The present invention provides an improved process for the preparation of 2,3,3,3-tetrafluoropropene by recycling the reaction by-products and attaining an equilibrium between feed and outlet composition.
Fluoro olefins play an important role as refrigerants. In recent years a fluoro olefin viz. 2,3,3,3-tetrafluoropropene (HFO-1234yf) has attracted attention as a new refrigerant to replace another fluorinated refrigerants namely 1,1,1,2-tetrafluoroethane (HFC-134a).
U.S. Pat. No. 2,931,840 describes a process for the preparation of HFO-1234yf by heating and decomposing a mixture of methyl chloride and chlorodifluoromethane or tetrafluoroethylene at a temperature from 700 to 950° C. by a common heating means such as an electric heater in a reactor.
It has been observed that the said process results in low yield due to formation of several by-products. It does not disclose any method for recycling the by-products.
Japan Publication No. 2016-027004 describes a process for the preparation of HFO-1234yf by feeding heat source selected from steam, nitrogen or carbon dioxide into a reactor containing a mixture of methyl chloride and tetrafluoroethylene at a temperature from 400 to 870° C. It further discloses recycling of vinylidenefluoride (VDF), hexafluoropropene (HFP), and chlorotrifluoroethylene (CTFE), which are used as raw materials for preparing HFO-1234yf, however, it discloses nothing about equilibrium between feed and outlet composition. Surprisingly, the present inventors observed that recycling of the composition comprising vinylidenefluoride (VDF), hexafluoropropene (HFP), octafluorocyclobutane (OFCB), 1-chloro-1,1,2,2,3,3-hexafluoropropane (R-226cb), chlorotetrafluoroethane (R-124), difluoromethane and trifluoromethane back into the reactor reduces further formation of these compounds by attaining an equilibrium, thereby increasing the yield of 2,3,3,3-tetrafluoropropene.
The present inventors have observed that upon feeding methylchloride and tetrafluoroethylene, pre-mixed or separately, into pre-heated reactor at 300° C. to 700° C. results in the formation of 2,3,3,3-tetrafluoropropene at high rate as compared to feeding heat source selected from steam, nitrogen or carbon dioxide into a reactor containing a mixture of methylchloride and tetrafluoroethylene at a similar temperature range.
The present inventors have further observed that feeding methylchloride and tetrafluoroethylene, pre-mixed or separately, into pre-heated reactor at 300° C. to 700° C. in the presence of initiator results in better selectivity towards 2,3,3,3-tetrafluoropropene. This was primarily because the content of methane (R50) reduces drastically upon the use of aforementioned initiators.
A first object of the present invention provides an improved process for the preparation of 2,3,3,3-tetrafluoropropene comprising an initiator.
Another object of the present invention provides an improved process for the preparation of 2,3,3,3-tetrafluoropropene, wherein recyclization of the reaction by-products result in equilibrium between feed and outlet composition.
A first aspect of the present invention provides an improved process for the preparation of 2,3,3,3-tetrafluoropropene comprising:
A second aspect of the present invention provides a process for the preparation of 2,3,3,3-tetrafluoropropene comprising:
A third aspect of the present invention provides a process for the preparation of 2,3,3,3-tetrafluoropropene comprising:
A fourth aspect of the present invention provides a process for the preparation of 2,3,3,3-tetrafluoropropene comprising:
A fifth aspect of the present invention provides a process for the preparation of 2,3,3,3-tetrafluoropropene comprising:
A first aspect of the present invention provides an improved process for the preparation of 2,3,3,3-tetrafluoropropene comprising:
The heat source provided in the reactor is electric furnace or electrical heater.
The methyl chloride, tetrafluoroethylene and an initiator used in the step b) are preheated at 250° C. to 400° C. using the electric furnace and are continuously introduced into the reactor either premixed or separately and first reaction mixture is obtained. The second reaction mixture component obtained in step c) comprises vinylidenefluoride, chlorotetra fluoroethane, hexafluoropropene, octafluorocyclobutane, chlorodifluoromethane, 1-chloro-2,2-difluoroethene, 1,1,2,2,3,3-hexafluoropropane, 1-chloro-1,1,2,2,3,3-hexafluoropropane, difluoromethane and trifluoromethane.
The present invention of first aspect is carried out in continuous reaction mode wherein reaction by-products are recycled back into the reactor.
The reaction by-products comprise second reaction mixture components.
Initially as the concentration of second reaction mixture components in reactor inlet increased, the concentration of second reaction mixture components in reactor outlet also increased however after a certain level further increase in second reaction mixture components in reactor outlet stopped with the increase in second reaction mixture components in reactor inlet, thereby attaining an equilibrium between feed and outlet of the reactor.
The recycling of the second reaction mixture back into the step b) reactor also resulted in controlling the heat generated during reaction, thereby controlling reaction exothermicity which reduced the further formation of second reaction mixture components and resulted in increasing the yield of 2,3,3,3-tetrafluoropropene.
A second aspect of the present invention provides a process for the preparation of 2,3,3,3-tetrafluoropropene comprising:
A third aspect of the present invention provides a process for the preparation of 2,3,3,3-tetrafluoropropene comprising:
A fourth aspect of the present invention provides a process for the preparation of 2,3,3,3-tetrafluoropropene comprising:
A fifth aspect of the present invention provides a process for the preparation of 2,3,3,3-tetrafluoropropene comprising:
The heat source provided in the reactor is electric furnace/electrical heater. Further, the heat source is used to provide a temperature in range of 250° C. to 700° C. or used to provide a temperature to a mixture of methylchloride and tetrafluoroethylene in the range of 250° C. to 700° C. in the reactor, or both to obtain a mixture.
In preferred embodiment the methylchloride is continuously introduced in the electric furnace set at the furnace temperature of 250° C. to 300° C., and methylchloride (R40) is heated at 300° C. The tetrafluoroethylene is continuously introduced into the tube in the electric furnace set at the furnace temperature of 300° C., and tetrafluoroethylene is preheated at 300° C. The initiator is continuously introduced into the tube in the electric furnace set at the furnace temperature of 300° C., and initiator is preheated at 300° C. These preheated material gas components (methylchloride, tetrafluoroethylene and initiator) are supplied to the reactor managed by the internal temperature.
The initiator used in the present inventions is selected from the group consisting of carbon tetrachloride, hexachloroethane, trichloroacetylchloride, chloroform, phosgene, thionyl chloride, sulfonyl chloride, trichloromethylbenzene, organic hypochlorites and inorganic hypochlorites or mixture thereof.
The concentration of initiator with respect to methyl chloride is selected from 0.1 to 8%. The mole ratio of methyl chloride to tetrafluoroethyelene is selected from 0.1 to 3:1.
The reaction mixture comprising 2,3,3,3-tetrafluoropropene, obtained by the present invention, is optionally, converted to anhydrous reaction mixture comprising 2,3,3,3-tetrafluoropropene.
In the present invention the above processes for the preparation of 2,3,3,3-tetrafluoropropene are optionally carried out in the presence of an inert gas selected from argon and nitrogen.
The isolation of 2,3,3,3-tetrafluoropropene, obtained by present invention, is carried out using several techniques known in the prior art such as distillation, adsorption, absorption and a like or combination thereof.
The residence time of the raw materials in the reaction zone is 0.1 second to 3.5 seconds.
The following examples are given by way of illustration and therefore should not be construed to limit the scope of the present invention.
A mixture of tetrafluoroethylene and methylchloride in the molar ratio of 1:0.82 respectively is preheated and then superheated to 350° C. and was fed to the Inconel reactor which pre-heated and maintained at 620° C. by electrical heater.
Comparative results of with and without initiator on the yield of 2,3,3,3-tetrafluoropropene:
A mixture of tetrafluoroethylene and methylchloride in the mol ratio of 1:1.16 respectively is preheated and then superheated to 350° C. and was fed to the Inconel reactor which is maintained at 550° C. by electrical heater.
The isolation of 2,3,3,3-tetrafluoropropene from the reaction mixture/composition, obtained by the process of present invention, is carried out by any method known in the art, for example, by series of distillations, absorption and adsorption or mixture thereof.
A mixture of methyl chloride and tetrafluoroethylene in the mole ratio of 0.88 together with carbon tetrachloride was preheated and then superheated to 350° C. and was fed to the reactor which was maintained at 620° C. by electrical heater. The reaction was exothermic and the temperature increased to 680° C. The reaction mixture thus obtained consisted of HFO1234yf, VDF and other by-products. The VDF was recycled back into the reactor. The reactor outlet samples were analyzed initially and after recycling of VDF using a gas chromatograph equipped with thermal conductivity detector. The results are shown in Table-1.
A mixture of methyl chloride and tetrafluoroethylene in the mole ratio of 0.88 together with carbon tetrachloride was preheated and then superheated to 350° C. and was fed to the reactor which was maintained at 620° C. by electrical heater. The reaction was exothermic and the temperature increased to 708° C. The reaction mixture thus obtained consisted of HFO1234yf, VDF and other by-products. The VDF was recycled back into the reactor. The reactor outlet samples were analyzed initially and after recycling of VDF using a gas chromatograph equipped with thermal conductivity detector. The results are shown in Table-2.
From the Tables-1 and Table-2, it is evident that initially as the concentration of VDF in reactor inlet increases, the concentration of VDF in reactor outlet also increases but after a certain level, further increase in VDF concentration in reactor outlet stops with the increase in VDF concentration in reactor inlet. Thus an equilibrium was said to be attained.
A mixture of methyl chloride and tetrafluoroethylene in the mole ratio of 0.88 was preheated and then superheated to 350° C. and was fed to the reactor which was maintained at 645° C. by electrical heater. The reaction was exothermic and the temperature increased to 680° C. The reaction mixture components thus obtained consisted of HFO-1234yf, octafluorocyclobutane (51.6 mole %), chlorotetrafluoroethane (33.4 mole %), 1-chloro-1,1,2,2,3,3-hexafluoropropane (9.8 mole %) and other by-products. The octafluorocyclobutane (51.6 mole %), chlorotetrafluoroethane (33.4 mole %), 1-chloro-1,1,2,2,3,3-hexafluoropropane (9.8 mole %) were recycled back into the reactor one by one. The reactor outlet samples were analyzed initially and after recycling of said reaction components using a gas chromatograph equipped with thermal conductivity detector. The results are shown in
The above experimental data clearly indicates that the presence of second reaction mixture components in reactor inlet results in an equilibrium which enhances the selectivity for the formation of 2,3,3,3-tetrafluoropropene.
However, this equilibrium is not limited to the compounds in the examples, it can be applied to most or all of the components of second reaction mixture.
Number | Date | Country | Kind |
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201611040763 | Nov 2016 | IN | national |
201711023883 | Jul 2017 | IN | national |
Filing Document | Filing Date | Country | Kind |
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PCT/IN2017/050555 | 11/24/2017 | WO | 00 |
Publishing Document | Publishing Date | Country | Kind |
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WO2018/100586 | 6/7/2018 | WO | A |
Number | Name | Date | Kind |
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2931840 | Marquis | Apr 1960 | A |
10239804 | George | Mar 2019 | B2 |
20150005538 | Furuta | Jan 2015 | A1 |
20160347692 | Tirtowidjojo | Dec 2016 | A1 |
Number | Date | Country |
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2826766 | Jan 2015 | EP |
2016027004 | Feb 2016 | JP |
2014080916 | May 2014 | WO |
Entry |
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International Search Report and Written Opinion pertaining to PCT/IN2017/050555 dated Jan. 30, 2018. |
Number | Date | Country | |
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20200010390 A1 | Jan 2020 | US |