bottom ratio refers to a proportion (wt. %) of an amount of liquid extracted from below the charging plate (for example, bottom of the column) of the high boiling point component removal column C with respect to a charged amount into the high boiling point component removal column C (also including an amount of the liquid recycled, when the liquid is recycled to the previous steps which will be described later). Note that when the liquid is recycled to the previous steps described below, the recovery ratio of 1,3 BG is improved as the discharge ratio to the outside is less.
The bottom ratio of the high boiling point component removal column C can also be preferably 25 wt. % or less, more preferably 20 wt. % or less, even more preferably 15 wt. % or less, 10 wt. % or less, 7 wt. % or less, 5 wt. % or less, 4 wt. % or less, 3 wt. % or less, or 2 wt. % or less, and can be 1 wt. % or less, from the perspective of improving the recovery ratio of 1,3 BG. In addition, the bottom ratio of the high boiling point component removal column is, for example, 0.01 wt. % or greater, preferably 0.1 wt. % or greater, 0.5 wt. % or greater, or 1 wt. % or greater, more preferably 2 wt. % or greater, 3 wt. % or greater, 4 wt. % or greater, 5 wt. % or greater, 6 wt. % or greater, 7 wt. % or greater, 8 wt. % or greater, 9 wt. % or greater, 10 wt. % or greater, or 15 wt. % or greater, and particularly preferably 20 wt. % or greater, from the perspective of reducing the dry point of the 1,3-butylene glycol product.
At least a portion of the liquid (hereinafter, sometimes referred to as “bottom”) in which the high boiling point component is concentrated, the high boiling point component having been extracted from below the charging plate of the high boiling point component removal column C, may be recycled to step prior to the high boiling point component removal (dashed arrow illustrated in the lower part of the high boiling point component removal column C in
{1−[GC area % of 1,3 BG in bottom×(bottom amount (part)−amount (part) of bottom recycled]/(GC area % of 1,3 BG in charged liquid×charged amount (part)}×100
Note that the low boiling point substance and the high boiling point substance may be hydrolyzed by water to produce 1,3 BG, while the high boiling point substance may be formed by polymerization of 1,3 BG. Further, trace impurities may be formed or disappear. Thus, the mass balance in the high boiling point component removal column may not always be retained.
The recovery ratio of 1,3 BG in the high boiling point component removal column C is, for example, greater than 80%, preferably 85% or greater, more preferably 90% or greater, even more preferably 95% or greater, and particularly preferably 99% or greater.
Examples of the step prior to the high boiling point component removal include acetaldehyde polymerization (aldol condensation of acetaldehyde), reaction (hydrogenation), dealcoholization (low boiling point component removal), dehydration, and desalting. The bottom is preferably recycled to the acetaldehyde polymerization (aldol condensation of acetaldehyde), among these steps, since 1,3 BG is produced by hydrolysis of the high boiling point substance. In addition, the hydrogen addition reduction may produce 1,3 BG, and the bottom may be recycled to the hydrogen addition from that viewpoint.
The amount of the bottom recycled to the step prior to the high boiling point component removal can be appropriately selected within a range of the amount of the bottom. The amount of the bottom recycled to the step prior to the high boiling point component removal is, for example, less than 30 wt. %, preferably 25 wt. % or less with respect to the charged amount into the high boiling point component removal column C. Note that the amount of the bottom recycled may be 20 wt. % or less, 15 wt. % or less, 10 wt. % or less, 7 wt. % or less, 5 wt. % or less, 4 wt. % or less, 3 wt. % or less, 2 wt. % or less, or 1 wt. % or less with respect to the charged amount into the high boiling point component removal column C. In addition, from the perspective of improving the recovery ratio of 1,3 BG in the high boiling point component removal column and the yield throughout the 1,3 BG production process, the amount of the bottom recycled to the step prior to the high boiling point component removal is, for example, 0.01 wt. % or greater, preferably 0.1 wt. % or greater, more preferably 2 wt. % or greater, 3 wt. % or greater, 4 wt. % or greater, 5 wt. % or greater, 7 wt. % or greater, or 10 wt. % or greater, and particularly preferably 20 wt. % or greater relative to the amount of charge into the high boiling point component removal column C. Note that, in a case where the amount of the bottom is minimized as much as possible, 1,3 BG can be recovered in a high yield, even without recycle to the previous steps.
The crude 1,3-butylene glycol stream taken out from above the charging plate of the high boiling point component removal column C can be a 1,3-butylene glycol product as it is in the production method 2 of the present disclosure. Alternatively, the crude 1,3-butylene glycol stream taken out from above the charging plate of the high boiling point component removal column C is subjected to alkaline treatment in the alkaline reactor D described below, and evaporated (or distilled) with the dealkalization column E, and the distillate at the top of the dealkalization column E can be a 1,3-butylene glycol product.
According to the producing method 2 of the present disclosure, the contents of acetaldehyde, crotonaldehyde and water in the charged liquid into the high boiling point component removal column are within the specific ranges, and the reflux ratio of the high boiling point component removal column is within the specific range. Therefore, it is possible to industrially efficiently produce high-purity 1,3-butylene glycol that is colorless and odorless (or almost colorless and odorless), unlikely to cause or increase coloration and odor over time, and, in addition, unlikely to cause an acid concentration increase over time also in a state containing water.
In the production method 1 of the present disclosure, the crude 1,3-butylene glycol stream taken out from above the charging plate of the high boiling point component removal column C is fed, for example, to the alkaline reactor (e.g., a flow-through tubular reactor) D and is treated with a base (treated with alkali). The base treatment can decompose by-products contained in the crude 1,3-butylene glycol. The base is added in the alkaline reactor D or its upstream piping or the like. The base is added in an amount of, for example, from 0.05 to 10 wt. %, preferably from 0.1 to 1.0 wt. % relative to the crude 1,3-butylene glycol stream subjected to the alkaline treatment. With the added amount of the base exceeding 10 wt. %, the base would precipitate in the distillation column, piping, or the like, and this may cause blockage. In addition, the decomposition reaction of a high boiling point compound would occur, and by-products may be formed on the contrary. With the added amount of the base of less than 0.05 wt. %, the effect of decomposing by-products is reduced.
The base added in the alkaline reactor D or its upstream piping is not particularly limited but is, for example, preferably an alkali metal compound. Examples of the alkali metal compound include sodium hydroxide, potassium hydroxide, sodium (bi)carbonate, and potassium (bi)carbonate. A basic ion exchange resin can also be used as the base. The base is preferably sodium hydroxide or potassium hydroxide from the perspective of reducing the by-products contained in the final 1,3-butylene glycol product. The base may be added as is in the solid form but is preferably added in an aqueous solution to facilitate operation and contact with a solution to be treated. One of the bases described above may be used alone, or two or more may be used simultaneously.
The reaction temperature in the alkaline reactor D is not particularly limited but is, for example, preferably from 90 to 140° C. and more preferably from 110 to 130° C. The reaction at a reaction temperature lower than 90° C. would require long reaction residence time and thus require a reactor with a large volume and make the process uneconomical. The reaction at a reaction temperature exceeding 140° C. would increase coloration in the final 1,3-butylene glycol product. The reaction residence time is, for example, preferably from 5 to 120 minutes and more preferably from 10 to 30 minutes. A reaction residence time shorter than 5 minutes may cause an insufficient reaction and deteriorate the quality of the final 1,3-butylene glycol product. A reaction residence time exceeding 120 minutes would require a large reactor and increase the cost of equipment, and thus would be disadvantageous from the economic point of view.
After exiting the alkaline reactor D, the reaction crude liquid stream is fed to the dealkalization column (e.g., thin film evaporator) E as necessary, and the base and the like are removed from the bottom of the column by evaporation. On the other hand, from the top of the dealkalization column E, a crude 1,3-butylene glycol stream after the removal of a base (which is used as the 1,3-butylene glycol product, in the production method 2 of the present disclosure) is produced. The evaporator used for the dealkalization column E is suitably a natural downward flow thin-film evaporator or a forced-stirring thin-film evaporator with a short residence time for the purpose of reducing the thermal history to the process fluid. A demister may be installed in a space above the charging position of the dealkalization column (e.g., thin film evaporator) E, and droplets of a base or the like may be removed. This makes it possible to prevent the base and the like from being mixed into the 1,3-butylene glycol product.
Evaporation is performed in the evaporator used for the dealkalization column E, for example, under a reduced pressure at the top of the column of 20 kPa or less (absolute pressure), preferably from 0.5 to 10 kPa (absolute pressure). The temperature of the evaporator is, for example, preferably from 90 to 120° C. The crude 1,3-butylene glycol stream containing a low boiling point substance distilled from the top of the column is fed to the product distillation column (product column) F. Note that, as described above, in the production method 2 of the present disclosure, the distillate (corresponding to E-1) from the top of the dealkalization column E can be a 1,3-butylene glycol product.
Note that the alkaline reactor D and the dealkalization column E may be installed between the desalting column B and the high boiling point component removal column C, between the dehydration column A and desalting column B (in this case, the desalting column may also serve as a dealkalization column), or before the dehydration column A. In addition, without the alkaline reactor D or the dealkalization column E being provided, the alkaline treatment can be performed by charging the base into a high boiling point component removal column charging line or into a dehydration column charging line, or adding the base to the reaction solution after the hydrogenation [and then charging the base into the dealcoholization column (low boiling point component removal column)].
In the production method 1 of the present disclosure, in the product column F for use in the product distillation, a charged liquid having a concentration of 1,3-butylene glycol of, for example, 97.6 area % or greater determined by GC analysis is distilled, a liquid with a concentrated low boiling point component is distilled from above the charging plate (corresponding to “X-6” in
The product column F can be, for example, a perforated-plate column, a bubble column, or the like, but is more preferably a packed column with a low pressure loss, filled with Sulzer Packing, Melapack (trade names of Sumitomo Heavy Industries, Ltd.). This is because 1,3-butylene glycol and trace impurities would be thermally decomposed at a high temperature (e.g., 150° C. or greater) and form a low boiling point substance, which is a coloring component, and thus the distillation temperature is to be lowered. In addition, this is also because a long thermal history (residence time) for 1,3-butylene glycol would also have a similar effect. Thus, the reboiler employed is preferably one with a short residence time of the process side fluid, for example, a thin-film evaporator, such as a natural downward flow thin-film evaporator or a forced-stirring thin-film evaporator.
A theoretical number of plates of the product column F is, for example, from 1 to 100 plates, preferably from 2 to 90 plates, from 3 to 80 plates, from 4 to 70 plates, from 5 to 60 plates, from 8 to 50 plates, or from 10 to 40 plates, and more preferably from 15 to 30 plates. A feed position for the charged liquid is, for example, from 10 to 90%, preferably from 20 to 80%, and more preferably from 30 to 70%, and even more preferably from 40 to 60% of a height of the column downward from the top of the column. In the distillation in the product distillation column F, a pressure (absolute pressure) at the top of the column is, for example, from 20 kPa or less, preferably from 0.1 to 10 kPa, more preferably from 0.3 to 8 kPa, and even more preferably from 0.5 to 5 kPa.
In
The concentration of 1,3-butylene glycol in the charged liquid (1,3-butylene glycol charged liquid) into the product column F is 97.6% or greater, preferably 97.8% or greater, more preferably 98% or greater, even more preferably 98.2% or greater (e.g., 98.4% or greater, 98.6% or greater, or 98.8% or greater), and particularly preferably 99% or greater (e.g., 99.1% or greater, 9.2% or greater, 99.3% or greater, 99.4% or greater, 99.5% or greater, 99.6% or greater, 99.7% or greater, 99.8% or greater, or 99.9% or greater).
The concentration of 1,3-butylene glycol in the charged liquid into the product column F can be improved, for example, by adjusting the distillation conditions of the dehydration column A; providing a dealcoholization column (low boiling point component removal column) before the dehydration column A, and adjusting the distillation conditions thereof; or adjusting the distillation conditions of the high boiling point component removal column C. For example, it is possible to increase the purity of 1,3-butylene glycol in charged liquid into the product column F by increasing the reflux ratio of the dealcoholization column (low boiling point component removal column), the dehydration column A, and/or the high boiling point component removal column C or increasing the number of plates.
Note that the concentration of 1,3-butylene glycol in the charged liquid into the product column F is an area proportion (area %) of the peak of 1,3-butylene glycol relative to the total peak area in the gas chromatographic analysis of the following conditions.
The conditions for the gas chromatographic analysis are as follows:
In the production method 1 of the present disclosure, the content of acetaldehyde in charged liquid into the product column F is 500 ppm or less, preferably 205 ppm or less (e.g., 200 ppm or less), more preferably 150 ppm or less, even more preferably 120 ppm or less, 100 ppm or less, 90 ppm or less, 80 ppm or less, 70 ppm or less, 60 ppm or less, 50 ppm or less, 40 ppm or less, 30 ppm or less, 20 ppm or less, or 10 ppm or less, and particularly preferably 5 ppm or less, and may be less than 2 ppm. The content of crotonaldehyde in the charged liquid into the product column F is 200 ppm or less, preferably 150 ppm or less, more preferably 130 ppm or less, even more preferably 110 ppm or less, 100 ppm or less, 80 ppm or less, 70 ppm or less, 60 ppm or less, 50 ppm or less, 40 ppm or less, 30 ppm or less, 20 ppm or less, 10 ppm or less, 5 ppm or less, or 3 ppm or less, and particularly preferably 2 ppm or less, and may be less than 1 ppm. The acetaldehyde content and the crotonaldehyde content in the charged liquid into the product column F can be reduced, for example, by providing a dealcoholization column (low boiling point component removal column) and a dehydration column upstream of the product column F, and adjusting the distillation conditions of the dealcoholization column (low boiling point component removal column) and the dehydration column. For example, increasing the reflux ratio and the number of plates, and the distillation ratio of the dealcoholization column (low boiling point component removal column) and the dehydration column can reduce the acetaldehyde content and the crotonaldehyde content of the charged liquid into the product column F. In addition, the acetaldehyde content and the crotonaldehyde content in the charged liquid into the product column F can be reduced by increasing the reaction temperature, increasing the residence time, or increasing the added amount of the base, in the alkaline reaction. Note that the acetaldehyde content and the crotonaldehyde content of the charged liquid into the product column F can be quantified by GC-MS analysis (gas mass spectrometry).
In the production method 1 of the present disclosure, a content of water in charged liquid into the product column F is 0.7 wt. % or less, preferably 0.6 wt. % or less, 0.5 wt. % or less, 0.4 wt. % or less, 0.3 wt. % or less, or 0.2 wt. % or less, and particularly preferably 0.1 wt. % or less. The content of water in the charged liquid into the product column F can be reduced by adjusting the distillation conditions of the dehydration column A. For example, increasing the reflux ratio and the number of plates, and the distillation ratio of the dehydration column A can reduce the concentration of water in the charged liquid into the product column F. Note that the water content of the charged liquid into the product column F can be quantified by the Karl Fischer water content measurement instrument.
The content of the low boiling point component (excluding water) in the charged liquid into the product column F is, for example, 1.8% or less, preferably 1.6% or less, more preferably 1.4% or less, more preferably 1.2% or less, 1.1% or less, 1% or less, 0.9% or less, 0.8% or less, 0.7% or less, 0.6% or less, 0.5% or less, 0.4% or less, 0.3% or less, or 0.2% or less, and particularly preferably 0.1% or less. The content of the low boiling point component (also referred to as “low boiling point substance”) excluding water in the charged liquid into the product column F is a total area proportion (area %) of peaks of shorter in retention time than the peak of 1,3-butylene glycol relative to the total peak area in the gas chromatographic analysis under the above conditions. The content of the low boiling point component (excluding water) in the charged liquid into the product column F can be reduced, for example, by providing a dealcoholization column (low boiling point component removal column) upstream of the product column F, and adjusting the distillation conditions of the dealcoholization column (low boiling point component removal column). For example, increasing the reflux ratio and the number of plates, and the distillation ratio of the dealcoholization column (low boiling point component removal column) can reduce the content of the low boiling point component (excluding water) in the charged liquid into the product column F.
The content of the high boiling point component (excluding water) in the charged liquid into the product column F is, for example, 1.8% or less, preferably 1.6% or less, more preferably 1.4% or less, more preferably 1.2% or less, 1.1% or less, 1% or less, 0.9% or less, 0.8% or less, 0.7% or less, 0.6% or less, 0.5% or less, 0.4% or less, 0.3% or less, or 0.2% or less, and particularly preferably 0.1% or less. The content of the high boiling point component (also referred to as “high boiling point substance” or “high boiling substance”) excluding water in the charged liquid into the product column F is a total area proportion (area %) of peaks of longer in retention time than the peak of 1,3-butylene glycol relative to the total peak area in the gas chromatographic analysis under the above conditions. The content of the high boiling point component (excluding water) in the charged liquid into the product column F can be reduced, for example, by adjusting the distillation conditions of the high boiling point component removal column. For example, increasing the reflux ratio, the number of plates, or the bottom ratio of the high boiling point component removal column can reduce the content of the high boiling point component (excluding water) in the charged liquid into the product column F.
In the production method 1 of the present disclosure, the reflux ratio [(product column reflux amount)/(product column distilled amount (discharge amount to outside of distillation column))] in the product column F is 0.3 or greater, preferably 0.4 or greater, more preferably 0.5 or greater, 1 or greater, 2 or greater, 3 or greater, 4 or greater, 5 or greater, 6 or greater, 7 or greater, 8 or greater, 9 or greater, 10 or greater, 20 or greater, or 50 or greater, and particularly preferably 400 or greater (for example, 500 or greater), from the perspective of increasing the initial boiling point of the 1,3-butylene glycol product. An upper limit of the reflux ratio of the product column F is, for example, 700 or 1000 from the perspective of energy cost.
In the production method 1 of the present disclosure, the distillation ratio of the product column F is, for example, less than 30 wt. %, 29 wt. % or less, more preferably 28 wt. % or less, even more preferably 27 wt. % or less, 26 wt. % or less, 25 wt. % or less, 24 wt. % or less, 23 wt. % or less, 22 wt. % or less, 21 wt. % or less, 20 wt. % or less, 19 wt. % or less, 18 wt. % or less, 17 wt. % or less, 16 wt. % or less, 15 wt. % or less, 12 wt. % or less, 10 wt. % or less, 8 wt. % or less, 5 wt. % or less, 3 wt. % or less, 2 wt. % or less, 1 wt. % or less, 0.8 wt. % or less, or 0.6 wt. % or less, and particularly preferably 0.4 wt. % or less, from the perspective of improving the recovery ratio of 1,3-butylene glycol. Note that the distillation ratio refers to a proportion (wt. %) of an amount of liquid extracted from above the charging plate of the product column F (for example, the top of the column) to the outside of the distillation column (when recycled to the previous step which will be described below, including also the amount of liquid recycled) with respect to a charged amount into the product column F.
At least a portion of the liquid (hereinafter, sometimes referred to as “distillate”) in which the low boiling component is concentrated, which is extracted from above the charging plate of the product column F, may be recycled to the step prior to the product distillation (dashed arrow illustrated on the right side of the product column F in
Examples of the step prior to the product distillation include dehydration and dealcoholization (low boiling point component removal). Note that the dealcoholization (low boiling point component removal) is preferably provided before the dehydration.
The amount of the distillate recycled to the step prior to the product distillation can be appropriately selected within the range of the amount of distillate. The amount of the distillate recycle to the step prior to the product distillation is less than 30 wt. %, for example, with respect to the charged amount into the product column F. Also, from the perspective of improving the 1,3 BG recovery ratio in the product column and the yield throughout the process, the amount of the distillate recycled to the step prior to the product distillation is, for example, 0.01 wt. % or greater, preferably 0.05 wt. % or greater, more preferably 0.1 wt. % or greater, 0.5 wt. % or greater, 1 wt. % or greater, 1.5 wt. % or greater, 2 wt. % or greater, 3 wt. % or greater, 4 wt. % or greater, 5 wt. % or greater, 7 wt. % or greater, or 10 wt. % or greater, and particularly preferably 20 wt. % or greater with respect to the charged amount into the product column F.
In the producing method 1 of the present disclosure, the contents of acetaldehyde, crotonaldehyde and water in the charged liquid into product column F are within the specific ranges, and the reflux ratio of the product column F is within the specific range. Therefore, it is possible to industrially efficiently produce high-purity 1,3-butylene glycol that is colorless and odorless (or almost colorless and odorless), unlikely to cause or increase coloration and odor over time, and, in addition, unlikely to cause an acid concentration increase over time also in a state containing water.
The recovery ratio of 1,3 BG in the product column F is, for example, greater than 80%, preferably 85% or greater, more preferably 90% or greater, even more preferably 95% or greater, and particularly preferably 99% or greater.
Note that, in the present specification, the recovery ratio of 1,3 BG in the product column F is a value (%) determined by the following formula.
{1−[GC area % of 1,3 BG in distillate×(distilled amount (part)−amount (part) of distillate recycled]/(GC area % of 1,3 BG in charged liquid×charged amount (part)}×100
Note that, as described above, the low boiling point substance and the high boiling point substance may be hydrolyzed by water to produce 1,3 BG, while the high boiling point substance may be formed by polymerization of 1,3 BG. Thus, the mass balance in the product column may not always be retained.
Each aspect disclosed in the present specification can be combined with any other feature disclosed herein. Note that each of the configurations, combinations thereof, and the like in each of the embodiments are an example, and various additions, omissions, and other changes may be made as appropriate without departing from the spirit of the present disclosure. The present disclosure is not limited by the embodiments and is limited only by the claims.
Hereinafter, the present disclosure will be specifically described with reference to examples. “Parts” used in the examples means “parts by weight” unless otherwise specified. Gas chromatographic analysis (GC analysis), initial boiling point measurement, and water content measurement were performed according to methods which will be described below.
The method of producing 1,3-butylene glycol will be described using
Relative to 100 parts of an acetaldol solution containing 30 wt. % of water (mixed solution of 69 parts of acetaldol and 29 parts of water, containing a total of 2 parts of low boiling and high boiling impurities, Na salt: less than 0.1 parts) as a raw material, 10 parts of hydrogen were charged in a reactor for liquid-phase hydrogen reduction, and 15 parts of Raney nickel were added as a catalyst. The reactor was kept at 120° C. and 10 MPa (gauge pressure), and liquid-phase hydrogen reduction was performed. After the catalyst was separated, the liquid after the reaction was neutralized with sodium hydroxide, and crude 1,3-butylene glycol (1) containing water was produced.
Note that the acetaldol solution containing 30 wt. % of water used as the raw material was produced by stirring acetaldehyde and water in the presence of 100 ppm by weight NaOH at 30° C. at a residence time of 10 hours and dimerizing the acetaldehyde [acetaldehyde polymerization (aldol condensation of acetaldehyde)].
The crude 1,3-butylene glycol (1) (corresponding to “X-1” in
The crude 1,3-butylene glycol (2) was then charged in the desalting column B. In the desalting column B, a salt, a high boiling point substance, and a portion of 1,3-butylene glycol were discharged as the evaporation residue from the bottom of the column (corresponding to “X-3” in
The crude 1,3-butylene glycol (3) was then charged in the high boiling point component removal column C. In the high boiling point component removal column C, distillation was performed under the conditions of a pressure at the top of the column of 5 kPa (absolute pressure) and a reflux ratio of 0.05, and a high boiling point substance and a portion of 1,3-butylene glycol were discharged from the bottom of the column (corresponding to “X-4” in
The crude 1,3-butylene glycol (4) was then charged in the alkaline reactor D. At this time, a 20 wt. % sodium hydroxide aqueous solution was added to give a concentration of sodium hydroxide of 0.1 wt. % relative to the charged liquid. The reaction temperature was maintained at 120° C. in the alkaline reactor D, and a reaction was performed at a residence time of 20 minutes.
A reaction crude liquid exiting the alkaline reactor D was then charged in the dealkalization column E. In the dealkalization column E, sodium hydroxide, a high boiling point substance, and a portion of 1,3-butylene glycol were discharged from the bottom of the column (corresponding to “X-5” in
The crude 1,3-butylene glycol (5) was then charged in the product column F. In the product column F, 10 parts of the low boiling point substance and a portion of 1,3-butylene glycol relative to 100 parts of the charged liquid amount were distilled off from the top of the column (corresponding to “X-6” in
The produced 1,3-butylene glycol product was measured for initial boiling point and water content, and subjected to GC analysis and GC-MS analysis. As a result, the 1,3-butylene glycol product had an initial boiling point of 203.3° C., a dry point of 209° C., a water concentration of 0.2 wt. %, an area ratio of 1,3-butylene glycol of 99.2%, a total area ratio of impurity peaks shorter in retention time than 1,3-butylene glycol of 0.08%, a total area ratio of impurity peaks longer in retention time than 1,3-butylene glycol of 0.7%, an acetaldehyde content of 1.5 ppm, and a crotonaldehyde content of 0.9 ppm. The potassium permanganate test value was 35 minutes. The 1,3-butylene glycol recovery ratio in the product column F was 90%.
The same operation as in Comparative Example 5 was performed except that the reflux ratio of the dehydration column A was changed to 50. A 1,3-butylene glycol product was produced from the bottom of the product column F. Note that, due to the changes in conditions employed in the dehydration column A, the dehydration column bottom composition changed, and the charged liquid compositions in the high boiling point component removal column C and the product column F changed. As a result, the product qualities changed.
The produced 1,3-butylene glycol product was measured for initial boiling point and water content, and subjected to GC analysis and GC-MS analysis. As a result, the 1,3-butylene glycol product had an initial boiling point of 206.7° C., a dry point of 208.9° C., a water concentration of 0.1 wt. %, an area ratio of 1,3-butylene glycol of 99.3%, a total area ratio of impurity peaks shorter in retention time than 1,3-butylene glycol of 0.05%, a total area ratio of impurity peaks longer in retention time than 1,3-butylene glycol of 0.7%, an acetaldehyde content of 0.7 ppm, and a crotonaldehyde content of 0.7 ppm. The potassium permanganate test value was 45 minutes. The 1,3-butylene glycol recovery ratio in the product column F was 90%.
Under the conditions shown in Table 1 and Table 2, the dehydration column A, the high boiling point component removal column C, and the product column F were operated. In Examples 3 to 21 and 23 to 26, the entire amount of the distillate from the product column F was recycled into hydrogen reduction reactor. In Example 22, the product column F was not used, and a distillate at the top of the dealkalization column E (demister was installed in a space above the charging position) was a 1,3-butylene glycol product. At this time, the concentration of the sodium hydroxide aqueous solution in the alkaline reactor D was set to 1.5 times, and the added amount of the sodium hydroxide aqueous solution was set to the half of the amount in Example 1. Thus, the increase in water content due to alkaline treatment was avoided as much as possible. Note that, when the alkali concentration of the sodium hydroxide aqueous solution is too high and crystals precipitate. Therefore, heating is preferably performed to 40° C. or greater. In Table 2, the column “Bottom from product column F” of Example 22 shows the composition and physical properties of the distillate at the top of the dealkalization column E. Note that, in Example 15, 8 parts of 10 parts of the bottom from the high boiling point component removal column was recycled into the hydrogenation, and 2 parts thereof was discharged to the outside of the system. In addition, in Example 24, the pressure of the hydrogen addition reaction was reduced to 7 MPaG (gauge pressure). Therefore, the acetaldehyde content and crotonaldehyde content of the charged liquid into the dehydration column are high. In Example 25, the reflux ratio of the dehydration column was reduced to 0.3, and the purity of 1,3-butylene glycol in the charged liquid into the product column was reduced, and the reflux ratio of the product column was increased to 20. In Example 26, the pressure of the hydrogen addition reaction was increased to 40 MPaG (gauge pressure) (the remaining conditions were the same as in Example 17).
Eighty (80) parts of a 1,3-butylene glycol product was obtained from the bottom of the product column F by the same method as in Comparative Example 5 except that the reflux ratio of the dehydration column A was changed to 0.5, that the distilled amount was changed to 42 parts, that the reflux ratio of the high boiling point component removal column C was changed to 0.02, that the reflux ratio of the product column F was changed to 0.05, and that the distilled amount was changed to 20 parts. The produced 1,3-butylene glycol product had an initial boiling point of 193.2° C., a dry point of 210.3° C., a water concentration of 0.6 wt. %, an area ratio of 1,3-butylene glycol of 98.3%, a total area ratio of impurity peaks shorter in retention time than 1,3-butylene glycol of 0.2%, a total area ratio of impurity peaks longer in retention time than 1,3-butylene glycol of 1.5%, an acetaldehyde content of 5 ppm, and a crotonaldehyde content of 4 ppm. The potassium permanganate test value was 0 minutes. The 1,3-butylene glycol recovery ratio in the product column F was 80%.
Eighty (80) parts of a 1,3-butylene glycol product was obtained from the bottom of the product column F by the same method as in Comparative Example 5 except that the charged composition in the dehydration column A was changed, the reflux ratio and the distilled amount were changed to 0.5 and 32 parts, respectively, that the reflux ratio of the high boiling point component removal column C was changed to 0.02, that the reflux ratio of the product column F was changed to 0.05, and that the distilled amount was changed to 20 parts. The produced 1,3-butylene glycol product had an initial boiling point of 199.0° C., a dry point of 210.1° C., a water concentration of 0.4 wt. %, an area ratio of 1,3-butylene glycol of 98.5%, a total area ratio of impurity peaks shorter in retention time than 1,3-butylene glycol of 0.1%, a total area ratio of impurity peaks longer in retention time than 1,3-butylene glycol of 1.4%, an acetaldehyde content of 4 ppm, and a crotonaldehyde content of 2 ppm. The potassium permanganate test value was 5 minutes. The 1,3-butylene glycol recovery ratio in the product column F was 80%.
Seventy (70) parts of a 1,3-butylene glycol product was obtained from the bottom of the product column F by the same method as in Comparative Example 5 except that the charged composition in the dehydration column A was changed, the reflux ratio and the distilled amount were changed to 0.5 and 32 parts, respectively, that the reflux ratio of the high boiling point component removal column C was changed to 0.02, that the reflux ratio of the product column F was changed to 0.05, and that the distilled amount was changed to 30 parts. The produced 1,3-butylene glycol product had an initial boiling point of 203.0° C., a dry point of 210.2° C., a water concentration of 0.2 wt. %, an area ratio of 1,3-butylene glycol of 98.4%, a total area ratio of impurity peaks shorter in retention time than 1,3-butylene glycol of 0.1%, a total area ratio of impurity peaks longer in retention time than 1,3-butylene glycol of 1.5%, an acetaldehyde content of 2 ppm, and a crotonaldehyde content of 1.3 ppm. The potassium permanganate test value was 30 minutes. The 1,3-butylene glycol recovery ratio in the product column F was 70%.
Eighty (80) parts of a 1,3-butylene glycol product was obtained from the bottom of the product column F by the same method as in Comparative Example 5 except that the charged composition in the dehydration column A was changed, the distilled amount was changed to 23 parts, that the reflux ratio of the high boiling point component removal column C was changed to 0.02, that the reflux ratio of the product column F was changed to 0.1, and that the distilled amount was changed to 20 parts. The produced 1,3-butylene glycol product had an initial boiling point of 203.1° C., a dry point of 209.5° C., a water concentration of 0.2 wt. %, an area ratio of 1,3-butylene glycol of 98.8%, a total area ratio of impurity peaks shorter in retention time than 1,3-butylene glycol of 0.1%, a total area ratio of impurity peaks longer in retention time than 1,3-butylene glycol of 1.1%, an acetaldehyde content of 2 ppm, and a crotonaldehyde content of 1.3 ppm. The potassium permanganate test value was 30 minutes. The 1,3-butylene glycol recovery ratio in the product column F was 80%.
A gas chromatographic analysis of the target 1,3-butylene glycol product was performed under the conditions below. A chromatogram of the gas chromatographic analysis of the 1,3-butylene glycol product in Comparative Example 5 is shown in
The conditions for the gas chromatographic analysis are as follows:
Measurement was made according to the test method specified in the normal pressure distillation test method of JIS K2254 “Petroleum products - distillation test method”.
Measurement was made using a Karl Fischer water content measurement instrument.
Analytical Instrument: Agilent 6890A-GC/5973A-MSD
Analytical Column: a column with dimethylpolysiloxane as a stationary phase, having a length of 30 m, an inner diameter of 0.25 mm, and a film thickness of 1.0 μm
Heating conditions: heating from 80° C. to 120° C. at 5° C./min, then heating again to 160° C. at 2° C./min and maintaining for 2 minutes, and further heating to 230° C. at 10° C./min and maintaining at 230° C. for 18 minutes
Sample Introduction Temperature: 250° C.
Carrier Gas: helium
Column Gas Flow Rate: 1 mL/min
Ion source temperature: EI 230° C., CI 250° C.
Q Pole temperature: 150° C.
Sample: subjected to analysis as it was
In the present specification, the potassium permanganate test value (PMT) is a value measured in accordance with the visual colorimetric procedure of JIS K1351 (1993).
The target 1,3-butylene glycol product was placed in a wide-mouth bottle, the bottle was stoppered tightly and kept in a constant temperature oven set at 180° C. for 3 hours. A Hazen color number (APHA) of the 1,3-butylene glycol product after the 1,3-butylene glycol product had been kept at 180° C. for 3 hours was measured using a color difference meter (“ZE6000” available from Nippon Denshoku Industries Co., Ltd.) and a quartz cell with an optical path length of 10 mm. The Hazen color number (APHA) of the 1,3-butylene glycol product prior to the test was similarly measured.
Furthermore, each impurity content of the 1,3-butylene glycol product before and after the coloration-over-time test 1 was measured by GC-MS analysis. Also, the initial boiling point, dry point, potassium permanganate test value, odor and acid content of the 1,3-butylene glycol product before and after the coloration-over-time test 1 were measured.
The target 1,3-butylene glycol product was placed in a wide-mouth bottle, and the bottle was stoppered tightly and kept in a constant temperature oven set at 100° C. for 75 days. A Hazen color number (APHA) of the 1,3-butylene glycol product after the 1,3-butylene glycol product had been kept at 100° C. for 75 days was measured using a color difference meter (“ZE6000” available from Nippon Denshoku Industries Co., Ltd.) and a quartz cell with an optical path length of 10 mm.
The target 1,3-butylene glycol product adjusted to a 90 wt. % aqueous solution and then kept at 100° C. for 1 week was used as a sample for an acid concentration analysis performed according to the technique below. In addition, the 1,3-butylene glycol product prior to the test was also subjected to acid concentration analysis by the following technique.
The sample was measured using an automatic potentiometric titrator (AT-510 available from Kyoto Electronics Manufacturing Co., Ltd.). First, 50 g of the sample was diluted with 50 g of distilled water and titrated with 0.01 N aqueous sodium hydroxide solution from a burette with stirring until the titration was automatically stopped at the endpoint. Then, the acid concentration (acid content) in terms of acetic acid was calculated based on the following equation.
Acid concentration (wt. %)=titration volume (mL) xFxAx (100/sample amount (g))
F: 1.0 (factor of the 0.01 N aqueous sodium hydroxide solution)
A: 0.0006 (grams of acetic acid corresponding to 1 mL of the aqueous sodium hydroxide solution)
The target 1,3-butylene glycol product (100 mL) was placed in a wide-mouth reagent bottle (internal volume: 100 mL), and the bottle was stoppered tightly and allowed to stand at room temperature for a while (about 120 minutes). Then, the stopper was opened, the content was transferred to a 300-mL wide-mouth beaker, and 100 mL of pure water was added into the beaker to make a total of 200 mL. The wide-mouth beaker was shaken manually to stir the content, and the odor was then immediately smelled and scored according to the following evaluation. The same odor test was performed also on the sample after the coloration-over-time test 1, and the sample after the water added heating test.
1: Odor is not sensed
2: Slightly odorous
3: Odor is clearly sensed
The target 1,3-butylene glycol product was measured for the fluorescence intensity change rate (fluorescent brightness change amount) correlated with odor described in WO 2019/035476. That is, the fluorescent brightness change amount was measured using an odor measurement device (odor sensor, the flavor fermentation manufactured by Komi Hakko Corp.), and the fluorescent brightness amount of the obtained Comparative Example 1 was evaluated as odor rank 4, and odor was evaluated as the following six ranks (0, 1, 2, 3, 4, or 5). The same odor test was performed also on the sample after the coloration-over-time test 1.
The coloration-over-time tests 1 and 2 and the water added heating test are accelerated tests assuming long-term storage of 1,3 BG products.
The results of the comparative examples and the examples are shown in Table 1, Table 2, and Table 3.
Since many impurities are produced in the 1,3 BG production process, the impurities shown in Table 3 are generally contained in the 1,3 BG product, though varying depending on the conditions for the aldol condensation, the conditions for the hydrogen addition reaction, and the subsequent purification conditions. For example, acetaldol, crotonaldehyde, various carbonyl compounds, and alcohols contained in the 1,3 BG product react with oxygen during long-term storage to produce peroxides. In particular, aldehydes produce peroxides relatively more easily than ketones, alcohols and hydrocarbons. Peroxides produced from impurities react with the product 1,3 BG and promote oxidation from the top (1,3 BG) of the tree (see the impurity formation pathway diagram). Note that acetaldol is mainly produced by dimerization of acetaldehyde. Therefore, reducing the amounts of a series of impurities in the reaction system or the purification system makes it possible to suppress the concentration of peroxides produced from impurities during long-term storage, and thus suppress the formation reaction of many impurities via the additional impurities formed from 1-hydroxy-3-butanone, acetaldol, and both compounds thereof by oxidation of 1,3 BG. For example, among the impurities shown in Table 3, the substances formed by reacting with oxygen during long-term storage in the presence of oxygen are 1-hydroxy-3-butanone, acetaldol, 2-butanol, the compound represented by Formula (8), the compound represented by Formula (9), the compound represented by Formula (10), and the like, and other impurities are formed in the presence of 1-hydroxy-3-butanone or acetaldol, 1,3 BG, and other impurities, as well as a small amount of water.
From the results of the Comparative Examples and the Examples, the smaller the sum of the contents of acetaldehyde, crotonaldehyde, methyl vinyl ketone, acetone, formaldehyde, butylaldehyde, acetaldol, 1-hydroxy-3-butanone, 2-butanol, the compound represented by Formula (1), the compound represented by Formula (2), the compound represented by Formula (3), the compound represented by Formula (4), the compound represented by Formula (5), the compound represented by Formula (6), the compound represented by Formula (7), the compound represented by Formula (8), the compound represented by Formula (9), and the compound represented by Formula (10) (sometimes referred to as “total content of the 19 impurities”) in the 1,3 BG product, the smaller the coloration level (APHA), acid content, and odor (odor evaluated by person and odor evaluated by odor sensor) of the 1,3 BG product, and the more excellent the initial boiling point, dry point, and PMT. Furthermore, the smaller the total content of the 19 impurities, the smaller the coloration level (APHA), acid content, and odor (odor evaluated by person and odor evaluated by odor sensor), and the more excellent all of the initial boiling point, dry point, and PMT, after the heating test under specific conditions assuming long-term storage.
More specifically, the 1,3 BG products obtained in Examples 6, 17 and 26, with the total content of the 19 impurities being less than 65 ppm, had an APHA of 2 or less, an acid content of 3 ppm or less, an odor evaluated by person and an odor evaluated by odor sensor of 1 or less both, a high initial boiling point, a low dry point, a long PMT, and high quality. Also, since these 1,3 BG products had an APHA of 13 or less, an acid content of 3 ppm or less, and an odor evaluated by person and an odor evaluated by odor sensor of 1 or less both, and are almost unchanged in initial boiling point, dry point, PMT, even after the heating test assuming long-term storage. In particular, the 1,3 BG products of these Examples were odorless immediately after manufacture, and did not cause odor even after the heating test. Also, these 1,3 BG products were unchanged in acid content and odor even after the heating test in the presence of water.
In contrast, the 1,3 BG products obtained in Comparative Examples 1, 2 and 5, with the total content of the 19 impurities being 65 ppm or greater, had an APHA of 4 or greater, an acid content of 6 ppm or greater, a low initial boiling point, a high dry point, a short PMT, and low quality. In addition, the 1,3 BG products of these Comparative Examples had an APHA of 25 or greater and an acid content of 8 ppm or greater, after the heating test assuming long-term storage. In addition, for the 1,3 BG product of Comparative Example 5, before the heating test, the odor evaluation by person was 1, but the odor evaluation by odor sensor was 2. This Comparative Example was different in odor from the Examples. In addition, for the 1,3 BG product of Comparative Example 5, after the heating test, the odor evaluation by person was 2, and the odor evaluation by odor sensor was 3. Both the odor evaluations worsened, and a more distinctive difference in odor between the Comparative Example and the Examples was observed. Also, the acid content and odor of the 1,3 BG products of these Comparative Examples further worsened after the heating test in the presence of water.
As a summary of the above, configurations and variations of the present disclosure are described below.
[1] A 1,3-butylene glycol product containing 1,3-butylene glycol, wherein a sum of contents of acetaldehyde, crotonaldehyde, methyl vinyl ketone, acetone, formaldehyde, butylaldehyde, acetaldol, 1-hydroxy-3-butanone, 2-butanol, a compound represented by Formula (1) below, a compound represented by Formula (2) below, a compound represented by Formula (3) below, a compound represented by Formula (4) below, a compound represented by Formula (5) below, a compound represented by Formula (6) below, a compound represented by Formula (7) below, a compound represented by Formula (8) below, a compound represented by Formula (9) below, and a compound represented by Formula (10) below is less than 65 ppm (or 50 ppm or less, 45 ppm or less, 40 ppm or less, 35 ppm or less, 30 ppm or less, 25 ppm or less, 20 ppm or less, 15 ppm or less, 13 ppm or less, 10 ppm or less, 8 ppm or less, 5 ppm or less, 4 ppm or less, 3 ppm or less, or 2 ppm or less).
[2] The 1,3-butylene glycol product according to [1], wherein a sum of the contents of the compounds represented by Formulas (1) to (7) above is less than 28 ppm (or 25 ppm or less, 20 ppm or less, 15 ppm or less, 12 ppm or less, 10 ppm or less, 8 ppm or less, 6 ppm or less, 4 ppm or less, 2 ppm or less, or 1.4 ppm or less).
[3] The 1,3-butylene glycol product according to [1] or [2], wherein a sum of the contents of the compounds represented by Formulas (8) to (10) above is less than 6 ppm (or 5 ppm or less, 4 ppm or less, 3 ppm or less, 2 ppm or less, 1 ppm or less, 0.8 ppm or less, or 0.6 ppm or less).
[4] The 1,3-butylene glycol product according to any one of [1] to [3], wherein a sum of the contents of the compounds represented by Formulas (1) to (10) above is less than 34 ppm (or 30 ppm or less, 25 ppm or less, 20 ppm or less, 18 ppm or less, 16 ppm or less, 14 ppm or less, 12 ppm or less, 10 ppm or less, 8 ppm or less, 7 ppm or less, 6 ppm or less, 5 ppm or less, 4 ppm or less, 3 ppm or less, or 2 ppm or less).
[5] The 1,3-butylene glycol product according to any one of [1] to [4], wherein
[6] The 1,3-butylene glycol product according to any one of [1] to [5], wherein a total content of acetaldehyde, crotonaldehyde, methyl vinyl ketone, acetone, formaldehyde, butylaldehyde, acetaldol, and 1-hydroxy-3-butanone is 31 ppm or less (or 30 ppm or less, 25 ppm or less, 20 ppm or less, 18 ppm or less, 16 ppm or less, 14 ppm or less, 13 ppm or less, 12 ppm or less, 11 pm or less, 10 ppm or less, 9 ppm or less, 8 ppm or less, 7 ppm or less, 6 ppm or less, 5 ppm or less, 4 ppm or less, 3 ppm or less, 2 ppm or less, or 1.5 ppm or less).
[7] The 1,3-butylene glycol product according to any one of [1] to [6], wherein a content of acetaldol and 1-hydroxy-3-butanone is less than 12 ppm (or 10 ppm or less, 9 ppm or less, 8 ppm or less, 7 ppm or less, 6 ppm or less, 5 ppm or less, 4 ppm or less, 3 ppm or less, 2 ppm or less, 1 ppm or less, 0.5 ppm or less, or 0.4 ppm or less).
[8] The 1,3-butylene glycol product according to any one of [1] to [7], wherein an acid concentration (in terms of acetic acid) is less than 6 ppm (or 5 ppm or less, 4 ppm or less, 3 ppm or less, 2 ppm or less, or 1 ppm or less).
[9] The 1,3-butylene glycol product according to any one of [1] to [8], wherein an acid concentration (in terms of acetic acid) is less than 9 ppm (or 8 ppm or less, 7 ppm or less, 6 ppm or less, 5 ppm or less, 4 ppm or less, 3 ppm or less, 2 ppm or less, or 1 ppm or less), after a 90 wt. % aqueous solution of the 1,3-butylene glycol product has been kept at 100° C. for 1 week.
[10] The 1,3-butylene glycol product according to any one of [1] to [9], wherein, for the acid concentration (in terms of acetic acid) of the 90 wt. % aqueous solution of the 1,3-butylene glycol product, a ratio of the acid concentration after the product has been kept at 100° C. for 1 week to the acid concentration before the product has been kept [(acid concentration after the product has been kept at 100° C. for 1 week)/(acid concentration before the product has been kept) x 100 (%)] is 150% or less (or 120% or less, or 110% or less).
[11] The 1,3-butylene glycol product according to any one of [1] to [10], wherein an APHA (Hazen color number) is 3 or less (or 2 or less, or 1 or less).
[12] The 1,3-butylene glycol product according to any one of [1] to [11], wherein an APHA is 11 or less (or 10 or less, 8 or less, 7 or less, 6 or less, 5 or less, 4 or less, 3 or less, or 2 or less), after the 1,3-butylene glycol product has been kept at 100° C. for 75 days in air atmosphere.
[13] The 1,3-butylene glycol product according to any one of [1] to [12], wherein, for the APHA of the 1,3-butylene glycol product, a ratio of the APHA after the product has been kept at 100° C. for 75 days to the APHA before the product has been kept [(APHA after the product has been kept at 100° C. for 75 days)/(APHA before the product has been kept)] is less than 3 (or 2.5 or less, 2 or less, 1.5 or less, or 1.2 or less).
[14] The 1,3-butylene glycol product according to any one of [1] to [13], wherein an initial boiling point is 204° C. or greater (or 204.5° C. or higher, 205° C. or higher, 206° C. or higher, 207° C. or higher, or 208° C. or higher).
[15] The 1,3-butylene glycol product according to any one of [1] to [14], which has a dry point of lower than 209° C. (or 208.8° C. or lower).
[16] The 1,3-butylene glycol product according to any one of [1] to [15], wherein a potassium permanganate test value (PMT) is 36 minutes or longer (or 38 minutes or longer, 40 minutes or longer, 50 minutes or longer, or 60 minutes or longer).
[17] The 1,3-butylene glycol product according to any one of [1] to [16], wherein a content of 1,3-butylene glycol (GC area ratio under the following GC analysis conditions) is 99.3% or greater (or 99.4% or greater, 99.5% or greater, 99.6% or greater, 99.7% or greater, or 99.8% or greater),
[18] The 1,3-butylene glycol product according to any one of [1] to [17], wherein, in the GC analysis, a total area ratio of peaks shorter in retention time than a peak of 1,3-butylene glycol is 0.09% or less (or 0.08% or less, 0.07% or less, 0.04% or less, 0.03% or less, 0.02% or less, 0.01% or less, 0.007% or less, 0.005% or less, or 0.003% or less).
[19] The 1,3-butylene glycol product according to any one of [1] to [18], wherein, in the GC analysis, a total area ratio of peaks longer in retention time than the peak of 1,3-butylene glycol is 0.7% or less (or 0.6% or less, 0.5% or less, 0.4% or less, 0.3% or less, 0.2% or less, or 0.1% or less).
[20] The 1,3-butylene glycol product according to any one of [1] to [19], wherein a content of water is 0.2 wt. % or less (or 0.15 wt. % or less, 0.1 wt. % or less, 0.07 wt. % or less, 0.05 wt. % or less, 0.03 wt. % or less, 0.02 wt. % or less, 0.01 wt. % or less, or 0.005 wt. % or less).
[21] The 1,3-butylene glycol product according to any one of [1] to [20], wherein a sum of the contents of acetaldehyde, crotonaldehyde, methyl vinyl ketone, acetone, formaldehyde, butylaldehyde, acetaldol, 1-hydroxy-3-butanone, 2-butanol and the compounds represented by Formulas (1) to (10) is less than 70 ppm (or 65 ppm or less, 60 ppm or less, 55 ppm or less, 50 ppm or less, 45 ppm or less, 40 ppm or less, 35 ppm or less, 30 ppm or less, 25 ppm or less, 20 ppm or less, 18 ppm or less, 15 ppm or less, 13 ppm or less, 10 ppm or less, 8 ppm or less, 5 ppm or less, 4 ppm or less, or 3.5 ppm or less), after the 1,3-butylene glycol product has been kept at 180° C. for 3 hours in air atmosphere.
[22] The 1,3-butylene glycol product according to any one of [1] to [21], wherein a sum of the contents of the compounds represented by Formulas (1) to (7) above is less than 40 ppm (or 35 ppm or less, 30 ppm or less, 25 ppm or less, 20 ppm or less, 15 ppm or less, 12 ppm or less, 10 ppm or less, 8 ppm or less, 6 ppm or less, 5 ppm or less, 4 ppm or less, 3 ppm or less, 2 ppm or less, or 1.4 ppm or less), after the 1,3-butylene glycol product has been kept at 180° C. for 3 hours in air atmosphere.
[23] The 1,3-butylene glycol product according to any one of [1] to [22], wherein a sum of the contents of the compounds represented by Formulas (8) to (10) above is less than 18 ppm (or 16 ppm or less, 14 ppm or less, 13 ppm or less, 12 ppm or less, 11 pm or less, 10 ppm or less, 9 ppm or less, 8 ppm or less, 7 ppm or less, 6 ppm or less, 5 ppm or less, 4 ppm or less, 3 ppm or less, 2 ppm or less, 1 ppm or less, or 0.6 ppm or less), after the 1,3-butylene glycol product has been kept at 180° C. for 3 hours in air atmosphere.
[24] The 1,3-butylene glycol product according to any one of [1] to [23], wherein a sum of the contents of the compounds represented by Formulas (1) to (10) above is less than 59 ppm (or 55 ppm or less, 50 ppm or less, 40 ppm or less, 30 ppm or less, 20 ppm or less, 18 ppm or less, 16 ppm or less, 14 ppm or less, 12 ppm or less, 10 ppm or less, 8 ppm or less, 7 ppm or less, 6 ppm or less, 5 ppm or less, 4 ppm or less, 3 ppm or less, or 2 ppm or less), after the 1,3-butylene glycol product has been kept at 180° C. for 3 hours in air atmosphere.
[25] The 1,3-butylene glycol product according to any one of [1] to [24], wherein
[26] The 1,3-butylene glycol product according to any one of [1] to [25], wherein a sum of the contents of acetaldehyde, crotonaldehyde, methyl vinyl ketone, acetone, formaldehyde, butylaldehyde, acetaldol, and 1-hydroxy-3-butanone is less than 12 ppm (or 10 ppm or less, 8 ppm or less, 7 ppm or less, 6 ppm or less, 5 ppm or less, 4 ppm or less, 3 ppm or less, 2 ppm or less, or 1.6 ppm or less), after the 1,3-butylene glycol product has been kept at 180° C. for 3 hours in air atmosphere.
[27] The 1,3-butylene glycol product according to any one of [1] to [26], wherein a sum of the contents of acetaldol and 1-hydroxy-3-butanone is less than 1 ppm (or 0.9 ppm or less, 0.8 ppm or less, 0.7 ppm or less, 0.6 ppm or less, 0.5 ppm or less, or 0.4 ppm or less), after the 1,3-butylene glycol product has been kept at 180° C. for 3 hours in air atmosphere.
[28] The 1,3-butylene glycol product according to any one of [1] to [27], wherein an APHA is less than 25 (or 20 or less, 18 or less, 15 or less, 14 or less, 13 or less, 12 or less, 11 or less, 10 or less, 9 or less, 8 or less, or 7 or less), after the 1,3-butylene glycol product has been kept at 180° C. for 3 hours in air atmosphere.
[29] The 1,3-butylene glycol product according to any one of [1] to [28], wherein an initial boiling point is 204° C. or higher (or 205° C. or higher, 206° C. or higher, or 207° C. or higher), after the 1,3-butylene glycol product has been kept at 180° C. for 3 hours in air atmosphere.
[30] The 1,3-butylene glycol product according to any one of [1] to [29], wherein a dry point is lower than 209° C., after the 1,3-butylene glycol product has been kept at 180° C. for 3 hours in air atmosphere.
[31] The 1,3-butylene glycol product according to any one of [1] to [30], wherein a potassium permanganate test value (PMT) is longer than 30 minutes (or 32 minutes or longer, 35 minutes or longer, 40 minutes or longer, 50 minutes or longer, or 60 minutes or longer), after the 1,3-butylene glycol product has been kept at 180° C. for 3 hours in air atmosphere.
[32] The 1,3-butylene glycol product according to any one of [1] to [31], wherein an acid concentration (in terms of acetic acid) is less than 8 ppm (or 7 ppm or less, 6 ppm or less, 5 ppm or less, 4 ppm or less, 3 ppm or less, 2 ppm or less, or 1 ppm or less), after the 1,3-butylene glycol product has been kept at 180° C. for 3 hours in air atmosphere.
[33] A moisturizer containing the 1,3-butylene glycol product described in any one of [1] to [32].
[34] The moisturizer according to [33], wherein a content of the 1,3-butylene glycol product described in any one of [1] to [32] is 10 wt. % or greater (or 30 wt. % or greater, 50 wt. % or greater, 80 wt. % or greater, or 90 wt. % or greater).
[35] A cosmetic product containing the moisturizer described in [33] or [34].
[36] The cosmetic product according to [35], wherein a content of the 1,3-butylene glycol product described in any one of [1] to [32] is from 0.01 to 40 wt. % (or from 0.1 to 30 wt. %, from 0.2 to 20 wt. %, from 0.5 to 15 wt. %, or from 1 to 10 wt. %).
[37] The cosmetic product according to [35] or [36], wherein the cosmetic product is a skin cosmetic product, a hair cosmetic, a sunscreen cosmetic product or a make-up cosmetic product.
[38] A method for producing 1,3-butylene glycol to yield a 1,3-butylene glycol product described in any one of [1] to [32] from a reaction crude liquid containing 1,3-butylene glycol,
The conditions for the gas chromatographic analysis are as follows:
[39] A method for producing 1,3-butylene glycol to obtain a 1,3-butylene glycol product described in any one of [1] to [32] from a reaction crude liquid containing 1,3-butylene glycol, the method including:
The conditions for the gas chromatographic analysis are as follows:
The 1,3-butylene glycol product according to the present disclosure has high purity and is colorless and odorless (or almost colorless and odorless), unlikely to cause or increase coloration and odor over time, and/or unlikely to cause an acid concentration increase over time even in a state containing water. This 1,3-butylene glycol product can be used as a raw material for a moisturizer and a cosmetic product that have excellent moisturizing performance and can retain high quality for a long period of time.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2019-239974 | Dec 2019 | JP | national |
| 2019-239975 | Dec 2019 | JP | national |
| 2019-239976 | Dec 2019 | JP | national |
| 2019-239977 | Dec 2019 | JP | national |
| 2019-239978 | Dec 2019 | JP | national |
| 2019-239979 | Dec 2019 | JP | national |
| 2020-006660 | Jan 2020 | JP | national |
| 2020-018910 | Feb 2020 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2020/048235 | 12/23/2020 | WO |
