Catalytic preparation of linear polyethylenepolyamines

Abstract

This invention is directed to thermally activated pelletted catalyst compositions comprising phosphorous compounds deposited on group IVb transition metal oxides and their use in the production of predominately linear polyethylenepolyamines from ethylenediamine and monoethanolamine.

Description

BACKGROUND OF THE INVENTION

1. Technical Field of the Invention

This invention relates to the preparation of predominatly linear polyethylenepolyamines from the starting reagents of ethylenediamine and monoethanolamine in the presence of unique thermally activated pelleted catalyst compositions having phosphorous deposited on a group IVb transition metal oxide.

2. Prior Art

Heretofore, polyethylenepolyamine compounds such as diethylenetriamine, triethylenetetramine and the higher homologs have been produced by the reaction of an alkyl halide such as ethylene dichloride with an amine such as ammonia or ethylenediamine at elevated temperatures and pressures. Normally, relatively high yields of predominatly non-cyclic polyethylenepolyamine compounds are obtained from this process with varying yields of heterocyclic amines. The large amounts of energy required to produce the reactants as well as the difficult separation procedures required to recover the more valuable linear polyethylenepolyamines diminish the usefulness of the ethylene dichloride process. The hydrohalide salts of ammonia and the polyethylenepolyamine products must also undergo difficult and time consuming caustic neutralization to yield the free polyethylenepolyamines.

It has heretofore been known that phosphates can be used to catalyze reactions to produce predominately heterocyclic rather than linear products. Thus, U.S. Pat. No. 3,297,701 teaches the use of aluminum phosphate to catalyse the reaction of ethanolamines and polyethylenepolyamines to yield cyclic compounds U.S. Pat. No. 3,342,820 discloses the use of aluminum phosphate for the preparation of heterocyclic compounds such as triethylenediamine. As another example, U.S. Pat. No. 4,103,087 also discloses the use of aluminum phosphate catalysts for producing heterocyclic product compounds.

More recently, investigators have found that more linear products can also be obtained in a catalyst conversion. Thus, Ford et. al. U.S. Pat. No. 4,316,840 discloses the preparation of polyalkylenepolyamines from ethylene diamine utilizing a metal nitrate or sulfate as a catalyst. U.S. Pat. No. 4,314,083 discloses the reaction of ethylene diamine with monoethanolamine to prepare noncyclic polyalkylenepolyamines using, as a catalyst, a salt of a nitrogen or sulfur-containing compound.

In inventions originating in our laboratories, Brennan et al. in U.S. Pat. No. 4,036,881 discloses the use of phosphorous-containing catalysts to catalyze the reaction of ethylenediamine with monoethanolamine. Excellent results were obtained when the reaction was conducted in an autoclave. However, when the phosphorous compound was supported on silica or diatomaceous earth, good results were obtained only at comparatively low conversions. Brennan et. al. U.S. Pat. No. 4,044,053 is also relevant in this regard. A recently filed Brennan copending application Ser. No. 283,713, filed July 16, 1981 and entitled "Preparation of Linear Polyethylenepolyamines With an Aluminum Phosphate Catalyst" (now abandoned) is directed to an aluminum phosphate catalyst. Excellent results were obtained using a catalyst of this nature in batch-type reactions. Brennan U.S. Pat. No. 4,103,087 discloses the use of pelleted aluminum phosphate to prepare di-(N,N-disubstituted amino)alkanes.

French Pat. No. 1,317,359 dated Feb. 8, 1963, discloses the preparation of granulated zirconium phosphate and its use as an ion-exchange resin. Winkler et al. in a 1966 publication [Deutsche Akad. Wiss., Berlin, Germany, Z. Anorg. Allgen. Chem. 346 (1-2), 92-112 (1966)]disclose compounds of the general formula Hx.sup.v P.sub.2 O.sub.3 wherein X represents arsenic, antimony and mixtures thereof. Also disclosed are compounds of the general formula H.sub.2 X.sup.iv P.sub.2 O.sub.3, wherein X represents silicon, germanium, tin, lead, titanium and zirconium. It is shown that the group IV phosphates have cation exchange properties.

Daniel Br. Apcn. 2,092,467 pub. Aug. 18, 1982, modifies iron phosphate catalysts disclosed in Cavaterra U.S. Pat. No. 3,948,959 for making methacrylic acid from isobutyric acid. Daniel uses such catalysts in admixture with a support prepared by calcining the dried powder recovered from a slurry of silica with phosphoric acid. Daniel teaches that the support is inert and that titania or zirconia can also be used.

SUMMARY OF THE INVENTION

A method of preparing novel catalyst compositions is disclosed. The catalyst is extremely useful in the improved production of predominatly linear polyethylenepolyamines from ethylenediamine and monoethanolamine. The novel phosphate catalysts of the claimed invention can be prepared by treating a group IVb metal oxide support with a phosphorous compound such that, in a thermally activated condition, the phosphorous is chemically bound to the support. These novel compositions can be used to catalyze the reaction of monoethanolamine with ethylenediamine to provide essentially linear polyethylenepolyamine reaction products.

DETAILED DESCRIPTION

In one aspect the invention is directed to improved catalyst compositions comprising a group IVb metal oxide to which phosphorous has been chemically bonded by thermal activation. In another aspect the catalysts are used in producing essentially linear polyethylenepolyamines such as diethylenetriamine, triethylenetetramine, tetraethylenepentamine and pentaethylenehexamine from the reaction of ethylenediamine and monoethanolamine. The inventor is unaware of the precise structural differences between the claimed catalysts and previous phosphate catalysts that have been tried in such reactions, but is cognizant of substantially higher rates of conversion to linear polyethylenepolyamines with the claimed catalysts.

The novel catalyst compositions catalyze the reaction of ethylenediamine with monoethanolamine at a temperature of from about 250.degree. C. to about 400.degree. C., preferably from about 300.degree. C. to about 350.degree. C. and a pressure of from about 500 to about 3000 psig. and preferably from about 1000 to about 2000 psig. Higher temperatures and pressures can be used, if desired, but there is no particular advantage in using such higher temperatures and/or pressures. The ratio of ethylenediamine to monoethanolamine may range from about 1:2 to about 5:1.

The pelleted catalyst compositions of the present invention are normally employed as a fixed bed of catalyst in a continuous reaction system. In a continuous process of this nature, the time of contact of the reactants with the catalyst is one of the interrelated factors that those skilled in the art will adjust, along with temperature, pressure, bed geometry, pellet size, etc. in order to obtain a desired rate of reaction and, hence, a desired percentage of conversion of the reactants. Thus, in a continuous process, it is not necessary to drive the reaction to completion because unreacted feedstock components can be recycled to the reactor.

It is customary to use cylindrically-shaped catalyst pellets having a diameter essentially equal to the length thereof, such as diameters and lengths ranging from about 1/32" to about 3/8". It will be understood that the shape and dimensions of the pellets are not critical to the present invention and that pellets of any suitable shape and dimensions may be used as desired, by one wishing to practice the process of the present invention.

When cylindrical pellets of catalyst of the type described above are used, the weighted hourly space velocity may be varied within wide limits (e.g., 0.1 to 5 w/hr/w) in order to obtain a desired rate of conversion, as explained above. Normally, space velocities of about 0.5 to 2 w/hr/w will be employed.

Catalyst life is an important factor in conducting a continuous reaction. For example, if a catalyst is easily poisoned, or if catalyst pellets do not have good structural properties, the economics of the process will be seriously and adversely affected.

The catalysts of the present invention are not particularly susceptible to poisoning so this normally does not present a problem. However, under the reaction conditions employed, amines of the type used and formed herein have the potential capability of leaching or otherwise adversely affecting the structural integrity of the pellets. In an extreme instance, catalyst pellets having good initial crush strength and surface hardness will be reduced to fines very rapidly when used under reaction conditions such as those employed herein.

It is a feature of the present invention that the pelleted catalyst compositions have improved resistance to physical degradation when used to catalyse the reaction of monoethanolamine with ethylenediamine.

The catalyst compositions of the present invention are prepared by depositing a phosphorus compound on a support comprising an oxide of a group IVb transition metal oxide. The group IVb transition metal oxides include the oxides of titanium, zirconium, hafnium and thorium. Pellets of the group IVb metal oxide may be prepared by extrusion or by compaction in conventional pelleting apparatus using a pelleting aid such as graphite. It is also within the scope of the present invention to deposit the phosphorus compound on a powdered IVb metal oxide followed by pelleting and calcination.

Any appropriate liquid or liquifiable phosphorus compound can be used as a source of the phosphorus. For convenience, phosphoric acid will normally be used. However, other phosphorus compounds such as phosphoryl chloride (POCl.sub.3), phosphorous acid, polyphosphoric acid, phosphorus halides, such as phosphorus bromide, alkyl phosphates and alkyl phosphites such as trimethyl phosphate, triethyl phosphate, trimethyl phosphite, triethyl phosphite, etc. may be utilized.

Preferably the catalyst composition is prepared by impregnating a preformed pellet. A suitable procedure to be used is to heat a liquid containing the liquid or liquifiable phosphorus compound at a temperature of about 100.degree. to about 150.degree. C. and to then add pellets in an amount about equal to the volume of the heated liquid. This treatment should be continued from about 0.5 to about 5 hours. At the end of that time, the resulting mixture of pellets and liquid is cooled, decanted to remove excess liquid followed by washing with an amount of water adequate to substantially completely remove un-adsorbed liquid. Temperatures above 150.degree. C. can be used, if desired, but there is no particular advantage in doing so.

It will be understood that the phosphorous that is present on a thus-treated pellet is not present as elemental phosphorous, but rather as phosphorous that is chemically bound, probably as an oxide, to the group IVb metal oxide support. This is demonstrated by the fact that repeated washing will not remove all of the phosphorous. However, the exact nature of the bonding is not completely understood.

The amount of phosphorous that is bonded or otherwise adheres to the support is a function of heating and other conditions used in the treating step and is also a function of the chemical identity of the phosphorous compound that is used as a source of phosphorous. Under the treating conditions exemplified above, at least about 2.5 wt % of phosphorous is caused to bond or otherwise permanently adhere to the pellets. There is an upper limit to the amount of phosphorous that bonds or otherwise permanently adheres to the support. This upper limit is, as indicated, a function of both the treating conditions and the chemical used as a source of the phosphorous. Normally, the maximum amount of phosphorous that can be caused to bond or otherwise permanently adhere to the pellets is within the range of about 5 to 10 wt %.

As a matter of convenience, the normal practice is to use only one chemical as a phosphorous source (e.g., phosphoric acid). However, mixtures of two or more such reagents may be used, if desired.

When the pellets are impregnated with the phosphorous compound at a temperature of at least about 100.degree. C., there is no absolute need to calcine the catalyst composition before use. However, the pellets can be calcined, if desired, as a precautionary measure and/or in order to still further improve the physical properties of the pellets. The pellets are suitably calcined at a temperature of about 200.degree. C. to about 800.degree. C. for a period of time within the range of 2 to 24 hours; more preferably at a temperature of about 500.degree. C. to about 700.degree. C. for about 4 to 16 hours.

Other procedures can be used in adding phosphorous to the group IVb metal oxide. For example, the pellets can be treated with the phosphorous compound at ambient temperatures or at more modest elevated temperatures of less than about 100.degree. C. In this situation, however, it is necessary to thermally activate the treated pellets by calcining under the conditions recited above.

Alternatively, the group IVb metal oxide can be treated with the phosphorous-containing compound in powdered form and the powder can thereafter be pelleted. If the treatment is conducted at a temperature of about 100.degree. C. or more, thermal activation will normally have been obtained and it will not be absolutely necessary to perform a calcining operation. If lower treating temperatures are used, calcining is normally a desired operation. The calcining operation can be conducted prior to or subsequent to the pelleting step. Any appropriate pelleting procedure of the type known to those skilled in the art may be used. For example, the treated powdered group IVb metal oxide can be mixed with graphite and/or other binders and compacted or extruded under conventional conditions.

There are many compounds which can be formed from the reaction of ethylenediamine and monoethanolamine besides the preferred linear polyethylenepolyamines such as diethylenetriamine, triethylenetetramine, tetraethylenepentamine and pentaethylenehexamine. Less desirable cyclics and other compounds, such as piperazine, N-(2-aminoethyl)ethanolamine and N-(2-aminoethyl)piperazine, are also formed. The more desired linear polyethylenepolyamines can be easily recovered from the reaction product mixture by conventional methods such as distillation. Such distillation recovery methods are well known in the art. An outstanding advantage of the claimed invention is that the lower molecular weight polyethylenepolyamines recovered from the reaction mixture can be further reacted with monoethanolamine to produce a larger percentage of the higher molecular weiqht linear polyethylenepolyamines.

The following examples will further illustrate the preparation of predominantly linear polyethylenepolyamines from ethylenediamine and monoethanolamine by the use of the catalyst compositions of the present invention. They are given by way of illustration and not as limitations on the scope of the invention. Thus, it will be understood that reactants, proportions of reactants, and time, temperature and pressure of the reaction steps may be varied with much the same results achieved.

For purposes of convenience and brevity, the reactant compounds employed and the products obtained have been abbreviated in the following examples and tables. The abbreviations employed for these various compounds are:

EDA--ethylenediamine MEA--monoethanolamine PIP--piperazine DETA--diethylenetriamine TETA--triethylenetetramine TEPA--tetraethylenepentamine AEEA--N-(2-aminoethyl)ethanolamine AEP--N-(2-aminoethyl)piperazine HEP--N-(hydroxyethyl)piperazine

EXAMPLE I

1. Titania Catalyst Preparation

A series of pelleted catalysts were prepared by depositing phosphorus on a titania support.

a. Phosphoric Acid

Titania supported phosphoric acid catalysts were prepared by heating about 100 cc of phosphoric acid to about 130.degree. C. under an inert atmosphere in a flask fitted with a condenser. 105 cc of titania pellets were slowly added through the condenser and the temperature was maintained for the desired period of time.

Thereafter the catalyst was recovered by first decanting the excess phosphoric acid followed by the addition to the pellets of a large quantity of water. The pellets and water were slowly stirred to dissipate heat. The pellets were washed several times with copious amounts of water and dried.

b. Phosphoryl Chloride on Titania

When using phosphoryl chloride as the source of phosphorus, a slight modification of the above identified procedures was necessary. The phosphoryl chloride was refluxed at 105.degree. C. The heat was turned off and the reflux was maintained by the addition of titania pellets at a rate sufficient to maintain a strong reflux. Thereafter, heat was used to maintain the temperature.

When the resulting reaction mixture was treated with water the phosphoryl chloride was hydrolysed. Constant stirring was very important in order to maintain good heat dissipation. Phosphorus bromide was also used as a source of phosphorus using the procedure outlined above for phosphoryl chloride.

For convenience, the catalysts prepared and a brief description of the same is set forth herein as Table I.

TABLE I______________________________________TITANIA CATALYST COMPOSITIONSType Number Composition______________________________________A 5464-72 40 wt. % Phosphate on aluminaA 5494-4 Titania (TiO.sub.2)A 5494-16 Titania treated with phosphoric acid (H.sub.3 PO.sub.4) for 1/2 hourA 5494-5 Titania treated with phosphoric acid for 2 hoursA 5494-17 Titania treated with phosphoric acid for 12 hoursA 5494-95 Titania treated with phosphoric acid for 2 hoursA 5494-96 Titania treated with phosphoric acid for 4 hoursB 5494-6 Titania treated with phosphoric acid for 2 hours and then calcined at 600.degree. C. for 16 hoursB 5494-65 Titania treated with phosphoric acid, pelletted and then calcined at 600.degree. C. for 16 hoursC 5494-11 Titania treated with phosphoric acid, aluminum nitrate (Al(NO.sub.3).sub.3) then calcined at 600.degree. C. for 16 hoursC 5494-76 Titania treated with phosphoric acid, aluminum nitrate and then calcined at 600.degree. C. for 16 hoursC 5494-77 Titania treated with phosphoric acid, aluminum nitrate and then calcined at 600.degree. C. for 16 hoursD 5494-13 Titania treated with phosphoryl chloride (POCl.sub.3) for 4 hoursD 5494-23 Titania treated with phosphoryl chloride for 4 hours and then calcined at 600.degree. C. for 16 hoursD 5494-31 Titania calcined at 600.degree. C., then treated with phosphoryl chloride and recalcined at 600.degree. C. for 16 hoursE 5494-19 Titania treated with phosphorous acid (H.sub.3 PO.sub.3) for 2 hoursE 5494-78 Titania treated with phosphorous acid for 2 hours and then calcined at 600.degree. C. for 16 hoursF 5494-18 Titania treated with polyphosphoric acid (PPA) for 2 hoursF 5494-87 Titania treated with polyphosphoric acid for 2 hours and then calcined at 600.degree. C. for 16 hoursG 5494-20 Titania treated with phosphorous bromide (PBr.sub.3) for 2 hours______________________________________

PREPARATION OF POLYETHYLENEPOLYAMINES FROM ETHYLENEDIAMINE AND MONOETHANOLAMINE USING TITANIA SUPPORTED PHOSPHORUS CATALYSTS

The catalysts described in Table I were utilized for the conversion of ethylenediamine and monoethanolamine to a polyethylenepolyamine reaction product in a 100 cc continuous reactor system. Pellets were placed in the reactor and the feedstock that was fed to the reactor was a mixture of ethylenediamine and monoethanolamine in a molar ratio of about two moles of ethylenediamine per mole of monoethanolamine.

In order to obtain a basis for comparison, the reaction temperature was varied so as to obtain about a 65% conversion of the monoethanolamine feedstock.

The reaction product was periodically sampled and analyzed by gas chromatographic analysis of the crude reactor effluent. Results were calculated on a feed-free basis.

The catalysts tested and the results obtained in the series of tests are set forth in Table II. In general, each feedstock was run for at least 21/2 hours to make sure that reaction conditions had stabilized.

Referring now to Table II it will be seen that the reference catalyst composition (5464-72) which comprised a commercially available 40 wt. % phosphate on aluminia catalyst of the type disclosed in Brennan U.S. Pat. No. 4,103,087 at column 8, lines 50-54 gave results which were improved upon in all instances. This run shows that with a pelleted aluminum phosphate catalyst, and in a continuous reaction, the results obtained are not so favorable as those reported for batch reactions in the copending application Ser. No. 283,713.

In particular, note that only about 77% of the triethylenetetramine fraction was noncyclic with this run. In contrast, with the catalyst of the present invention the noncyclic content was normally in excess of 90%. Note also that there was also a significantly smaller yield of diethylenetriamine with the reference catalyst.

The second reference catalyst (5494-4) was untreated titania pellets and it is seen that they were essentially inert insofar as conversion of monoethanolamine and ethylenediamine is concerned.

The type A titania supported catalysts wherein the source of phosphorus was phosphoric acid gave uniformly good results. Essentially equivalent results were obtained with the type B catalyst, however, the pellets were not quite so strong. The same comment applies to type C catalysts wherein the support was treated with phosphoric acid and thereafter there was an additional treatment with aluminum nitrate. The best pellet strength was obtained with the type D catalyst based on phosphoryl chloride.

Thus, Table II demonstrates that with titania supported pelleted catalyst in a continuous reaction system, it is possible to obtain excellent results in the reaction of monoethanolamine with ethylenediamine. The percentage of noncyclic reaction products is very high, being over 90% in all cases except for type G (when phosphorus bromide was the source of phosphorus). Diethylenetriamine yields of from about 50 to about 70% were obtained with this group of catalysts. Uniformly good yields of triethylenetetramine were also obtained.

TABLE II__________________________________________________________________________TITANIA SUPPORTED PHOSPHOROUS CATALYSTSPhosphorous Temp., 0.degree. C. Selectivity Ratio:Cata- on Cat. @ 65% AEP & DETA TETA Pellet Cat.lyst (wt. %) MEA Conv. Pip. DETA AEEA HEP TETA TEPA PIP % N.C. Strength Type__________________________________________________________________________5464-72 333 6.7 38.5 2.6 4.5 18.3 5.9 7.7 775494-4 -- -- -- -- -- -- -- -- --5494-16 2.2 331 2.6 61.8 0.5 1.6 18.0 .about.3 23.5 96 14 A5494-5 1.9/2.2 328 2.7 59.2 0.6 2.3 19.5 4.5 23.5 .about.95 16 A5494-17 1.6/2.2 306 2.2 52.9 0.6 1.8 18.5 3.4 .about.24 97 10 A5494-95 331 2.5 49.2 .about.0.5 2.3 17.8 2.8 94 A5494-96 333 2.5 57.3 1.9 15.8 .about. 1 .about.25 97 A5494-6 2.1 325 2.8 59.0 0.7 2.1 19.6 4.2 19.7 96 5 B5494-65 301 3.8 64.4 0.5 3.7 .about.20.5 2.5 17.0 92 B5494-11 1.3 340 3.2 56.1 0.5 2.3 18.9 4.0 17.4 95 6.7 C5494-76 2.1 .about.337 .about.2.6 .about.54.6 .about.1.1 -- 18.8 .about.2 97 9.7 C5494-77 2.1 331 2.8 53.6 0.6 2.5 17.8 1.8 17.0 97 C5494-13 5.3 311 2.4 65.9 0.3 2.1 19.0 >2.5 25.2 95 12.7 D5494-23 6.5 314 2.3 66.3 0.4 1.8 19.6 3.5 27.2 96 18 D5494-31 323 2.4 59.2 1.2 1.7 18.2 3.0 29.7 97 9.7 D5494-19 3.8 311 2.3 70.0 0.3 1.6 17.7 2.3 29.5 97 9.3 E5494-78 5.2 328 2.3 69.8 0.3 2.3 19.6 3.4 97 7.3 E5494-18 2.4 309 2.5 64.0 0.5 1.8 16.8 .about.3 25.5 96 11.6 F5494-87 2.3 334 .about.3 .about.73 0.8 .about.3 .about.20 .about.98 5.0 F5494-20 325 5.0 54.4 5.9 18.7 4.7 10.3 83 G__________________________________________________________________________

ANALYSIS OF CATALYST PELLETS

In an attempt to obtain a better understanding of the catalytic phenomena involved, three of the catalyst compositions of Table II were subjected to a detailed analysis utilizing a scanning electron microscope (SEM).

The results of the first series of analyses is given in Table III attached. Note that with catalyst 5494-6, the phosphorus was concentrated in the initial 50 microns of the pellet surface.

In addition, the exterior surface at the end of the pellet was also analyzed and the results of this analysis are set forth in Table IV.

In respect of catalyst 5494-11, wherein the titania was treated with aluminum nitrate and phosphoric acid and then calcined, an analysis of the interior of the surface is given in Table V.

The scanning electron microscope analysis of the surface of catalyst 5494-11 is given in Table VI.

TABLE III______________________________________Analysis of H.sub.3 PO.sub.4 /TiO.sub.2 /Calcined (5494-6)Interior Surface of Fractured PelletWeight % of Detected Elements 50.mu. 10.mu. in from in fromEle- Outer 39.mu. 50.mu. 100.mu. opposite oppositement Edge in. in. in. Center side side______________________________________Na 2.4 0.7 0 0 0 0 1.5Al 2.7 1.9 0 0 0 0 0Si 3.4 1.5 0 0 0 0 0P 35.3 10.8 tr tr 0.2 0 20.4Cl 5.3 2.1 0 0 0 0 0K 7.3 2.0 0 0 0 0 0Ca 1.9 1.6 1.5 0.9 2.0 2.0 0.5Ti 41.7 79.3 98.5 99.1 97.8 98.0 77.6 100.0 99.9 100.0 100.0 100.0 100.0 100.0______________________________________ Above data indicate that the phosphorus is concentrated at the surface of the catalyst pellet in a layer less than 50 microns thick. TABLE IV______________________________________Analysis of H.sub.3 PO.sub.4 /TiO.sub.2 /Calcined(5494-6), ContinuedExterior Surface (End) of PelletConcentration, Weight % of Detected ElementsElement 1 2 3 4 5 6 7______________________________________Na 1.1 0.8 0.9 0.6 1.0 1.1 0.8Al 0.1 0.2 0.7 0.1 3.2 3.3 0.2Si 1.4 1.2 1.6 1.1 2.8 3.0 1.7S 0 0 0 0 0 0 1.2Cl 0 0 0 0 0 0 0.8K 0 0 0 0 0 0 1.2Ca 0 1.0 0.5 0.5 3.7 3.1 0.8Ti 66.3 68.6 67.1 72.1 61.3 60.5 62.0P 31.0 28.2 29.3 25.5 27.9 29.0 31.3 99.9 100.0 100.1 99.9 99.9 99.9 100.0______________________________________ Above data indicate that the phosphorus concentration is relatively constant across the exterior surface of the pellet. TABLE V______________________________________Analysis of H.sub.3 PO.sub.4 /TiO.sub.2 /Al(NO.sub.3)/CalcinedSample No. 4 (5494-11)Interior Surface (Fractured) of PelletConcentrations, Wt % of Detected ElementsElement 1 2 3______________________________________Al 2.5 0.88 1.5P 1.7 0 0Ca 1.2 0.82 1.5Ti 94.6 98.3 97.0 100.0 100.0 100.0______________________________________ Edge of fractured pellet was very rough, so that the closest analysis to the edge was 7 microns away. At this location, the "P" concentration was very low. Comparing this with data in Table VI, it is evident that the phosphorus exists within a very thin surface layer, much thinner than tha for H.sub.3 PO.sub.4 /TiO.sub.2 /calcined, and that the "P" concentration are lower than those for the H.sub.3 PO.sub.4 /TiO.sub.4 /calcined catalysts. TABLE VI______________________________________Analysis of H.sub.3 PO.sub.4 /TiO.sub.2 /Al(NO.sub.3).sub.3 /CalcinedSample No. 4 (5494-11), ContinuedExterior Surface (End Face) of PelletEle- Concentration, Weight % of Detected Elementsment 1* 2 3 4 5 6 7______________________________________Na 0 0 0 0 0.4 0.3 0.1Al 0 1.0 1.2 1.9 1.5 1.2 1.1Si 0 0.4 0.4 0 0 0 0P 5.3 12.5 10.8 12.5 15.8 10.0 12.9Ca 0 0.5 0.6 1.0 0.8 0.2 0.7Ti 94.7 85.6 87.0 84.7 81.6 88.3 85.3 100.0 100.0 100.0 100.1 100.1 100.0 100.1______________________________________ *Values suspect The above data indicates that "P" concentrations are relatively constant across the end surface of the pellet. 1 No reason can be offered for the low value on analysis #1. All "P" concentrations are lower than those for the H.sub.3 PO.sub.4 /TiO.sub.2 /calcined catalysts.

In the case of the preceding analysis, it was demonstrated that the phosphorus was concentrated near the surface of the pellet. When catalyst 5494-13 was analyzed using the scanning electron microscope, different results were obtained, as is shown by Table VII.

TABLE VII______________________________________Analysis of POCl.sub.3 /TiO.sub.2Sample No. 5 (5494-13)Interior (Fracture) Surface of PelletConcentration, Wt % of Detected ElementsElement 1 2 3 4 5______________________________________Si 0.3 1.5 0.6 1.0 0.7P 6.8 8.2 7.2 8.7 8.5Cl 0.6 0.8 1.1 1.2 1.2K 0.1 0 0 0Ca 0.9 0.6 0.4 0.6 0.5Ti 91.4 89.0 90.7 88.5 89.2 100.1 100.1 100.0 100.0 100.1______________________________________ The above data indicate that the "P" concentration is approximately constant throughout the bulk of the catalyst particle, rather than being limited to a thin layer at the surface as in H.sub.3 PO.sub.4 /TiO.sub.2 /calcined and H.sub.3 PO.sub. 4 /TiO.sub.2 /Al(NO.sub.3).sub.3 /calcined.

Further, when the exterior surface was analyzed, as set forth in Table VIII, it was found that the phosphorus was concentrated more in the interior of the catalyst than on the exterior. This demonstrates the need for caution when extrapolating from one catalyst composition to another in reactions of this nature.

TABLE VIII______________________________________Analysis of POCl.sub.3 /TiO.sub.2Sample No. 5 (5494-13) ContinuedExterior Surface (End) of PelletConcentration, Wt % of Detected ElementsElement 1 2 3 4 5______________________________________Si 0.1 0.4 0.3 0.6 0.5P 3.7 6.3 4.5 6.1 6.6Cl 1.8 1.1 24.7* 0.7 1.1Ca 0.8 0.8 0.4 0.7 0.6Ti 93.7 91.5 70.1 91.9 91.2 100.1 100.1 100.0 100.0 100.0______________________________________ *Value suspect The above data indicate that "P" is distributed rather evenly across the exterior surface of the catalyst pellet, but is lower in concentration on the surface than inside the pellet. It is interesting that the lowest "P" concentration above corresponds to the lowest concentration within the pellet.

The catalyst compositions were also analyzed by X-ray defraction in bulk and after being powdered.

The results of the X-ray examination indicated that the titania that was used was in a single phase, namely as anatase. Phosphating of the titania with phosphoric acid produced the well known compound Ti(HPO.sub.4).sub.2.2H.sub.2 O. In addition, an unknown Ti-PO.sub.4 compound was also detected. The X-ray defraction pattern was quite similar to that of three known triphosphates, namely AgTi.sub.2 (PO.sub.4).sub.3, BaFeTi(PO.sub.4).sub.3 and GeNb(PO.sub.4).sub.3. Accordingly, the unknown was identified as a triphosphate possibly formed by the following reaction:

2TiO.sub.2 +2Ti(HPO.sub.4).sub.3 .fwdarw.2HTi.sub.2 (PO.sub.4).sub.3 +2H.sub.2 O

Indexing of the unknown's pattern is given in Table IX, which follows:

TABLE IX______________________________________Indexing of Ti, PO.sub.4 Unknown Pattern d-Spacings, A MillerIntensity Obsd Calculated.sup.1 Indices______________________________________w 6.05 6.11 (012)w 4.35 4.41 (014)w 4.20 4.23 (110)m 3.68 3.68 (006)s 3.50 3.48 (202) TiO.sub.2 alsom 3.32 3.29 (106)w 3.22 3.16 (007)w 3.03 3.05 (024)m 2.75 2.75 (211)m 2.03 2.04 (036)w 1.95 1.96 (128)w 1.83 1.84 (0 .multidot. 0 .multidot. 12)w 1.60 1.60 (140)w 1.28 1.28 (514)w 1.25 1.25 (3 .multidot. 1 .multidot. 14)______________________________________ .sup.1 Calculated using 1/d = 4/3(1/a.sup.2)(h.sup.2 + hk + k.sup.2) + (1/c.sup.2)l.sup.2, where hkl are Miller indices, a and c are lattice constants, 8.474 and 22.11A, respectively.

The X-ray defraction analysis studies further indicated that calcining converted essentially all of the Ti(HPO.sub.4).sub.2.H.sub.2 O to the new compound. The crystal size of the latter was determined to be about 125A. However, with respect to catalyst 5494-11 it was found that only a part of the Ti(HPO.sub.4).sub.2 was converted to the new compound. The new compound was not detected in sample 5494-13.

The results obtained from the catalyst pellet analysis are extremely interesting in a number of respects. First, it is clearly demonstrated that new catalyst compositions were obtained in the case of the samples 5494-6 and 5494-11. Otherwise the new phosphorus compound would not have been found.

Further, the superior activity obtained with a titania support is not solely attributable to the presence of the new compound as shown by the results obtained in Table II.

Finally, the interaction between the phosphorus and the titania support will vary depending upon the chemical nature of the source of the phosphorus but, again as shown by Table II, uniformly good results are obtained when titania is used as a catalyst support for a phosphorus containing compound.

EXAMPLE II

Zirconia Supported Phosphorus Containing Catalyst Compositions

A series of phosphorus containing zirconia supported catalyst compositions were prepared using the procedure outlined above in Example I. The pelleted catalysts were tested in the 100 cc continuous reactor described in Example I using the same conversion conditions. The catalyst compositions that were prepared are given in Table X. The results obtained with this group of catalysts is set out in Table XI.

TABLE X______________________________________Zirconia Catalyst CompositionsType Number Composition______________________________________ 5464-72 40 wt % Phosphate on alumina 5484-37 ZirconiaH 5484-6 Zirconia treated with 11 wt % phosphoric acid (H.sub.3 PO.sub.4) for 1 hour at 125.degree. C.H 5484-63 Pelleted zirconia treated with phos- phoric acid for 1 hour at 125.degree. C.H 5484-17 Zirconia treated with 22 wt % phosphoric acid for 1 hour at 125.degree. C.H 5484-83 Zirconia treated with 11 wt % phosphoric acid for 1 hour at 125.degree. C.H 5484-84 Zirconia treated with 11 wt % phorphoric acid for 2 hours at 125.degree. C.H 5484-85 Zirconia treated with 11 wt % phosphoric acid for 4 hours at 125.degree. C.H 5494-71 Zirconia treated with 11 wt % phosphoric acid for 24 hours at 125.degree. C.J 5484-64 No. 5484-63 calcined at 600.degree. C. for 16 hoursJ 5484-29A Zirconia treated with 10 wt % phosphoric acid for 1 hour at 125.degree. C. and then calcined at 600.degree. C. for 16 hoursJ 5484-56 No. 5484-29A after 300 hours of reaction timeJ 5484-46 Zirconia treated with 15 wt % of phos- phoric acid and then calcined for 16 hours at 600.degree. C.J 5484-47A Zirconia treated with 11 wt % of phos- phoric acid for 1 hour at 125.degree. C. and then calcined at 600.degree. C. for 16 hoursK 5494-79 Zirconia treated with phosphorous acid (H.sub.3 PO.sub.3) for 2 hoursL 5494-83 No. 5494-79 calcined at 600.degree. C. for 16 hoursM 5494-29 Zirconia treated with phosphoryl chloride for 4 hoursN 5494-30 No. 5494-29 calcined at 600.degree. C. for 16 hoursO 5494-86 Zirconia treated with polyphosphoric acid (PPA) for 2 hoursP 5494-88 No. 5494-86 calcined at 600.degree. C. for 16 hoursQ 5494-81 Zirconia treated with phosphorous bromide for 2 hours______________________________________ TABLE XI__________________________________________________________________________Zirconia Supported Phosphorous CatalystsPhosphorous Temp., 0.degree. C. Selectivity Ratio: on Cat. @ 65% AEP & DETA TETA Pellet Cat.Catalyst (wt. %) MEA Conv. Pip. DETA AEEA HEP TETA TEPA PIP % N.C. Strength Type__________________________________________________________________________5464-72 333 6.7 37.5 1.8 5.9 19.7 7.7 5.8 765484-37 -- -- -- -- -- -- -- -- --5484-6 316 3.9 54.2 0.9 1.5 17.1 2.4 15.7 .about.96 H5484-63 318 3.5 56.4 1.3 2.1 15.8 -- 15.3 H5484-28 322.5 3.7 56.2 1.1 2.2 16.8 2.2 15.4 H5484-83 322 5.1 50.8 0.7 3.7 15.5 3.0 10.5 H5484-84 320 4.4 54.0 0.4 2.5 15.2 3.1 12.5 H5484-85 322 4.8 55.6 0.9 2.2 12.4 2.4 12.3 H5494-71 319 3.4 71.3 1.0 2.0 19.5 .about.2 17.0 96 16.7 H5484-64 322 4.0 54.0 -- 1.6 15.7 .about.2.5 13.0 J5484-29A 323 3.7 51.2 1.1 2.2 17.3 2.7 13.8 J5484-56 323 4.5 52.5 0.2 3.2 16.8 3.5 12.2 J5484-46 325 3.7 53.2 0.7 1.8 15.2 -- 14.8 J5484-47A 324 3.7 54.5 1.2 2.2 15.1 .about.2 14.8 J5494-79 6.5 .about.333 .about.8.5 .about.62 .about.0.4 .about.6.4 .about.19.0 .about.3.2 -- 13.7 K5494-83 >330.sup.(1) -- -- -- -- L5494-29 0.9 328 4.8 56.5 0.4 3.2 18.5 6.0 11.5 91 8.0 M5494-30 1.4 331 4.0 57.5 0.3 3.6 22.5 5.0 14.5 93 13.3 N5494-86 2.4 3.26 5.1 65.3 0.5 3.7 21.0 4.2 12.4 95 7.0 O5494-88 2.6 .about.337 .about.6 .about.67 .about.0.2 .about.4.5 .about.19 .about.2.5 .about.92 12.7 P5494-81 2.0 332 4.6 62.7 1.2 2.6 20.6 .about.3.7 11.7 96 6.0 Q__________________________________________________________________________ .sup.(1) The highest MEA conversion attained at this temperature was only about 24%

With reference to Table XI, it will be seen that once again there was a good conversion of the monoethanolamine and ethylenediamine to noncyclic products characterized by good yields of diethylenetriamine and triethylenetetramine.

This series of tests demonstrates that the zirconia supported catalysts give results equivalent to those obtained with titania.

An attempt to analyze the zirconia supported catalysts using a scanning electron microscope were unsuccessful because the phosphorus content of the PK emission line waivelength, 6.1549A is very close to the ZrL - emission line, 6.0776A. These two lines could not be resolved using the electronic discriminator with which the scanning electron microscope was fitted.

Insofar as X-ray defraction analysis is concerned, it was determined that the zirconia was an equimix of monoclinic zirconia, baddeleyite and a tetragonal phase usually formed at higher temperatures.

Surface scrapings from the zirconia catalyst that had been treated with the phosphorous compound contained some rather large crystals of ZrP.sub.2 O.sub.7. Because of their low surface area, it is doubtful that this ZrP.sub.2 O.sub.7 is responsible for the excellent activity of the zirconia supported catalyst. The ZrP.sub.2 O.sub.7 X-ray pattern is weak, indicating that ZrP.sub.2 O.sub.7 represents a small fraction of the phosphorus present. It is probable that another phosphorous comound that is amorphous is the catalytically active species.

EXAMPLE III

Recycle Studies

The IV.sub.b metal oxide supports tend to shift product distribution towards diethylenetriamine. There are times when it is desirable to obtain greater yields of triethylenetetramine or tetraethylenepentamine. Accordingly, a series of recycle tests were run to determine the feasibility of recycle of diethyletriamine. The reaction sequence described above for the 100 ml. reactor was used for the recycle studies. However, 20 wt. % of the ethylenediamine in the feed was replaced with diethylenetriamine in two runs and all of the monoethanolamine was replaced with diethylenetriamine in the other two runs.

The catalyst compositions that were used are identified in Table XII and the results of the simulated recycle tests are set out in Table XIII.

TABLE XII______________________________________Catalyst Compositions, Simulated RecycleType Number Description______________________________________A 5494-7 Titania treated with phosphoric acid for 2 hoursA 5494-8 Titania treated with phosphoric acid for 2 hoursH 5494-2 Zirconia treated with phosphoric acid for 2 hoursH 5494-3 Zirconia treated with phosphoric acid for 2 hours______________________________________ TABLE XIII__________________________________________________________________________Simulated Recycle of Diethylene TriamineSelectivity Ratio: AEP & DETA TETA FeedCatalyst PIP DETA AEEA HEP TETA TEPA PIP % NC Recycle__________________________________________________________________________5494-7 3.3 51.5 1.6 2.5 29.0 6.5 15.6 96 20% DETA5494-8 5.0 33 1.6 5.9 39.7 22.5 6.5 .about.94 100% DETA5494-2 5.9 32.5 0.9 5.0 21.0 7.8 5.8 88 20% DETA5494-3 7.5 39.5 0.5 8.0 37.5 15.2 5.3 .about.85 100% DETA__________________________________________________________________________

As will be seen from Table XIII, with both titania and zirconia, the very high selectivity to noncyclic products was once again obtained. There was a significant increase in the yield of triethylenetetramine and also an improvement in the yield of tetraethylenepentamine.

EXAMPLE IV

This example is illustrative of the long term stability and activity of catalyst compositions of the present invention and of the low susceptibility of such catalyst compositions to poisoning.

A fresh batch of catalyst (5544-20) was prepared using the procedure of Example Ib to prepare a catalyst as set forth in Example I in respect of catalyst 5494-23.

Catalyst 5544-20 was used for a prolonged life study using the equipment and procedures of Exmple I. In this instance, however, more severe reaction temperature conditions were used in order to accelerate the effects of long term usage. For this purpose a monoethanolamine conversion of 80% was established and maintained throughout about 2000 hours of reaction time. At the end of that time the run was arbitrarily terminated. Representative results of the test are set forth in Table XIV.

TABLE XIV__________________________________________________________________________2000 Hour Catalyst Life Study - Titania HavingPhosphorous Derived from Phosphoryl Chloride Deposited Thereon Temp., .degree.C. Ratio: % NCElapsed @ 80% MEA Selectivity DETA inTime Conversion PIP DETA AEEA AEP TETA TEPA PIP TETA__________________________________________________________________________ 125 315 2.6 48.0 0.2 2.7 17.9 2.5 18.8 93 715 325 2.5 54.6 0 2.3 19.4 4.4 21.8 95 925 330 2.7 55.3 0.1 2.5 20.7 5.0 20.7 921195 335 2.5 53.3 0.1 2.4 19.8 5.7 21.4 941340 340 2.8 51.6 0 2.7 21.1 5.7 18.8 911645 350 3.6 48.0 0.2 3.3 19.8 5.7 13.4 921815 350 3.8 48.3 0 3.4 20.6 5.8 12.9 .about.852012 355 3.4 52.2 0 3.1 20.9 5.6 15.3 93__________________________________________________________________________

As can be seen from Table XIV, the catalyst had good initial selectivity and the selectivity remained good throughout the run.

The temperature required to maintain MEA conversion at 80% increased from 315.degree. C. to about 335.degree. C. during the first 1000 hours of operating, indicating a slight loss in activity. The use of a temperature of 355.degree. C. at the end of the run indicates an overall moderate loss of activity.

EXAMPLE V

This example is illustrative of the utility of hafnia as a support in the preparation and use of the catalyst compositions of the present invention.

The amount of hafnia available was insufficient to permit the preparation of the number of pellets required for a continuous evaluation using the equipment and reaction conditions of Example I. However, enough hafnia was available to permit a batch evaluation using powdered catalyst.

Catalyst Preparation

Typically, these catalysts were prepared by addition of 50 g of the metal oxide powder to 150 cc of 85% H.sub.3 PO.sub.4 at 130.degree. C. This temperature was maintained for approximately five hours. The solids were then separated by filtration through a fritted glass funnel; filter paper systems were not adequate as the phosphoric acid caused disintegration of the paper and subsequent product loss. The product was then washed to remove excess phosphoric acid and dried.

General Experimental Procedures

All batch reactions were carried out in a 300 cc stainless steel, rocking autoclave. They were used with glass liners to minimize the effects of catalyst derived impurities from the clave walls.

The general procedure consisted of placing 6.1 g (20 wt % basis MEA) of catalyst in a liner followed by addition of 60.5 g of a 1.1 EDA/MEA mixture (30 g EDA and 30.5 g MEA). The liner was placed in the reactor, the system was purged with nitrogen, and finally heated to 315.degree. C. for 2 hours. The crude reaction product was filtered from the catalyst and analyzed by GC using an OV-17 chromatography column.

The suports used for this series of tests included titania, zirconia and hafnia. Powdered T1067 was also run to provide a basis for comparison.

The results are set forth in Table XV.

TABLE XV______________________________________Batch Run Evaluation of Titania, Zirconiaand Hafnia as Catalyst Supports Ratio:Catalyst Conversion Selectivity DETASupport EDA MEA PIP DETA AEEA PIP______________________________________Titania 51 83 6.5Zirconia 3.5 5.2 5.1Hafnia 5.8 6.4 4.7 65.7 5.4 14.0T-1067 6.3 17.7 3.0 53.7 17.9 17.7______________________________________

Batch tests such as those summarized in Table XV are characterized by poor reproducibility. However, they do provide a qualitative measure of catalyst suitability.

It can be concluded from the results of Table XV that pelleted thermally activated catalyst compositions comprising hafnia having phosphorous derived from phosphoric acid deposited thereon will give results analogous to those obtained in Example I and Example II where titania and zirconia, respectively, were used as supports.

The foregoing examples of the present invention have been given by way of illustration only and are not intended as limitations on the scope of the invention which is defined by the following claims.

This specification includes data related to the invention disclosed and claimed herein and also, for comparative purposes, data is disclosed herein that is also disclosed and claimed in copending U.S. patent applications, filed of an even date herewith, as follows:

__________________________________________________________________________Application Filing DocketSerial No. Date Inventors No. Title__________________________________________________________________________455,158 Jan 3, 1983 Vanderpool 80067 Calcined Catalyst and & Watts Preparation of Linear Polyethylenepoly- amines Therewith455,159 January 3, 1983 Vanderpool 80068 Linear Polyethylene- & Larkin polyamine Preparation and Catalyst455,156 January 3, 1983 Vanderpool 80069 Modified Catalysts & Renken and Preparation of Polyethylenepoly- amines Therewith455,155 January 3, 1983 Vanderpool 80142 Preparation of Linear & Watts Polyamines from Novel Catalysts455,153 January 3, 1983 Renken 80158 Supported Catalysts and Preparation of Linear Polyethylene- polyamines Therewith__________________________________________________________________________

Claims

1. In a method wherein monoethanolamine is reacted with ethylenediamine in a reaction zone in the presence of a phosphorus containing catalyst to provide an essentially noncyclic product comprising polyethylenepolyamines, the improvement for conducting said process on a continuous basis which comprises:

a. using, as a catalyst, a thermally activated pelleted group IVb metal oxide having about 0.5 to about 10 wt. % of phosphorus thermally chemically bonded to at least the surface thereof,

b. continuously contacting a mixture of ethylenediamine and monoethanolamine in a molar ratio of about 1 to 5 moles of ethylenediamine per mole of monoethanolamine with said pelleted catalyst at a temperature of about 250.degree. to about 400.degree. C. and a pressure of about 500 to about 3000 psig. to obtain an essentially noncyclic reaction product.

2. A method as claim 1, wherein the group IVb metal oxide is titania.

3. A method as in claim 2, wherein the source of phosphorus is phosphoric acid.

4. A method as in claim 2, wherein the titania pellets are initially treated with phosphoric acid and are thereafter treated with aluminum nitrate.

5. A method as in claim 1, wherein the reaction product is fractionated to obtain at least a fraction comprising diethylenetriamine and wherein at least a portion of said diethylenetriamine is recycled to the reaction zone.

6. In a method wherein monoethanolamine is reacted with ethylenediamine in a reaction zone in the presence of a phosphorus-containing catalyst to provide an essentially noncyclic product comprising polyethylenepolyamines, the improvement for conducting said process on a continuous basis which comprises:

a. using, as a catalyst, a composition prepared by treating pellets of a group IVb metal oxide with a liquid containing a liquid or liquefiable phosphorus compound at a temperature within the range of about 100.degree. to about 150.degree. C. for about 0.5 to about 5 hours to thermally chemically bond to at least the surface of said pellets from about 0.5 wt. % to about 10 wt. % of phosphorus and thereafter water washing, recovering and drying the thus treated pellets,

b. continuously contacting a mixture of ethylenediamine and monoethanolamine in a molar ratio of about 1 to 5 moles of ethylenediamine per mole of monoethanolamine with said pelleted catalyst at a temperature of about 250.degree. to about 400.degree. C. and a pressure of about 500 to about 3000 psig. to obtain an essentially noncyclic reaction product.

7. A method as in claim 6 wherein the group IVb metal oxide is titania and wherein the treated pellets contain titanium triphosphate.

8. A method as in claim 6 wherein the groop IVb metal oxide is zirconia and wherein the treated pellets contain an amorphous compound of zirconia and phosphorous.