Process of Formic Acid Production by Hydrolysis
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(19) TZZ ¥_T (11) EP 2 747 883 B1 (12) EUROPEAN PATENT SPECIFICATION (45) Date of publication and mention (51) Int Cl.: of the grant of the patent: B01J 14/00 (2006.01) C07C 51/09 (2006.01) 15.02.2017 Bulletin 2017/07 C07C 53/02 (2006.01) B01J 10/00 (2006.01) B01D 3/10 (2006.01) C07C 51/44 (2006.01) (21) Application number: 12751504.7 (86) International application number: (22) Date of filing: 27.08.2012 PCT/EP2012/066622 (87) International publication number: WO 2013/030162 (07.03.2013 Gazette 2013/10) (54) PROCESS OF FORMIC ACID PRODUCTION BY HYDROLYSIS OF METHYL FORMATE VERFAHREN ZUR HERSTELLUNG VON AMEISENSÄURE DURCH HYDROLYSE VON METHYLFORMIAT PROCÉDÉ DE PRODUCTION D’ACIDE FORMIQUE PAR HYDROLYSE DE FORMIATE DE MÉTHYLE (84) Designated Contracting States: • TREJBAL, Jiri AL AT BE BG CH CY CZ DE DK EE ES FI FR GB 278 01 Kralupy nad Vltavou (CZ) GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO • ROOSE, Peter PL PT RO RS SE SI SK SM TR 9831 Sint-Martens-Latem (BE) (30) Priority: 27.08.2011 US 201161528204 P (74) Representative: Gevers Patents Intellectual Property House (43) Date of publication of application: Holidaystraat 5 02.07.2014 Bulletin 2014/27 1831 Diegem (BE) (73) Proprietor: Taminco (56) References cited: 9000 Gent (BE) WO-A1-00/39067 US-A- 4 262 140 US-B1- 6 713 649 US-B2- 6 696 603 (72) Inventors: • PASEK, Josef 160 00 Praha 6 (CZ) Note: Within nine months of the publication of the mention of the grant of the European patent in the European Patent Bulletin, any person may give notice to the European Patent Office of opposition to that patent, in accordance with the Implementing Regulations. Notice of opposition shall not be deemed to have been filed until the opposition fee has been paid. (Art. 99(1) European Patent Convention). EP 2 747 883 B1 Printed by Jouve, 75001 PARIS (FR) 1 EP 2 747 883 B1 2 Description - The temperature in the bottom of the column is 150 °C at a pressure of 3,5 bar, and the extent of decom- FIELD OF THE INVENTION position of formic acid to CO and water is very re- markable at this temperature. Depending on the [0001] The present invention relates to methods and 5 magnitude of the liquid hold-up in the bottom of the apparatus for the production of formic acid by hydrolysis column, 4 to 10 % of formic acid decompose. The of methyl formate. formed water then further dilutes formic acid. [0002] The present invention further relates to meth- - The specific heat consumption is considerable, and ods for the removal of methanol which is formed as a the heat duty of the reboiler is around 2400 kWh/t of side product during this production. 10 formic acid 85 %. This value is valid for inlet concen- tration of formic acid to the rectification column of 45 BACKGROUND OF THE INVENTION %. - For the conditions of the rectification, the column, [0003] Hydrolysisof methyl formate is a dominantproc- packing, distributors, reboiler and even the condens- ess of formic acid production. Formic acid of a concen- 15 er have to be manufactured from non-metallic ma- tration of 85 % wt. is sold predominantly on the market, terials. Formic acid corrodes even the most high- only a minor part requires a concentration of 90 % and quality stainless steels under the conditions of the higher. rectification. [0004] Methyl formate usually containing 3 to 8 % of methanol is typically hydrolyzed at 100 to 140 °C using 20 [0006] Formic acid production is described e. g. by pat- water and methyl formate as starting components at a ents Leonard Jackson Day US 4299981, Bethlehem molar ratio of water/ester of between 0,8 and 7. Hydrol- Steel Corp. US 3907884. However, it is assumed by mis- ysis of methyl formate has an unfavorable chemical equi- take in the second of the mentioned patents that formic librium [equilibrium constant K = 0,18 to 0,24]. In the acid forms with water an azeotrope with minimum of b.p., present industrial processes, non-reacted ester and25 but it forms an azeotrope with maximum of b.p. in a matter formed methanol are separated after the completion of of fact. the reaction from the reaction mixture by distillation. For- [0007] It has been found in the context of the present mic acid of a concentration of between 20 to 50 % is invention that the extent of formic acid decomposition obtained depending on the starting molar ratio of H 2O/es- can be limited by decreasing the temperature in the rec- ter. During rectification of the reaction mixture to dilute 30 tification column at the expense of decreasing the con- formic acid, very volatile methyl formate gets separated centration of formic acid in the bottom stream of the col- rapidly in the column, and this enables reverse esterifi- umn. Decomposition of formic acid has high activation cation of formic acid by the methanol which still remains energy, and it is strongly inhibited by the presence of after removal of the methyl formate. water. Decreasing temperature by 10 °C and increasing This rectification is performed at as low temperature as 35 water concentration from 15 % to 20 up to 25 % decreas- possible, and thus optionally at a pressure lower than es the rate of the decomposition of the acid to one third. atmospheric pressure (US 4299981). However, the nor- The acid which obtained by this method and has a con- mal b.p. of methylformate is 32 °C, and it is not possible centration of 75 to 80 % is then rectified to the acid of 85 to use common cooling water in the condenser at a re- % and higher at a reduced pressure. duced pressure. The extent of the reverse esterification 40 [0008] Formic acid can be extracted from diluted solu- in the rectification column can eliminate up to 20 % of tions to various solvents, such that water does not have formic acid that has been originally formed in the reactor. to be separated from formic acid by distillation. Extraction Methyl formate that formed in the rectification column by and extraction agents based on amides of acids are de- this reverse reaction can be returned to the hydrolysis, scribed in e.g. patent publications DE2914671, thoughwater formed by theesterification dilutes obtained 45 US6867329, US6696603 and DE4444979. More in par- formic acid, and it increases heat consumption. ticular, US6696603 discloses a process for obtaining an- [0005] Separation of 85 % of formic acid from diluted hydrous or substantially anhydrous formic acid, in which acid is complicated by nearly the same b.p. of water and the aqueous formic acid is supplied to a separate extrac- formic acid (the normal b.p. of the acid is 101 °C) and tion column in which it is partly dehydrated by means of further by formation of an azeotropic mixture with maxi- 50 carboxylic acid amide. mum of b.p. To obtain formic acid with a concentration [0009] Extractive rectification of a mixture of water and of 85 % in the bottom of a dewatering column, it would formic acid is also patented, which uses similar solvents be necessary to rectify the diluted acid at a pressure as used in the above mentioned extraction methods. This around 3,5 bar. Water with a low content of formic acid process described in e.g. DE2545730, US4935100, up to 1 % distillates via the top of the column, it is sent 55 US5006205, US5173156 and CN101481304. back to the hydrolysis. This procedure of isolation of for- [0010] There is a need to obtain improved methods for mic acid of 85 % is complicated by several circumstanc- formic acid production wherein a greater conversion of es: methyl formate into formic acid is obtained such that heat 2 3 EP 2 747 883 B1 4 for both distillation of non-reacted ester and for separa- formate vapor is introduced per kg of formic acid formed. tion of water from formic acid can be saved. Unfortunate- With an increasing volume of methyl formate vapours ly, methyl formate has the lowest b.p. (32 °C) among the concentration of formic acid in the reaction mixture leav- all concerned components, and the higher equilibrium ing the last unit of the cascade increases as well. conversion of hydrolysis can not be achieved by sepa- 5 [0015] In embodiments of these methods, the passing ration of the product from reactor by distillation. Further- of the methyl formate vapor stream is performed in a more, formic acid can not be extracted selectively, be- countercurrent flow. cause all solvents extract methyl formate preferably. [0016] In embodiments of these methods, the hydrol- [0011] Prior art methods for formic acid production ex- ysis of methyl formate to formic acid is performed con- ist wherein weak bases are added to the reaction mixture, 10 tinually in a reactor-mixer cascade and wherein methyl which bond formic acid and thus increase the conversion formate vapor is fed to the last unit of the reactor-mixer of methylformate. Methyl formate and methanol are then cascade and wherein water is fed to the first (through the distilled from the obtained salt of formic acid with the middle) reactor-mixer. base, and then the base is separated from formic acid at Embodiments of methods of the present invention envis- a higher temperature by distillation. Various bases are 15 age a batch design of methyl formate hydrolysis wherein described in DE2744313. Also dialkylamides can be methyl formate vapours are passed through the reaction used to shift the equilibrium of hydrolysis DE3411384.