United States Patent (10) Patent No.: US 7,223,893 B2 Small Et Al

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United States Patent (10) Patent No.: US 7,223,893 B2 Small Et Al US007223893B2 (12) United States Patent (10) Patent No.: US 7,223,893 B2 Small et al. (45) Date of Patent: *May 29, 2007 (54) LINEAR ALPHA-OLEFIN DIMERS 5,955,555 A 9, 1999 Bennett ...................... 526,133 POSSESSING SUBSTANTIAL LINEARITY 6,103,946 A 8/2000 Brookhart, III et al. .... 585/523 6,291,733 B1* 9/2001 Small et al. ................ 585,512 (75) Inventors: Brooke L. Small, Kingwood, TX (US); 6,489,497 B1 12/2002 Brookhart, III et al. .... 556/138 Eduardo J. Baralt, Kingwood, TX (US) FOREIGN PATENT DOCUMENTS (73) Assignee: Chevron Phillips Chemical Company WO WO 99,55646 * 11, 1999 (*) Notice: Subject to any disclaimer, the term of this Highly Active Iron and Cobalt Catalysts for the Polymerization of patent is extended or adjusted under 35 Ethylene, Brooke L. Small, Maurice Brookhart, and Alison M.A. U.S.C. 154(b) by 85 days. Bennett, Journal of the American Chemical Society; vol. 120, No. 16, pp. 4049-4050, 1998. This patent is Subject to a terminal disis- CatalyzedBeach et byal.; (n3-4-Cyclooctene-1-yl)-(1.1.1.5.5.5-Hexafluoro-2,4- Linear Dimerization of Propylene and 1-Butene Ca10. Pentanedionato)Nickel: Journal of Molecular Cataysis: 1986; vol. 34, pp. 345-354. (21) Appl. No.: 10/056,137 , pp * cited by examiner (22) Filed: Jan. 24, 2002 Primary Examiner Thuan Dinh Dang (65) Prior Publication Data S.C. & SC Fin Conley Rose, P.C.; Rodney . Uarroll, K. KaRan Ree US 20O2/O177744 A1 Nov. 28, 2002 57 ABSTRACT Related U.S. Application Data (57) (63) Continuation of application No. 09/660,450, filed on Linear 1-butene dimers and other linear alpha-olefin dimers Sep. 12, 2000, now abandoned s a- ws are manufactured in high yield and with high selectivity by O. I Z. s coupling of alpha-olefins. The coupling is accomplished by (51) Int. Cl. contacting alpha olefins with an iron-based catalyst activated CD7C I3/00 (2006.01) with an aluminum-based co-catalyst. The catalyst is struc (52) U.S. Cl 585/17:585/511:58.5/510 tured to preclude formation of multiple dimer products, and 58 Fi id f Cl- - - - - - ficati - - - - - -s h s s 585/17 the byproducts of the olefin coupling consist almost exclu (58) Field of Classification Search ............ 585f511.51 o sively of methyl branched olefin dimers. The dimers have S lication file f let h hist s potentially diverse use in areas stretching form pharmaceu ee appl1cauon Ille Ior complete searcn n1story. ticals to plastics. Linear 1-butene dimers may be particularly (56) References Cited useful in the production of plasticizer alcohols which may in turn be used to manufacture high quality plastics with U.S. PATENT DOCUMENTS reduced leaching. 3,346,662 A * 10, 1967 Antonsen .................... 585,512 4,069.273 A 1, 1978 Komoto ...................... 585,511 9 Claims, 5 Drawing Sheets U.S. Patent US 7,223,893 B2 'N Q5 N U.S. Patent May 29, 2007 Sheet 2 of 5 US 7,223,893 B2 Fe-based precatalysts foro-olefin dimerization. U.S. Patent May 29, 2007 Sheet 3 of 5 US 7,223,893 B2 (),s??ues)Jeeu?T 3ripOJ Jeeu% U.S. Patent May 29, 2007 Sheet 4 of 5 US 7,223,893 B2 FIG. 4 Abundance TIC: C4DIMER7.D 6500000 6000000 5500000 5000000 4500000 4000000 3500000 3000000 2500000 2000000 1500000 1000000 500000 Time -- s s s s s s U.S. Patent May 29, 2007 Sheet S of 5 US 7,223,893 B2 eueplAuA N (euenq- uOly) eude Ç(5)I.H penSqnS). h euleu US 7,223,893 B2 1. 2 LINEAR ALPHA-OLEFN DIMERS S. Sveida & M. Brookhart, “Ethylene Oligomerization POSSESSING SUBSTANTIAL LINEARITY and Propylene Dimerization Using Cationic (C.-Diimine) Nickel(II) Catalysts,” 18 Organometallics 65-74 (1999) dis This application is a continuation of application Ser. No. cusses catalysts prepared from aryl-substituted C-diimine 09/660,450 filed on Sep. 12, 2000, now abandoned. 5 ligands complexed with nickel(II) bromide and activated with aluminum alkyl activators. This article indicates that FIELD OF THE INVENTION the active catalysts dimerize propylene generating product mixtures that have roughly equal compositions of n-hexenes This invention relates to linear and mono-branched olefin and 2-methylpentenes with 2,3-dimethylbutenes as minor dimers and to methods of making same. 10 products. The catalysts are said to dimerize higher olefins Such as 1-butene and 4-methyl-1-pentene very slowly. BACKGROUND OF THE INVENTION Only a few catalysts are known to produce linear alpha olefin dimers, and these catalysts or catalyst systems gen Dimerization reactions are widely used industrially and erally exhibit low activity and low selectivity. A recent the dimerization of olefins by transition metals has been 15 article by B. Ellis, W. Keim and P. Wasserscheid, on “Linear widely studied. Some reviews or reports of such studies Dimerisation of But-1-ene in Biphasic Mode Using Buffered include, for example, a chapter by Yves Chauvin and Hélene Chloroaluminate Ionic Liquid Solvents’ in Chem. Commun. Olivier on “Dimerization and Codimerization' in Applied 337-338 (1999), notes these problems with catalysts for Homogeneous Catalysis with Organometallic Compounds, olefin dimerization, but also notes the desirability of obtain VCH, New York (Comils & Herrmanned. Vol. 1) 258-268 ing linear olefin dimers, particularly those derived from (1996) and a number of articles cited therein. 1-butene. The article reports some efforts toward improving Many catalysts are known to dimerize olefins, particularly the activity of known catalysts while retaining dimer selec into branched olefins. However, few such catalysts or cata tivity and product linearity. lyst systems have shown promising commercial viability U.S. Pat. No. 5,196,624, issued Mar. 23, 1993 to Threlkel due to a variety of limiting factors, including competing side 25 et al. and U.S. Pat. No. 5,196,625, also issued Mar. 23, 1993 reactions, catalyst cost and activity, lack of selectivity for to Threlkel et al. disclose dimerization processes for pro dimer formation, and severity of the reaction conditions. ducing linear and mono-branched Co to Cs olefins employ The catalysts that are selective for dimer preparation ing a catalyst mixture comprising a nickel(II) compound, a produce mostly vinylidene dimers or di-branched dimers, or phosphite compound and an alkyl aluminum halide. These they are unselective in product distribution, producing 30 processes are said to have high yields. branched, linear, and vinylidene dimers. For example, U.S. Additional and better catalyst systems or improved dimer Pat. No. 4,658,078, issued Apr. 14, 1987 to Slaugh et al. ization methods for making linear alpha-olefin dimers are teaches a process for dimerizing alpha olefins to vinylidene still needed, particularly if dimers such as linear 1-butene olefins. U.S. Pat. No. 4,973,788, issued Nov. 27, 1990 to Lin dimers are to ever be commercially viable. et al. teaches a process for dimerizing vinyl-olefin mono 35 mers said to have selectivity of at least 85 percent to form SUMMARY OF THE INVENTION vinylidene olefins but at a slow reaction rate requiring a long reaction time. The present invention provides linear alpha (O-) olefin W. P. Kretschmer, S. I. Troyanov, A. Meetsma, B. Hessen dimers that may be produced quickly and efficiently without & J. H. Teuben, “Regioselective Homo- and Codimerization 40 forming significant non-linear byproducts. The mechanism of C-Olefins Catalyzed by Bis(2,4,7-trimethylindenyl)yt or process for producing these linear alpha olefin dimers trium Hydride” 17 Organometallics 284-286 (1998) dis requires a coupling of two olefins per dimer. An initial olefin, cusses compounds which are catalysts for various branched Such as butene for example, undergoes 1.2 insertion, and a dimers including trimers and also for vinylidenes. second olefin, Such as butene for example, undergoes 2.1 H. Heijden, B. Hessen & A. G. Orpen, “A Zwitterionic 45 insertion. A complex results that beta (B-) eliminates to Zirconocene Alkyl Complex as a Single-Component C.-Ole produce the linear dimer, such as 1-butene dimer for fin Dimerization Catalyst, 120 J. Am. Chem. Soc. 1112 example. 1113 (1998) discusses a Zwitterionic zirconocene said to be The coupling is facilitated by a transition metal-based a single-component catalyst that is highly selective although catalyst (or pre-catalyst) that has been activated by an only moderately active for head-to-tail dimerization of 50 aluminum co-catalyst. The intermediary complex formed is C-olefins. an organo-metallic complex. X. Yang, C. Stem, & T. Marks, “Cationic Zirconocene The aluminum-based co-catalyst is preferably an alumox Olefin Polymerization Catalysts Based on the Organo-Lewis ane or a Lewis acid/trialkylaluminum combination Such as Acid Tris(pentafluorophenyl)borane. A Synthetic, Struc trialkylaluminum/borane. The transition metal-based cata tural, Solution Dynamic, and Polymerization Catalytic 55 lyst is preferably an iron-based catalyst and most preferably Study,” 116 J. Am. Chem. Soc. 10015-10031 (1994) teaches selected from the group having one of the six formulas among other things a cationic hydrido complex said to be shown in FIG. 2. highly active for the catalytic dimerization of propylene to The process is preferably carried out under inert atmo form a mixture of 2-methyl-1-pentene and 2-methyl-2- sphere at a temperature ranging from about Zero degrees pentene. 60 Centigrade to about eighty degrees Centigrade for these M.Mitkova, A. Tomov, & K. Kurtev, "A Kinetic Study of catalysts, although higher temperatures may also be used, Propylene Dimerization by Binuclear Nickel-Ylide Com depending on the particular catalyst selected. In a batch plexes in Presence of Diethylaluminum Chloride as cocta application, the reaction initially generates heat which may lyst,” 110 J.
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