Method for the removal of phosgene impurities from boron trichloride

Abstract

Phosgene, COCl.sub.2, an impurity in BCl.sub.3 is removed by exposing a BCl.sub.3 mixture containing the impurity to an electrical discharge (i.e., electrical excitation energy level) directed through the mixture. The BCl.sub.3 gas with COCl.sub.2 impurity can be flowing or stationary as desired for a particular process.

Description

BACKGROUND OF THE INVENTION

Commerical processes for producing BCl.sub.3 (boron trichloride) result also in the production of the impurity COCl.sub.2 (phosgene). The removal of COCl.sub.2 has been a problem, particularly where it is desired not to introduce other contaminants in the BCl.sub.3 either by the process directly or indirectly. COCl.sub.2 causes difficulties when BCl.sub.3 is used in the electronics industry in the manufactured of electrical components, when BCl.sub.3 is used as a catalyst in numerous ways such as in the production of styrene, when BCl.sub.3 is used as an additive for high energy fuels, or when BCl.sub.3 is used in the refining of various refractory metals, etc. In the past, removal of the impurity from BCl.sub.3 by economical methods has proven unsuccessful.

More recently, U.S. Pat. No. 4,063,896 issued to James A. Merritt and Lawrence C. Robertson on Dec. 20, 1977 and assigned to The United States of America as represented by the Secretary of the Army, discloses a method wherein phosgene as an impurity in BCl.sub.3 is dissociated by CO.sub.2 laser radiation. In this method the power level of a cw CO.sub.2 multiline laser can be varied to accomplish the irradiation to effectively dissociate the COCl.sub.2 into its dissociation products, substantially CO and Cl.sub.2. The BCl.sub.3,.nu..sub.3 (956 cm.sup.-1) fundamental is resonant with CO.sub.2 (P.sub.20) laser line and strongly absorbs this energy which is followed by an intramolecular V-V transfer of energy to the COCl.sub.2 which results in its dissociation. The gaseous compound C.sub.2 H.sub.4 having combination bands and overtones that match reasonably close to the energy levels of COCl.sub.2 can also serve as a diluent for COCl.sub.2 to effect transfer of energy for dissociation of COCl.sub.2 by cw CO.sub.2 laser radiation.

Although the aforementioned method for removing COCl.sub.2 from BCl.sub.3 by laser is a meritorious achievement, the method has the limitation of requiring a laser source.

Therefore, an object of this invention is to provide a method which does not require a laser for purifying BCl.sub.3 of the impurity COCl.sub.2.

Another object of this invention is to provide a method for purifying BCl.sub.3 of the impurity COCl.sub.2 by an electric excitation selected from electrical discharge excitations, radio frequency excitation, or electron beam excitation.

SUMMARY OF THE INVENTION

A mixture of c.p. grade BCl.sub.3 which is contaminated with 0.1% COCl.sub.2 is introduced into a cell fitted with IR windows on each end of the cell for observation and monitoring purposes. This cell (e.g. glass) is provided with a pair of tungsten electrodes for maintaining an electrical discharge. The electrodes which can be positioned on either side of the glass cell are connected to either a high power (current and/or voltage) supply or an r.f. (radio frequency) source such as achieved from Tesla coils for maintaining a discharge through the mixture. Also, electron beam excitation of the gas mixture can be employed in the method of this invention.

After one minute of discharge through the BCl.sub.3 contaminated with COCl.sub.2, all of the COCl.sub.2 was removed as evidenced by no COCl.sub.2 detectable by a FTS-20B spectrometer. The pressure of BCl.sub.3 was at about 100 torr. The pressure of BCl.sub.3 can be varied since the electrical excitation energy level can be varied by adjustment of the power level as well as the number of electrodes as required for the system employed.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Purifying of BCl.sub.3 contaminated with COCl.sub.2 is accomplished by passing an electrical discharge through a mixture of BCl.sub.3 and COCl.sub.2 in a reaction cell. The COCl.sub.2 is readily decomposed to harmless products for end use of BCl.sub.3.

Electrodes for maintaining an electrical discharge are positioned on either side of a cell filled with BCl.sub.3 gas containing COCl.sub.2 as an impurity. The reaction cell is fitted with IR windows for observation and monitoring purposes. The BCl.sub.3 gas with COCl.sub.2 impurity can be flowing or stationary as desired for the particular process. The electrodes (tungsten) are connected to either a high power (current and/or voltage) supply or an r.f. source such as Tesla coils for maintaining a discharge through the mixture. Electron beam excitation can also be employed to decompose COCl.sub.2 impurity.

One experimental set-up included filling the reaction cell with BCl.sub.3 and contaminant (about 0.1% COCl.sub.2 as is present in c.p. grade BCl.sub.3) to about 100 torr pressure. An electrical discharge was passed through the gas mixture for about one minute during which time all of the COCl.sub.2 was decomposed without decomposing the BCl.sub.3. No COCl.sub.2 was detectable with a FTS-20B spectrometer.

Additional evaluations of the method of this invention indicate that purification of boron trichloride (BCl.sub.3) containing phosgene (COCl.sub.2) impurity is accomplished by delivering an electrical excitation energy level from a means selected from the group of electrical excitation means consisting of:

1. R.F. excitation of BCl.sub.3 +COCl.sub.2 to remove COCl.sub.2 impurity; 2. Excitation of BCl.sub.3 containing the COCl.sub.2 impurity by direct current in a resistive medium; 3. Excitation of BCl.sub.3 containing the COCl.sub.2 impurity by alternating current in a resistive medium; and, 4. Electron beam excitation of BCl.sub.3 containing the COCl.sub.2 impurity.

The reaction cell can vary in design but generally would be fitted with inlet and outlet means, pressure measuring means, one or more pairs of electrodes as required by method employing direct or alternating current for delivering excitation to gas mixture, windows through which process can be monitored, focusing means, and other commonly employed fixtures and devices as required for batch or continuous processes of operation for the electrical excitation means selected. For example, when employing r.f. excitation energy or electron beam excitation energy, windows transparent to the excitation energy are employed when the excitation source is external to the reaction cell. An alternate embodiment includes the excitation source to be located within the reaction cell as explained in further detail below.

Another experimental set-up included filling a reaction cell, wherein an electron beam source is internally mounted, with gas mixture of BCl.sub.3 and contaminant (about 0.1% COCl.sub.2 as is present in c.p. grade BCl.sub.3) to a predetermined pressure of about 100 torr. The electron beam excitation energy source is activated to cause a discharge of electron beam excitation to be directed through the gas mixture to effect complete decomposition of the COCl.sub.2 as determined by monitoring means. The electron beam excitation source can be employed with a flowing system or stationary system of operation by employing conventional adaptations as required.

The term resistive medium as used in this invention means the BCl.sub.3 and COCl.sub.2 in a diluent gas which may be employed as a carrier medium. The excitation level can be adjusted to the level required to effect decomposition of COCl.sub.2 in a flowing or stationary mode of operation. Also, the excitation can be repeated as the need requires as indicated by monitoring of COCl.sub.2 to determine when all of the COCl.sub.2 has been decomposed.

The purity of BCl.sub.3 achieved as a result of purification by the method of this invention employing any of the enumerated means for excitation meets the needs for many end uses for BCl.sub.3 such as for catalyst use in the electronics industry in the manufacture of electrical components, for catalyst use in numerous ways such as in the production of styrene, for use in rocket propellant manufacture, and for use in the refining of various refractory metals, etc.

Claims

1. A method for the removal of phosgene impurities from boron trichloride comprising:

(i) Admitting a gaseous mixture of BCl.sub.3 containing COCl.sub.2 as an impurity into a reaction cell to achieve a predetermined pressure in said reaction cell that is operable with the electrical excitation energy level employed to effect decomposition of said COCl.sub.2 impurity;

(ii) delivering an electrical excitation energy level for a predetermined time period through said gaseous mixture to effect decomposition of said COCl.sub.2 impurity;

(iii) monitoring said COCl.sub.2 impurity concentration level to determine when all of said COCl.sub.2 impurity has been decomposed; and,

(iv) repeating said step of delivering an electrical excitation energy level when said monitoring step determines that COCl.sub.2 impurity is present in said reaction cell.

2. The method of claim 1 wherein said predetermined pressure is about 100 torr and wherein said electrical excitation energy level delivered is a direct current discharge that is delivered through said gaseous mixture for a predetermined time period of about one minute and wherein said monitoring step employs a spectrometer.

3. The method of claim 1 wherein said predetermined pressure is about 100 torr and wherein said electrical excitation energy level delivered is an alternating current discharge that is delivered through said gaseous mixture for a predetermined time period of about one minute and wherein said monitoring step employs a spectrometer.

4. The method of claim 1 wherein said predetermined pressure is about 100 torr and wherein said electrical excitation energy level delivered is a focused radio frequency energy that is delivered through said gaseous mixture for a predetermined time period of about one minute and wherein said monitoring step employs a spectrometer.

5. The method of claim 1 wherein said predetermined pressure is about 100 torr and wherein said electrical excitation energy delivered is a focused electron beam that is delivered through said gaseous mixture for a predetermined time period of about one minute and wherein said monitoring step employs a spectrometer.