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Feb. 27, 1962 W. REPPE ETAL 3,023,237 PROCESS for PRODUCING ACRYLIC ACID Filed May L, 1959

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Feb. 27, 1962 W. REPPE ETAL 3,023,237 PROCESS for PRODUCING ACRYLIC ACID Filed May L, 1959 Feb. 27, 1962 W. REPPE ETAL 3,023,237 PROCESS FOR PRODUCING ACRYLIC ACID Filed May l, 1959 SEPARATOR REACTOR INVENTORS WALTER REPPE ROBERT STADLER - 3,023,237 United States Patent Office Patented Feb. 27, 1962 1. 2 It is a disadvantage of this process that the entire 3,023,237 carbon monoxide required for the carbonylation of the PROCESS FOR PRODUCNg ACRYLC ACD acetylene must be furnished by the expensive and poison Walter Reppe and Robert Stadler, Heidelberg, Germany, assignors to Badische Anilin- & Soda-Fabrik Aktien ous metal carbonyls. geseischaft, Ludwigshafen (Rhine), Germary 5 In the production of acrylic acid and its esters by the Filed May 1, 1959, Ser. No. 820,279 so-called catalytic method (German Patents 854,948, Claims priority, application (Germany Feb. 17, 1953 881,650 and 805,641, copending application Serial No. 288,534, now Patent 2,738,364, and J. W. Reppe, Acety 18 (Caims. (C. 260-533) lene Chemistry, C. A. Meyer & Co., Inc., New York This invention relates to the production of acrylic acid O (1949), page 161), acetylene, free carbon monoxide and by the carbonylation of acetylene in the presence of Water, a compound with a reactive hydrogen atom are reacted and more particularly, to an improved method of pro in the presence of catalytic amounts of carbonyl-form ducing acrylic acid in a novel aqueous reaction medium ing metals or the oxides or salts of such metals. For containing an activated carbonylation catalyst. the formation of acrylic acid this process can be illus It has already been proposed to produce acrylic acid trated by the equation by bringing acetylene and carbon monoxide into contact catalyst with water in the presence of catalytic quantities of com CH2--CO-H2O - - CH-CH-COOH pounds of metals of the iron Group, i.e. iron, nickel or While nickel carbonyl is the most suitable catalyst in cobalt, the reaction being carried out under super-atmos Such a process it has the disadvantage of favoring the pheric pressures and at elevated temperatures. The same 20 formation of by-products such as acetaldehyde and vinyl type of catalytic reaction has also been employed in the bromide. production of acrylic acid esters by substituting alcohols Various additives such as metals, metal compounds or in place of water. The improved production of such complex-forming organic compounds of phosphorus, acrylic acid esters forms the subject matter of our co arsenic, antimony and nitrogen have been suggested in pending application, Serial No. 468,580, filed November 25 order to increase the activity and the life of the catalyst 12, 1954 and issued as U.S. Patent 2,883,418. The pres employed in the catalytic synthesis of acrylic compounds ent application is a continuation-in-part of our prior from acetylene, carbon monoxide and compounds con copending application, Serial No. 410,179, filed February taining a reactive hydrogen atom. 15, 1954, abandoned after the filing of this application. These processes yield fairly satisfactory results when The catalytic methods of producing acrylic acid and 30 employed for the synthesis of acrylic acid esters. How acrylic acid esters are generally conceded to be superior ever, in the production of free acrylic acid, such processes to the vairous known stoichiometric methods in which Work only with low yields and poor throughputs. Fur nickel carbonyl in substantial amounts is required as an thermore, the carbonyl-forming metal catalysts such as essential ingredient of the reaction mixture. Since nickel nickel halides have been employed according to the prior carbonyl is an expensive and poisonous compound, much 35 art in relatively high amounts and the catalyst forms time and effort has been devoted in research to find a thereby with the liquid reaction medium a non-homoge commercially useful catalytic method whereby the use neous System. of nickel carbonyl can be avoided. Various modifica U.S. Patent 2,613,222 shows the preparation of acrylic tions of the catalytic method have therefore been sug 40 acid and its anhydrides by a process in which the catalytic gested, and while fairly satisfactory results have been reaction between water, acetylene and carbonyl monoxide obtained in the synthesis of acrylic acid esters, the results must be first initiated by a stoichiometric interaction be when producing acrylic acid itself have been especially tween water, acetylene, nickel carbonyl and an acid. The disappointing and unsatisfactory on an industrial scale. stoichiometric reaction which precedes the catalytic reac It has been our observation that the acetylene employed 45 tion must furthermore be maintained while there is im as a starting material tends to be transformed into acetal posed upon it the catalytic reaction. In such a process at dehyde during the synthesis of acrylic acid. The activity least 35%, but preferably 40% to 50% of the total car of the known catalysts under known reaction conditions bon monoxide is carbon monoxide supplied by nickel thereby decreases relatively quickly so as to substantially carbonyl. reduce the rate of conversion with correspondingly low 50 It is a disadvantage of this process that a great deal yields. of the reaction must be performed by the stoichiometric The prior art, including that appearing in our copend method which entails a high demand of pre-formed nickel ing parent application, which is pertinent to the manu carbonyl, therefore requiring particular safety measures. facture of acrylic acid may be set forth as follows: One object of the invention is to avoid the formation of In the manufacture of acrylic compounds such as 55 by-products, especially acetaldehyde, in the production acrylic acid or acrylic acid esters by the so-called stoichi of acrylic acid by employing a particular activated catalyst. ometric method (German Patents 855, 110, 872,042, Another object of the invention is to provide an im 872,341 and 872,939), stoichiometric amounts of a metal proved production of acrylic acid in which the catalyst has carbonyl are reacted with acetylene an a compound with a long life and its activity is increased and maintained. a reactive hydrogen atom such as water or an alcohol 60 Yet another object of the invention is to produce acrylic in the presence of an acid. This process can be illus acid with a specific catalyst and under reaction conditions, trated by the following equation: including the use of a novel aqueous reaction medium, whereby high throughputs can be obtained. CH-4Ni(CO)4-HO--/2 HCI Together with the foregoing objects, a principal object saCH2=CH-COOH-4 NiCl3--4H. 65 of the invention is to provide a process for the production 3,023,237 - - - - - 3 A. of acrylic acid on a large scale. These and other objects Sometimes it has been found useful to add a small amount and advantages of the invention will become more appar (less than 1 percent by weight) of powdered copper. ent upon a consideration of the following detailed spec However, the process works generally quite satisfactorily ification. without it. Furthermore, a small amount of halogen hy We have found in accordance with the present invention dride, e.g. 0.1 to 1 percent by weight of hydrogen bro that in carrying out the carbonylation of acetylene in the mide, is useful. presence of water it is very advantageous to use an excess The amount of the catalyst required is relatively small by volume of an organic solvent with reference to the and depends to some extent on the kind of metal, which volume of water employed, said organic solvent being compound thereof is used, and on the composition of inert to acetylene under the reaction conditions and mis 10 the liquid reaction medium. Generally speaking, the cible with water. We have further found that the amount concentration is a catalytic quantity, i.e. not more than of the carbonylation catalyst, i.e. of a compound derived 2 percent and preferably not more than 0.5 percent by from a metal of the Iron Group, should be so chosen that weight of the compound of the metal of the Iron Group, this catalyst is homogeneously dissolved in the liquid re calculated on the liquid reaction medium. Satisfactory action medium constituted by the mixture of water and results have been obtained in the range of about 0.05 inert organic solvent. It has also been established by to 2 percent. The amount of the copper compound used us that the catalysts should be activated by including in as an activator is in general somewhat lower than that the reaction medium a small amount of a soluble copper of the catalyst, i.e. usually not more than 0.1 percent by compound. weight of the copper compound calculated on the liquid As organic solvents we prefer oxygen-containing water 20 reaction medium. Satisfactory results have been ob miscible liquids which are inert under the reaction con tained from about 0.02 percent by weight of the activator ditions, i.e. which are not irreversibly changed by the up to as much as an equal amount with reference to a presence of water and which are not able to react with nickel halide employed in the reaction medium. acetylene or carbon monoxide. The solvents, therefore, The reaction conditions used in the carbonylation are should not contain free hydroxy, mercapto or carboxy 25 within the conventional range. We prefer to use acety groups, olefinic or acetylenic linkages, or primary or sec lene and carbon monoxide in substantially equimolecular ondary amino groups. Their boiling point should prefer ratios, but the CH:CO ratio may vary within wide ably be below that of acrylic acid, i.e. below about 142 limits, e.g.
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