Hydroformylation process

Claim 2

A hydroformylation process for the production of n-valeraldehyde which comprises contacting a C 4 - olefin feedstock with carbon monoxide and hydrogen in a hydroformylation zone in the presence of a catalytic quantity of a rhodium complex catalyst, said C 4 -olefin feedstock comprising butene-1 and at least one other C 4 -olefin selected from cis-butene-2, trans-butene-2, and iso-butylene and said rhodium complex catalyst comprising rhodium in complex combination with carbon monoxide and a triorganophosphine ligand, and in the presence of at least about 100 moles of free triorganophosphine ligand per gram atom of rhodium, at a temperature in the range of from about 80°C to about 130°C, and at a total pressure of not more than about 50 kg/cm 2 absolute, the partial pressure of carbon monoxide being less than about 1.5 kg/cm 2 absolute and the partial pressure of hydrogen being in the range of from about 1.5 to about 7.5 kg/cm 2 absolute, and recovering from the hydroformylation zone unreacted C 4 -olefins and n-valeraldehyde.

Claim 3

A process according to claim 1, in which the temperature in the hydroformylation zone ranges from about 90°C to about 110°C.

Claim 4

A process according to claim 1 or claim 2, in which the total pressure is in the range of from about 4 to about 20 kg/cm 2 absolute.

Claim 5

A process according to any one of claims 1 to 3, in which the partial pressure of carbon monoxide ranges from ibout 0.5 to about 1.0 kg/cm 2 absolute.

Claim 6

A process according to any one of claims 1 to 4, in which the partial pressure of hydrogen ranges from about 1.25 to about 3.0 kg/cm 2 absolute.

Claim 7

A process according to any one of claims 1 to 5, in which the partial pressure of butene-1 ranges from about 0.4 to about 1.5 kg/cm absolute.

Claim 8

A process according to any one of claims 1 to 6, in which the feedstock comprises from about 20 mole % up to about 80 mole % of butene-1.

Claim 9

A process according to any one of claims 1 to 7, in which the triorganophosphine is triphenylphosphine.

Claim 10

A process for the production of n-valeraldehyde which comprises: (i) providing a hydroformylation zone containing a liquid charge comprising (a) a rhodium complex catalyst wherein rhodium is in complex combination with carbon monoxide and a triorganophosphine, (b) excess free triorganophosphine in an amount of at least 100 moles per gram atom of rhodium, (c) liquid n-valeraldehyde product, and (d) polymeric aldehyde condensation products; (ii) feeding a liquid C 4 -olefin feedstock to the hydroformylation zone, said C 4 -olefin feedstock comprising butene-1 and at least one-other C 4 -olefin selected from cis-butene-2, trans-butene-2, and iso-butylene; (iii) supplying make up hydrogen and carbon monoxide to the hydroformylation zone; (iv) maintaining in the hydroformylation zone a temperature in the range of from about 80°C to about 130°C, a total pressure of not more than about 50 kg/cm 2 absolute, a partial pressure of butene-1 of less than about 4.0 kg/cm 2 absolute, a partial pressure of carbon monoxide of less than about 1.5 kg/cm 2 absolute and a partial pressure of hydrogen of from about 1.5.to about 7.5 kg/cm2 absolute; (v) recovering from the hydroformylation zone a liquid reaction product; (vi) reducing the pressure of the liquid reaction product; (vii) thereafter flashing unreacted C 4 -olefins and product n-valeraldehyde from the liquid reaction product; (viii) recycling resulting liquid reaction residue, now depleted in the C 4 -olefins and product n-valeraldehyde, to the hydroformylation zone; (ix) condensing product n-valeraldehyde and unreacted C 4 -olefins; and (x) recycling unreacted C 4 -olefins to the hydroformylation zone.

Claim 11

A process for the production of n-valeraldehyde which comprises: (i) providing a hydroformylation zone containing a liquid charge comprising (a) a rhodium complex catalyst wherein rhodium is in complex combination with carbon monoxide and a triorganophosphine, (b) excess free triorganophosphine in an amount of at least 100 moles per gram atom of rhodium, (c) liquid n-valeraldehyde product, and (d) polymeric aldehyde condensation products; (ii) feeding a liquid C 4 -olefin feedstock to the hydroformylation zone, said C 4 -olefin feedstock comprising butene-1 and at least one-other C 4 -olefin selected from cis-butene-2, trans-butene-2, and iso-butylene; (iii) supplying make up hydrogen and carbon monoxide to the hydroformylation zone; (iv) maintaining in the hydroformylation zone a temperature in the range of from about 80°C to about 130°C, a total pressure of not more than about 50 kg/cm 2 absolute, a partial pressure of butene-1 of less than about 4.0 kg/cm 2 absolute, a partial pressure of carbon monoxide of less than about 1.5 kg/cm 2 absolute and a partial pressure of hydrogen of from about 1.5.to about 7.5 kg/cm2 absolute; (v) recovering from the hydroformylation zone a liquid reaction product; (vi) reducing the pressure of the liquid reaction product; (vii) thereafter flashing unreacted C 4 -olefins and product n-valeraldehyde from the liquid reaction product; (viii) recycling resulting liquid reaction residue, now depleted in the C 4 -olefins and product n-valeraldehyde, to the hydroformylation zone; (ix) condensing product n-valeraldehyde and unreacted C 4 -olefins; and (x) recycling unreacted C 4 -olefins to the hydroformylation zone.

Claim 12

A process according to claim 9, in which pressure reduction in step (vi) is effected at or below reaction temperature.