Catalytic Process for Polyhydric Alcohols and Derivatives

This invention is concerned with a process for the manufacture of polyhydric alcohols, their ether and ester derivatives, and oligomers of such alcohols. This invention also produces monohydric alcohols such as methanol, and their ether and ester derivatives.

Polyhydric alcohols are presently being produced synthetically by the oxidation of petroleum derived materials. Owing to the limited availability of petroleum sources, the cost of these petroleum derived materials has been steadily increasing. Many have raised the dire prediction of a significant oil shortage in the future. The consequence of this has been the recognition of the need for a low cost source of chemicals which can be converted into such polyhydric alcohols.

It is known that monofunctional compounds such as methanol can be obtained by reaction between carbon monoxide and hydrogen at elevated pressures e.g., up to about 1000 atmospheres, and temperatures ranging from 250.degree. C to 500.degree. C, using mixtures of copper, chrominum and zinc oxides as the catalyst therefor. It is disclosed in U.S. Pat. No. 2,451,333 that polyhydroxyl compounds are produced by reaction of formaldehyde, carbon monoxide, and hydrogen in the presence of hydrogenation catalysts. It has also been reported that formaldehyde can be produced by reaction between carbon monoxide and hydrogen at elevated pressures but repeated attempts to carry out this synthesis of formaldehyde have invariably failed to yield any substantial quantity of the desired product. It is generally recognized that the previously disclosed processes for the synthesis of formaldehyde from carbon monoxide and hydrogen at high pressures are either completely inoperative or else give rise to insignificantly small quantities of formaldehyde.

In British Pat. No. 655,237, published July 11, 1951, there is disclosed the reaction between carbon monoxide and hydrogen at elevated pressures and temperatures up to 400.degree. C, using certain hydrogenation catalysts as exemplified by cobalt-containing compounds. U.S. Pat. Nos. 2,534,018; 2,570,792, and 2,636,046 are substantially similar in disclosure to the above said British patent. The only catalysts employed in the numbered examples of said U.S. Pat. No. 2,636,046 are those which contain cobalt.

It is also well-known that nickel is predominantly a catalyst for synthesis and for reforming methane according to the reaction

which proceeds from left to right at temperatures below about 500.degree. C. and in the opposite direction at higher temperatures; see Kirk-Othmer, Encyclopedia of Chemical Technology, Second Edition, Volume 4, pages 452-453, John Wiley and Sons, New York (1964).

In U.S. Pat. No. 3,833,634, issued September 3, 1974 there is disclosed a process for the preparation of polyhydric alcohols by contacting a mixture of carbon monoxide and hydrogen with a catalytic amount of rhodium in complex combination with carbon monoxide.

Copending application, Ser. No. 462,109, filed Apr. 19, 1974, characterizes an improvement on the invention of U.S. Pat. No. 3,833,634. There is disclosed in Ser. No. 462,109 a process for manufacturing polyhydric alcohols, their ether and ester derivatives, oligomers of such alcohols and monohydric alcohols and their ether and ester derivatives by reacting oxides of carbon and hydrogen in the presence of a rhodium carbonyl complex which is provided to the reaction as a rhodium carbonyl cluster which possesses an infrared spectrum which exhibits three intense wavelength bands between about plus and minus 10 cm.sup.-.sup.1 of about 1868 cm.sup.-.sup.1, about 1838 cm.sup.-.sup.1, and about 1785 cm.sup.-.sup.1 at a pressure of at least about 500 pounds per square inch, in association with a counter-ion. Suitable counter-ions for the cluster are a variety of metals and organic compounds.

This invention is directed to a process for making polyhydric aliphatic alcohols and their ether, ester, and oligomer derivatives, such as alkane polyols, most specifically, alkane diols and triols, containing 2 or 3 carbon atoms, their ether and ester and oligomer derivatives.

As with the process of Ser. No. 462,109, and U.S. Pat. No. 3,833,634, a by-product of this invention is the manufacture of the lesser valuable, but valuable nevertheless, monohydric alkanols such as methanol, ethanol, and propanol, and their ether and ester derivatives. The products of this invention contain carbon, hydrogen, and oxygen.

The process of the present invention involves the production of polyhydric alcohols, their ether and ester derivatives, oligomers of such alcohols, monohydric alcohols and their ether and ester derivatives, by reacting the oxides of carbon and hydrogen in the presence of a quaternary phosphonium cation and a rhodium carbonyl complex at a temperature of about 100.degree. C to about 375.degree. C and a pressure of hydrogen and oxides of carbon of from about 1000 psia to about 15,000 psia sufficient to produce said diols and triols.

Illustrative of rhodium carbonyl complexes suitable for use in the practice of the present invention are those wherein (1) rhodium is in complex combination with carbon monoxide, and/or (2) rhodium is in complex combination with carbon monoxide and hydrogen, and/or (3) rhodium is in complex combination with at least one organic ligand, and/or (4) rhodium is in complex combination with carbon monoxide, hydrogen and at least one organic ligand, and (5) mixtures and/or combinations thereof.

For example, the rhodium carbonyl complexes used in this invention may be in the form of rhodium carbonyl clusters. P. Chini, in a review article entitled "The Closed Metal Carbonyl Clusters" published in Review (1968), Inorganica Chemica Acta, pages 30-50, states that a metal cluster compound is "a finite group of metal atoms which are held together entirely, mainly, or at least to a significant extent, by bonds directly between the metal atoms even though some nonmetal atoms may be associated intimately with the cluster". The rhodium carbonyl cluster compounds of this invention contain rhodium bonded to rhodium or rhodium bonded to another metal such as cobalt, and/or iridium. The preferred rhodium carbonyl cluster compounds of this invention are those which contain rhodium-rhodium bonds. These compounds desirably contain carbon and oxygen in the form of carbonyl (--C--O), in which the carbonyl may be "terminal", "edge bridging", and/or "face bridging". They may also contain hydrogen and carbon in forms other than carbonyl. The following are illustrative of what is believed to be the structure of two distinct rhodium carbonyl clusters and both are suitable for use in this invention: ##SPC1##

The structures of the rhodium carbonyl clusters may be ascertained by X-ray crystal diffraction, nuclear magnetic resonance spectra, NMR, or infrared spectra as disclosed in the article entitled "Synthesis and Properties of the Derivatives of the [Rh.sub.12 (CO).sub.30 ].sup.2.sup.- Anion" by P. Chini and S. Martinengo; appearing in Inorganica Chemica Acta, 3:2 pp 299-302, June (1969). Of particular analytical untility in the present invention is the use of infrared spectroscopy which allows for qualitative and what is presently believed to be quantitative characterization of the particular rhodium carbonyl cluster present during the operation of the process of the present invention.

Rhodium carbonyl complexes, such as the rhodium carbonyl clusters characterized previously, function in association with oxides of carbon and hydrogen as herein defined, to produce the polyhydric alcohols, etc. The exact mechanism by which the complexes act to catalyze the reaction is not fully appreciated at this time. In the case of the clusters it is believed that the reaction is dependent upon the existence of the following equilibria:

such an equilibria may be in situ formed from a less complex rhodium carbonyl compound or a more complexed rhodium carbonyl compound. However, it may be that such cluster equilibria is symptomatic of an intermediate transitory rhodium carbonyl structure which serves to convert the carbon monoxide and hydrogen to the polyhydric alcohol.

The quaternary phosphonium cations useful in the present invention are those which are stable and remain substantially inert under the reaction conditions of the present invention. Suitable quaternary phosphonium cations are those of the formula: ##EQU1## wherein R.sub.1, R.sub.2, R.sub.3, and R.sub.4 are any organic radicals which are bonded to the phosphorous atom by a saturated aliphatic carbon atom, such as a straight or branched chain alkyl group, having from 1 to 20 carbon atoms, in the alkyl chain, such as methyl, ethyl, n-propyl, isopropyl, n-butyl, octyl, 2-ethyl hexyl, dodecyl, and the like; or a cycloaliphatic group (cycloalkyl) including the monocyclic and bicyclic groups such as cyclopentyl, cyclohexyl, bicyclo-[2.2.1] heptyl groups, and the like; or an organic radical which contains ethylenic unsaturation, provided the unsaturation is sterically masked or in a position so as not to adversely affect the production of polyhydric alcohols such as oleylmethallyl, allyloxyethyl, and the like; or an araalkyl group such as benzyl, beta-phenylethyl, 3-phenyl-propyl and the like; or a functionally substituted alkyl such as beta-hydroxyethyl, ethoxymethyl, ethoxyethyl, phenoxyethyl and the like; or a polyalkylene ether group of the formula: (C.sub.n H.sub.2n O).sub.x -OR wherein n has an average value from 1 to 4, x has an average value from 2 to about 150, and R may be hydrogen or alkyl of 1 to about 12 carbon atoms. Illustrative of such polyalkylene ether groups are poly(oxyethylene),poly(oxypropylene), poly(oxybutylene-1,4), poly(oxyethyleneoxypropylene), poly(oxyethyleneoxybutylene) and the like. Preferably, the organic radicals, R.sub.1 to R.sub.4, of formula II are alkyl having from 1 to 12 carbon atoms in the alkyl chain.

The precise role of the quaternary phosphonium cation in the reaction of carbon monoxide and hydrogen catalyzed by the rhodium carbonyl complexes to produce polyhydric alcohols is not clearly understood. The reaction is believed to involve the reaction of carbon monoxide with the active catalytic species to form a radical of CO which may or may not require the addition of another radical of CO prior to hydrogenation to form the polyhydric alcohol or methanol. Certain infrared analysis showed that under reaction conditions which favor the production of polyhydric alcohols, the characteristic 3 band pattern of the [Rh.sub.12 (CO).sub.34-36 ].sup.2.sup.- cluster was present. In terms of the results achieved, it would appear that the quaternary phosphonium cation functions in a manner which may reduce factors which inhibit the aforementioned CO radical formation.

The role of the anion of the added quaternary phosphonium cation under the reaction conditions of the present process is not fully appreciated at present. The anion may be partially or wholly dissociated from the cation under reaction conditions and possibly functioning as a ligand by competing with CO for active sites on the rhodium molecule.

The rhodium carbonyl complex is, as characterized above, a rhodium containing compound in which the rhodium is at least complexed with CO. This can be achieved with just carbon monoxide or in addition to the carbon monoxide there may be included hydrogen and/or other organic materials to create the complex. In the last case, "complex" includes a coordination compound formed by the union of one or more electronically rich organic molecules or atoms capable of independent existence with one or more electronically poor molecules or atoms, each of which is also capable of independent existence. These organic rhodium carbonyl complexes are derived from the association of organic Lewis bases with the rhodium carbonyl complex in solution. The precise role of these Lewis bases in the reaction of the present invention is not fully appreciated at present. They may be functioning as ligands and/or forming counter-ions under the reaction conditions of the present process or they may be functioning just merely as Lewis bases and neutralizing or tying up a molecular species which, if allowed to remain "free" or in its non-base bound state, would adversely affect the productivity of the present invention. For the sake of convenience, these Lewis bases will hereinafter be referred to as organic ligands.

Organic ligands which are suitable in the practice of the invention contain at least one Lewis base nitrogen atom and/or at least one Lewis base oxygen atom said atoms possessing a pair of electrons available for the formation of coordinate bonds with rhodium. In suitable embodiments the organic ligands contain from 1 and upwards to 4 Lewis base atoms, preferably from 1 to 3 such atoms, and most preferably 1 or 2 Lewis base atoms. These organic ligands are said to be multidentate or polydentate, that is to say, such ligands are bidentate, tridentate, or quadridentate, depending on whether 2, 3 or 4 Lewis base atoms are involved in the formation of chelate structures with rhodium.

Organic ligands which contain at least one Lewis base nitrogen atom will oftentimes hereinafter be referred to as "organic nitrogen ligands"; those ligands which contain at least one Lewis base oxygen atom will oftentimes be referred to as "organic oxygen ligands"; and those which contain at least one Lewis base nitrogen atom plus at least one Lewis base oxygen atom will oftentimes be referred to as "organic aza-oxa ligands".

Suitable organic nitrogen ligands most generally contain carbon, hydrogen and nitrogen atoms. Suitable organic oxygen ligands most generally contain carbon, hydrogen, and oxygen atoms. Suitable organic aza-oxa ligands most generally contain carbon, hydrogen, oxygen, and nitrogen atoms. The carbon atoms can be acyclic and/or cyclic such as aliphatic cycloaliphatic, aromatic (including fused and bridged) carbon atoms, and the like. Preferably, the organic ligands contain from 2 to 20 carbon atoms. The nitrogen atoms can be in the form of imino (--N=), amino (--N--), nitrillo (N), etc. Desirably, the Lewis base nitrogen atoms are in the form of imino nitrogen and/or amino nitrogen. The oxygen atoms can be in the form of groups such as hydroxyl (aliphatic or phenolic), carboxyl ##EQU2## carbonyloxy ##EQU3## oxy (--O--), carbonyl ##EQU4## etc., all of said groups containing Lewis base oxygen atoms. In this respect, it is the "hydroxyl" oxygen in the ##EQU5## group and the "oxy" oxygen in the ##EQU6## group that are the Lewis base atoms. The organic ligands may also contain other atoms and/or groups such as alkyl, cycloalkyl, aryl, chloro, thiaalkyl, trialkylsilyl, and the like.

Illustrative organic oxygen ligands include, by way of illustrations, glycolic acid, methoxyacetic acid, ethoxyacetic acid, digylcolic acid, thiodiglycolic acid, diethyl ether, tetrahydrofuran, dioxane, tetrahydropyran, pyrocatechol, citric acid, 2-methoxyethanol, 2-ethoxyethanol, 2-n-propoxyethanol, 2-n-butylethanol, 1,2,3,-trihydroxybenzene, 1,2,4-trihydroxybenzene, 2,3,-dihydroxynaphthalene, cyclohexane-1,2-diol, oxetane, 1,2-dimethoxybenezene, 1,2-diethoxybenzene, methyl acetate, ethanol, 1,2-dimethoxyethane, 1,2-diethoxyethane, 1,2-di-n-propoxyethane, 1,2-di-n-butoxyethane, pentane-2,4,-dione, hexane-2,4-dione, heptane3,5-dione, octane-2,4-dione, 1-phenyl-butane-1,3-dione, 3-methylpentane-2,4-dione; the mono- and dialkyl ethers of propylene glycol, of diethylene glycol, of dipropylene glycol; and the like.

Illustrative organic aza-oxa ligands include, for example, ethanolamine, diethanolamine, isopropanolamine, di-n-propanolamine, N,N-dimethylglycine, N,N-diethylglycine, iminodiacetic acid, N-methyliminodiacetic acid, N-methyldiethanolamine, 2-hydroxypyridine, methyl-substituted 2-hydroxypyridine, morpholine, substituted morpholines such as 4-methylmorpholine, 4-phenylmorpholine, picolinic acid, methyl-substituted picolinic acid, nitrilotriacetic acid, 2,5-dicarboxypiperazine, N-(2-hydroxyethyl) iminodiacetic acid, ethylenediaminetetraacetic acid, 2,6-dicarboxypyridine, 8-hydroxyquinoline, 2-carboxyquinoline, cyclohexane-1,2-diamine-N,N,N',N'-tetra acetic acid, the tetramethyl ester of ethylenediamine-tetraacetic acid, and the like.

Illustrative of Lewis base nitrogen containing compounds suitable for use in the practice of the present invention are, e.g., piperdine; substituted piperidines such as 2-methyl piperidine, 3-methylpiperidine, 4-ethylpiperidine, and 3-phenylpiperidine; pyridine; substituted pyridines such as 2-methylpyridine, 2-phenylpyridine, 2-methyl-4-ethylpyridine, 2,4,6,-trimethylpyridine, 2-methoxypyridine, 2-chloropyridine, and 2-(dimethylamino)pyridine; quinoline; substituted quinolines, such as 2-(dimethylamino)-6-methoxyquinoline; 4,5-phenanthroline; 1,8-phenanthroline; 1,5-phenanthroline; alkylene polyamines such as N,N,N',N'-tetramethylethylenediamine, N,N,N',N'-tetraethylethylenediamine, N,N,N',N'-tetra-n-propylethylenediamine, N,N,N',N'-tetramethylmethylenediamine, N,N,N',N'-tetraethylmethylenediamine, N,N,N',N'-tetraisobutylmethylenediamine; piperazine; substituted piperazines such as N-methylpiperazine, N-ethylpiperazine, 2-methyl-N-methylpiperazine; 2,2'-dipyridyl, methyl-substituted 2,2'-dipyridyl; ethyl-substituted 2,2'-dipyridyl; 4-triethyl-silyl-s,s'-dipyridyl; 1,4-diazabicyclo-[2.2.2]-octane; methyl-substituted 1,4-diazabicyclo-[2.2.2]-octaine; purine; 2-amino-pyridine; triethylamine; tri-n-butylamine; dodecyclamine; aniline; benzylamine; benzyltrimethylammonium acetate and formate; naphthylamine; benzylamine; cyclohexylamine; and the like.

In the practice of the present invention a normally liquid organic solvent is employed in an amount sufficient to maintain a homogeneous reaction mixture containing the complex and the quaternary phosphonium cation. Illustrative of the solvents which are generally suitable in the practice of the present invention include, for example, saturated and aromatic hydrocarbons, e.g. hexane, octane, dodecane, naptha, decalin, tetrahydronaphthaline, kerosene, mineral oil, cyclohexane, cycloheptane, alkylcycloalkane, benzene, toluene, xylene, naphthalene, alkylnaphthalene, etc.; ethers such as tetrahydrofuran, tetrahydropyran, diethyl ether, 1,2-dimethoxybenzene, 1,2-diethoxybenzene, the mono- and dialkyl ethers of alkylene glycols and polyalkylene glycols, such as ethylene glycol, of propylene glycol, of butylene glycol, of diethylene glycol, of dipropylene glycol, of triethylene glycol, of tetraethylene glycol, of pentaethylene glycol, of dibutylene glycol, of oxyethyleneoxypropylene glycol, etc., preferably, those in which the alkylene group contains 2 carbon atoms in the divalent moiety, such as, ethylene and 1,2-propylene; carboxylic acids such as acetic acid, propionic acid, butyric acid, caproic acid, stearic acid, benzoic acid, cyclohexanecarboxylic acid etc.; alkanols such as methanol, ethanol, propanol, isobutanol, 2-ethyl-hexanol, etc.; ketones such as acetone, methyl ethyl ketone, cyclohexanone, cyclopentanone, etc.; esters such as methyl acetate, ethyl acetate, propyl acetate, butyl acetate, methyl propionate, ethyl butyrate, methyl laurate, etc.; water; anhydrides such as phthalic anhydride, acetic anhydride, etc.; lactones such as .gamma.-butyrolactone and .delta.-valerolactone, etc.; and others. Gamma-butyrolactone and the mono and dialkylethers of triethylene and tetraethylene glycol are the preferred solvents in the practice of the present invention.

It should be noted that the use of reactive solvents in the practice of desirable embodiments of the invention can give rise to a range of useful products. For instance, the mono- and diacetate esters of ethylene glycol can be obtained by using acetic acid as the solvent in the reaction medium. The use of alkanols, e.g., methanol and ethanol, can result in the monoalkyl ethers of ethylene glycol.

In one of the embodiments of the present invention the quaternary phosphonium cation is provided to the reaction mixture in its simple salt form. Suitable salts useful in the present invention include those of the general formula R'X wherein R' may be any of the quaternary phosphonium cations defined by formula (II) above, and X is any anion, inorganic or organic, and may be hydroxide; a halogen, such as fluorine, chlorine, bromine and iodine, a carboxylate group, such as formate, acetate, propionate and butyrate and the like, an alkoxide group such as methoxide, ethoxide, phenoxide, and the like, a functionally substituted alkoxide or phenoxide group such as methoxyethoxide, ethoxyethoxide, phenoxyethoxide and the like; a pyridinolate or quinolinolate group; mixtures of the above; and others.

In another embodiment of the present invention, the anion of the quaternary phosphonium salt may be any of the rhodium carbonyl anions. Suitable rhodium carbonyl anions include [Rh.sub.6 (CO).sub.15 ].sup.2.sup.-, [Rh.sub.6 (CO).sub.15 Y].sup.- wherein Y may be halogen, such as chlorine, bromine or iodine, [Rh.sub.6 (CO).sub.15 (COOR")].sup.- wherein R" is lower alkyl or aryl such as methyl, ethyl or phenyl, [Rh.sub.6 (CO).sub.14 ].sup.2.sup.-, [Rh.sub.7 (CO).sub.16 ].sup.3.sup.-, and [Rh.sub.12 (CO).sub.30 ].sup.2.sup.-.

The tetraorgano phosphonium rhodium carbonyl cluster salts may be prepared by dissolving the alkali metal or tetraalkylammonium salts of the rhodium carbonyl cluster in a suitable solvent such as tetrahydrofuran (THF) and then adding the desired tetraorgano phosphonium acetate salt, slightly in excess of the stoichiometric amount. The mixture is stirred at room temperature from about 2 to about 30 minutes and/or until solution is effected as evidenced by the particular clusters' coloration of the solution (brown for Rh.sub.6 cluster anions, green for Rh.sub.7 cluster anions, and purple for Rh.sub.12 cluster anions), and then water is added in a sufficient amount (from about 50 to about 200 percent by weight of the solvent) to crystallize out the tetraorgano phosphonium rhodium carbonyl cluster salt. In preparing the [Rh.sub.7 (CO).sub.16 ].sup.3.sup.- salt, acetonitrile is the preferred solvent.

In preparing the tetraorgano phosphonium salts of the Rh.sub.6 and Rh.sub.7 carbonyl clusters it is preferred to carry out the reaction in the absence of water. A suitable method would be to add the tetraorgano phosphonium chloride salt to a solution of the alkali metal cluster salt whereby the alkali metal chloride precipitates out leaving the tetraorgano phosphonium cluster salt behind in solution. The tetraorgano phosphonium cluster salt can be recovered by filtering off the insoluble alkali metal chloride and low temperature, low pressure evaporation of the filtrate solution.

The above alkali metal and tetraalkyl ammonium rhodium carbonyl cluster salts may be prepared by the methods disclosed in the following articles by P. Chini and S. Martinengo.

"Synthesis and Characterisation of the [Rh.sub.6 (CO).sub.15 ].sup.2.sup.- and [Rh.sub.7 (CO).sub.16 ].sup.3.sup.- Anions", P. Gazetta chimica Chimica 102, pp 344-354, (1972), and

"Synthesis and Properties of the Derivatives of the [Rh.sub.12 (CO).sub.30 ].sup.2.sup.- Anion", Inorganica Chemica Acta, 3:2, pp 299-302, (June 1969).

The quantity of quaternary phosphonium cation that is provided to the reaction can vary over wide limits. Preferably the cation is present in the reaction mixture in an amount of about 0.8 to about 2.0 moles of the phosphonium cation for every 6 moles of rhodium present in the reaction mixture. More preferably the phosphonium cation is present in the reaction mixture in an amount of about 1.2 to about 1.6 moles, most preferably about 1.2 to about 1.4 moles, for every six moles of rhodium present in the reaction mixture.

The quantity of catalyst employed is not narrowly critical and can vary over a wide range. In general, the novel process is desirably conducted in the presence of a catalytically effective quantity of the active rhodium species which gives a suitable and reasonable reaction rate. Reaction proceeds when employing as little as about 1 .times. 10.sup.-.sup.6 weight percent, and even lesser amounts, of rhodium metal based on the total weight of reaction mixture. The upper concentration limit can be quite high, e.g., about thirty weight percent rhodium, and higher, and the realistic upper limit in practicing the invention appears to be dictated and controlled more by economics in view of the exceedingly high cost of rhodium metal and rhodium compounds. No particular advantages at the relatively high concentrations of rhodium are manifest. Depending on various factors such as the cation of choice, the partial pressures of oxides of carbon and hydrogen, the total operative pressure of the system, the operative temperature, the choice of the normally-liquid organic solvent, and other considerations, a catalyst concentration of from about 1 .times. 10.sup..sup.-5 to about 1 .times. 10.sup..sup.-1 weight percent rhodium (contained in the complex catalyst) based on the total weight of reaction mixture, is generally desirable in the practice of the invention.

The operative temperature which may be employed can vary over a wide range of elevated temperatures. In general, the novel process can be conducted at a temperature in the range of from about 100.degree. C. and upwards to approximately 375.degree. C., and higher. Operative temperatures outside this stated range, though not excluded from the scope of the invention, do not fall within certain desirable embodiments of the invention. At the lower end of the temperature range, and lower, the rate of reaction to desired product becomes markedly slow. At the upper temperature range, and beyond, signs of some catalyst instability are noted. Notwithstanding this factor, reaction continues and polyhydric alcohols and/or their derivatives are produced. Suitable operative temperatures are between about 150.degree. C. to about 300.degree. C., preferably from about 190.degree. C. to about 275.degree. C., and more preferably about 190.degree. C. to about 240.degree. C.

The equilibrium reaction for forming ethylene glycol is:

at relatively high temperatures the equilibrium increasingly favors the left hand side of the equation. When the above reaction is catalyzed by a rhodium carbonyl complex, the presence of a quaternary phosphonium cation, as opposed to no added cation, in the reaction mixture allows for operation of the process at lower partial pressures of carbon monoxide and hydrogen to drive the reaction to the formation of a fixed quantity of ethylene glycol.

This novel process is suitably effected over a wide superatmospheric pressure range. At pressures below about 500 psia, the rate of desired product formation is quite slow and consequently, relatively faster reaction rates and/or higher conversions to the desired product can be obtained by higher operative pressures, e.g., at a pressure of at least about 800 psia. From the standpoint of ease of operation and cost a suitable pressure range for effecting the novel process is from about 1000 psia to about 15,000 psia, preferably about 2000 psia to about 12,000 psia, and more preferably about 3000 psia to about 8,000 psia, although higher pressures may be employed. The pressures referred to above represent the total pressure of hydrogen and oxides of carbon.

The novel process is effected for a period of time sufficient to produce the desired polyfunctional oxygen-containing products and/or derivatives thereof. In general, the residence time can vary from minutes to several hours, e.g., from a few minutes to approximately 24 hours, and longer. It is readily appreciated that the residence period will be influenced to a significant extent by the reaction temperature, the concentration and choice of the catalyst, the total gas pressure and the partial pressure exerted by its components, the concentration and choice of diluent, and other factors. The synthesis of the desired product(s) by the reaction of hydrogen with an oxide of carbon is suitably conducted under operative conditions which give reasonable reaction rates and/or conversions.

The relative amounts of oxide of carbon and hydrogen which are initially present in the reaction mixture can be varied over a wide range. In general, the mole ratio of CO:H.sub.2 is in the range of from about 20:1 to about 1:20, suitably from about 10:1 to about 1:10, and preferably from about 5:1 to about 1:5. It is to be understood, however, that molar ratios outside the aforestated broad range may be employed. Substances or reaction mixtures which give rise to the formation of carbon monoxide and hydrogen under the reaction conditions may be employed instead of mixtures comprising carbon monoxide and hydrogen which are used in preferred embodiments in the practice of the invention. For instance, polyhydric alcohols are obtained by using mixtures containing carbon dioxide and hydrogen. Mixtures of carbon dioxide, carbon monoxide and hydrogen can also be employed. If desired, the reaction mixture can comprise steam and carbon monoxide.

The novel process can be executed in a batch, semi-continuous, or continuous fashion. The reaction can be conducted in a single reaction zone or a plurality of reaction zones, in series or in parallel, or it may be conducted intermittently or continuously in an elongated tubular zone or series of such zones. The material of construction should be such that it is inert during the reaction and the fabrication of the equipment should be able to withstand the reaction temperature and pressure. The reaction zone can be fitted with internal and/or external heat exchanger(s) to thus control undue temperature fluctuations, or to prevent any possible "run-away" reaction temperatures due to the exothermic nature of the reaction. In preferred embodiments of the invention, agitation means to vary the degree of mixing of the reaction mixture can be suitably employed. Mixing induced by vibration, shaker, stirrer, rotatory, oscillation, ultrasonic, etc., are all illustrative of the types of agitation means which are contemplated. Such means are available and well-known to the art. The catalyst may be initially introduced into the reaction zone batchwise, or it may be continuously or intermittently introduced into such zone during the course of the synthesis reaction. Means to introduce and/or adjust the reactants, either intermittently or continuously, into the reaction zone during the course of the reaction can be conveniently utilized in the novel process especially to maintain the desired molar ratios of and the partial pressures exerted by the reactants.

As intimated previously, the operative conditions can be adjusted to optimize the conversion of the desired product and/or the economics of the novel process. In a continuous process, for instance, when it is preferred to operate at relatively low conversions, it is generally desirable to recirculate unreacted synthesis gas with/without make-up carbon monoxide and hydrogen to the reactor. Recovery of the desired product can be achieved by methods well-known in the art such as by distillation, fractionation, extraction, and the like. A fraction comprising rhodium catalyst, generally contained in byproducts and/or normally liquid organic diluent, can be recycled to the reaction zone, if desired. All or a portion of such fraction can be removed for recovery of the rhodium values or regeneration to the active rhodium species, if necessary. Fresh rhodium catalyst can be intermittently added to the recycle stream or directly to the reaction zone.

The active forms of the rhodium carbonyl complexes may be prepared by various techniques. They can be preformed as indicated previously and then introduced into the reaction zone. Alternatively, any of the host of rhodium-containing substances as well as the cation forming substances can be introduced into the reaction zone and, under the operative conditions of the process (which of course includes hydrogen and carbon monoxide), the active catalytic rhodium carbonyl complex and/or cluster can be generated in situ. Illustrative of rhodium-containing substances which can be conviently introduced or placed in the synthesis zone include, for example, rhodium oxide, (Rh.sub.2 O.sub.3), tetrarhodium dodecacarbonyl, dirhodium octacarbonyl, hexarhodium hexadecacarbonyl (Rh.sub.6 (CO).sub.16), rhodium (II) formate, rhodium (II) acetate, rhodium (II) propionate, rhodium (II) butyrate, rhodium (II) valerate, rhodium (III) naphthenate, rhodium dicarbonyl acetylacetonate, rhodium tris(acetylacetonate), rhodium trihydroxide, indenylrhodium dicarbonyl, rhodium dicarbonyl (1-phenylbutane-1,3-dione), tris (hexane-2,4-dionato)rhodium (III), tris(heptane-2,4-dionato)rhodium(III), tris (1-phenylbutane-1,3-dionato)rhodium(III), tris(3-methylpentane-2,4-dianato(rhodium(III) and tris(1-cyclohexylbutane-1,3-dionato(rhodium(III).

The preparation of rhodium carbonyl complex compounds is conveniently carried out in a diluent or mixture of diluents, e.g., benzene. Tetrarhodium dodecacarbonyl, though of limited solubility, can be added to the diluent in a finely divided form. Any of several of the rhodium-containing compounds illustrated previously can be employed in lieu of Rh.sub.4 (CO).sub.12. Organic ligands such as 2-hydroxypyridine or other counter-ion forming compounds can also be added thereto. A cluster forming reaction can be effected under a carbon monoxide pressure, with or without H.sub.2, of about 1 to about 15 atmospheres, and higher, using a temperature of about 30.degree. C. to about 100.degree. C., for a period of time ranging from minutes to a few days, generally from about 30 minutes to about 24 hours. The resulting rhodium cluster compound contained in the organic diluent is catalytically active in this process. The compound contains rhodium in clustered combination with carbon monoxide and the counter ion of choice.

The equipment arrangement and procedure which provides the capability for determing the existence of rhodium carbonyl complexes and clusters by their characteristic infrared spectra during the course of the manufacture of polyhydric alcohols from carbon monoxide and hydrogen, pursuant to this invention, is disclosed and schematically depicted in U.S. Patent application, Ser. No. 462,109, filed April 18, 1974, the disclosure of which is incorporated herein by reference.

A particularly desirable infrared cell construction is described in copending U.S. Pat. application, Ser. No. 451,437, filed Mar. 15, 1974, and its disclosure of a preferred cell construction is incorporated herein by reference.

The "oxide of carbon" as covered by the claims and as used herein is intended to mean carbon monoxide and mixtures of carbon dioxide and carbon monoxide, either introduced as such or formed in the reaction.

The following examples are merely illustrative and are not presented as a definition of the limits of the invention.

A 150 ml. capacity stainless steel reactor capable of withstanding pressures up to 7,000 atomspheres was charged with a premix of 75 cubic centimeters (cc) of the dimethylether of tetraethylene glycol (tetraglyme), 3.0 millimoles (mmol), .77 gms, of rhodium dicarbonylacetylacetonate (Rh(CO).sub.2 AcAc), 10 mmol of distilled 2-hydroxypyridine. The reactor was sealed and charged with a gaseous mixture, containing equal molar amounts of carbon monoxide and hydrogen, to a pressure of 8,000 pounds per square inch (psig). Heat was applied to the reactor and its contents, when the temperature of the mixture inside the reactor reached 190.degree. C., as measured by a suitably placed thermocouple, an additional adjustment of carbon monoxide and hydrogen (H.sub.2 :CO=1:1 mole ratio) was made to bring the pressure back to 8000 psig. The temperature was maintained at 220.degree. C. for 4 hours. During this period of time additional carbon monoxide and hydrogen were added whenever the pressure inside the reactor dropped below about 7500 psig. With these added repressurizations the pressure inside the reactor was maintained at 8000 psig .+-. 400 psig over the entire 4 hour period.

After the 4 hour period, the vessel and its contents were cooled to room temperature, the excess gas vented and the reaction product mixture was removed. Analysis of the reaction product mixture was made by gas chromatographis analysis using a Hewlitt Packard FM.sup.TM model 810 Research Chromatograph.

Analysis of the product mixture shows 2.1 grams of methanol, 1.0 grams of ethylene glycol, 0.15 grams of methyl formate, 0.02 grams of ethanol and 0.03 grams of ethylene glycol monoformate.

The same equipment and procedure used in Example 1 were used in Examples 2 through 12, listed in Tables I and II below, except for the reactants and conditions specified. The quaternary phosphonium salt was added with the initial charge of reactants in Examples 2 through 13.

The quaternary phosphonium acetate salt used in Examples 8 through 12 contained one mole of bound acetic acid per mole of phosphonium salt. The salt in these examples was used as purchased from Research Organic Chemicals of Sun Valley, California, and on analysis showed on a weight percent basis 63.41% carbon, 11.48% hydrogen and 8.09% phosphorus.

In all the examples no special precautions were taken concerning the moisture content of the reactants or solvents which typically contain small amounts of water, e.g., from trace amounts upward.