Process for Producing Laurolactam Verfahren Zur Herstellung Von Laurolactam Procédé De Production De Laurolactame

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Process for Producing Laurolactam Verfahren Zur Herstellung Von Laurolactam Procédé De Production De Laurolactame (19) TZZ _T (11) EP 2 292 599 B1 (12) EUROPEAN PATENT SPECIFICATION (45) Date of publication and mention (51) Int Cl.: of the grant of the patent: C07D 201/04 (2006.01) C07D 225/02 (2006.01) 06.01.2016 Bulletin 2016/01 C07B 61/00 (2006.01) (21) Application number: 09750568.9 (86) International application number: PCT/JP2009/059197 (22) Date of filing: 19.05.2009 (87) International publication number: WO 2009/142206 (26.11.2009 Gazette 2009/48) (54) PROCESS FOR PRODUCING LAUROLACTAM VERFAHREN ZUR HERSTELLUNG VON LAUROLACTAM PROCÉDÉ DE PRODUCTION DE LAUROLACTAME (84) Designated Contracting States: • YASUMATSU, Ryouta AT BE BG CH CY CZ DE DK EE ES FI FR GB GR Ube-shi HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL Yamaguchi 755-8633 (JP) PT RO SE SI SK TR • KAWAI, Joji Ube-shi (30) Priority: 20.05.2008 JP 2008131425 Yamaguchi 755-8633 (JP) 20.10.2008 JP 2008269262 (74) Representative: Cabinet Plasseraud (43) Date of publication of application: 52, rue de la Victoire 09.03.2011 Bulletin 2011/10 75440 Paris Cedex 09 (FR) (73) Proprietor: Ube Industries, Ltd. (56) References cited: Ube-shi, Yamaguchi 755-8633 (JP) WO-A1-2007/125002 WO-A1-2008/096873 WO-A1-2009/069522 JP-A- 2001 342 174 (72) Inventors: JP-A- 2006 219 470 • KUGIMOTO, Junichi Ube-shi • FURUYA YOSHIRO ET AL: "CYANURIC Yamaguchi 755-8633 (JP) CHLORIDE AS A MILD AND ACTIVE BECKMANN • II, Nobuhiro REARRANGEMENT CATALYST", JOURNAL OF Ube-shi THE AMERICAN CHEMICAL SOCIETY, Yamaguchi 755-8633 (JP) AMERICAN CHEMICAL SOCIETY, • DOI, Takashi WASHINGTON, DC; US, vol. 127, 1 January 2005 Ube-shi (2005-01-01), pages 11240-11241, XP002441494, Yamaguchi 755-8633 (JP) ISSN: 0002-7863, DOI: 10.1021/JA053441X & • FUJITSU, Satoru FURUYA YOSHIRO ET AL: "SUPPORTING Ube-shi INFORMATION: CYANURIC CHLORIDE AS A Yamaguchi 755-8633 (JP) MILD AND ACTIVE BECKMANN • GOTOU, Tadashi REARRANGEMENT CATALYST", JOURNAL OF Ube-shi THE AMERICAN CHEMICAL SOCIETY, Yamaguchi 755-8633 (JP) AMERICAN CHEMICAL SOCIETY, • SHIMOMURA, Hideo WASHINGTON, DC; US, vol. 127, 1 January 2005 Ube-shi (2005-01-01), page S1-S6, XP002441494, ISSN: Yamaguchi 755-8633 (JP) 0002-7863, DOI: 10.1021/JA053441X 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 2 292 599 B1 Printed by Jouve, 75001 PARIS (FR) (Cont. next page) EP 2 292 599 B1 • RUSSELL R: "One-Pot Synthesis Aids Scale-Up and Data Collection", PHARMACEUTICAL TECHNOLOGY, ADVANSTAR COMMUNICATIONS,INC, US, no. Nov, 1 November 2003 (2003-11-01), page 17,22, XP002433225, ISSN: 1543-2521 2 EP 2 292 599 B1 Description Technical Field 5 [0001] The present invention relates to an industrially useful process for producing laurolactam from cyclododecanone oxime. Background Art 10 [0002] A common industrial process for producing an amide compound involves Beckmann rearrangement of a cor- responding oxime compound. For example, ε-caprolactam which is industrially useful is produced by Beckmann rear- rangement of cyclohexanone oxime. Rearrangement catalysts used are generally concentrated sulfuric acid and oleum. Since these strong acids must be used in the stoichiometric amounts or more, they form a large amount of ammonium sulfate as a byproduct during neutralization. Although laurolactam, which is a starting material for Nylon 12, is also 15 produced in a similar manner, the process is more complex because cyclododecanone oxime as an intermediate product has a high melting point. In producing ε-caprolactam, both cyclohexanone oxime and ε-caprolactam have relatively low melting points, so that oxime formation or rearrangement reaction can be conducted in a solvent-free system, but production of laurolactam requires a reaction solvent. This reaction solvent must be able to substantially dissolve cy- clododecanone oxime and be inert to concentrated sulfuric acid or oleum, and therefore the selection of the solvent is 20 considerably restricted. [0003] The following references have described a known process for industrially producing laurolactam from cyclodo- decanone and an aqueous solution of hydroxylamine. [0004] Patent Reference 1 has described the following process. Cyclododecanone is converted into an oxime using isopropylcyclohexane as a solvent, and after separating layers, a resulting solution of cyclododecanone oxime in iso- 25 propylcyclohexane is slowly added to concentrated sulfuric acid at a low temperature to prepare a solution of a cyclodo- decanone oxime sulfate adduct in sulfuric acid. After separating and recovering isopropylcyclohexane, the residual solution of cyclododecanone oxime sulfate adduct in sulfuric acid is heated to carry out Beckmann rearrangement of the oxime. After the rearrangement reaction, water is added to the system to dilute sulfuric acid and from the mixture, the laurolactam produced is extracted with an organic solvent. Here, the extraction solvent may be isopropylcyclohexane 30 or cyclododecanone. The extraction solvent is recovered by distillation from the resulting extraction solution and then laurolactam in the residue is purified by distillation. [0005] This process does not generate ammonium sulfate as a byproduct in the rearrangement reaction step, but requires enormously large facilities and energy for treating a large amount of waste diluted sulfuric acid. Furthermore, since cyclododecanone reacts with concentrated sulfuric acid to form a byproduct, the oxime-forming reaction must be 35 completed for eliminating residual cyclododecanone, but due to hydrophobicity of isopropylcyclohexane, a mass transfer rate is low in an oil-water interface, leading to a longer oxime-forming reaction. As a whole, the process involves many steps of separation, recovery and recycling of solvents and, therefore, requires considerably large equipment expenses and energy. [0006] Patent Reference 2 has described the following process. A mixture of cyclododecanone and cyclohexanone 40 is blended with an aqueous solution of hydroxylamine to produce oximes. Cyclohexanone oxime produced has a low melting point and is a good solvent for cyclododecanone oxime, so that the reaction can be conducted at 100 °C or lower and at an ambient pressure. Furthermore, cyclohexanone oxime is adequately hydrophilic for the oxime-forming reaction to quickly proceed, and the mixture is transferred to the rearrangement step without residual cyclohexanone or cyclodo- decanone. A rearrangement catalyst used is concentrated sulfuric acid or oleum. Whereas laurolactam produced has 45 a high melting point, it is highly soluble in caprolactam having a low melting point which is simultaneously produced. Therefore the reaction can be carried out even at a temperature of 100 °C or lower. The resulting rearrangement reaction solution is neutralized with ammonia water and then extracted with an organic solvent. Caprolactam can be dissolved in water to some extent, but is extracted into an organic solvent due to salting-out effect of ammonium sulfate formed by neutralization. Next, a large amount of water is added to the solution containing extracted laurolactam and caprolactam, 50 and caprolactam is extracted into the aqueous phase. From the separated organic phase, the organic solvent is recovered and laurolactam is purified by distillation. On the other hand, the aqueous phase is concentrated and after removing impurities, caprolactam is purified. [0007] This process is excellent in that laurolactam and caprolactam can be produced together. However, as a process for producing laurolactam, it has the following problems; (1) separation and purification of caprolactam requires large 55 amounts of equipment expenses, resulting in low investment efficiency and the process involves operations of low energy efficiency such as concentration of an aqueous solution of caprolactam; (2) there is a restriction to a production ratio of laurolactam/caprolactam; and (3) caprolactam is a low-value-added product in comparison with laurolactam and an use efficiency of hydroxylamine is low. 3 EP 2 292 599 B1 [0008] Patent Reference 3 has described Beckmann rearrangement of an oxime compound in a polar solvent, wherein a rearrangement catalyst used is an aromatic compound (1)containing, as an aromatic-ring member, at least one carbon atom having a leaving group, (2)containing at least three aromatic-ring members, which are either or both of heteroatoms or/and carbon atoms having an electron- withdrawing group, and (3)wherein two of the heteroatoms and/or carbon atoms 5 having an electron-withdrawing group are at the ortho- or para-position to the carbon atom having an electron-withdrawing group. Non-Patent Reference 1 has described in detail a rearrangement reaction using the rearrangement catalyst disclosed in Patent Reference 3. Focusing attention on a low yield of rearrangement when a non-polar solvent is used in Non-Patent Reference 1, Patent Reference 4, 5 and 6 have improved the yield and thus extended the range of solvents which can be used, to non-polar solvents. Generally, a non-polar solvent is more thermally and chemically stable, has 10 a lower boiling point and has a smaller evaporative latent heat than a polar solvent, and thus, can be easily recovered and recycled, while it little dissolves a polar organic material or an inorganic material. [0009] We have selected trichlorotriazine among the catalysts disclosed in Patent Reference 3, and have investigated its reaction with cyclododecanone oxime. [0010] Patent Reference 3 and Non-Patent Reference 1 have explained a mechanism of the catalytic action of trichlo- 15 rotriazine (R3-Cl wherein R3 represents dichlorotriazinyl) in Beckmann rearrangement of a ketoxime (R 1-C(-R2)=N-OH wherein R1 and R2 represent alkyl or these may together form cycloalkane) as follows. [0011] First, hydrogen chloride is eliminated from trichlorotriazine and the ketoxime to form R 1-C(-R2)=N-O-R3 (ether).
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