Process for continuous alkylation of arylhydroxides using ion exchange resins

Claim 1

CONTINUOUS PROCESS FOR THE ALKYLATION OF PHENOLS COMPRISING THE STEPS OF (A) MAINTAINING IN A CONTINUOUSLY RECIRCULATING REACTION STREAM, A SOLVENT-FREE LIQUEFIED MIXTUR CONSISTING ESSENTIALLY OF PHENOL AND A LIQUEFIED OLEFIN HAVING FROM 4 TO 12 CARBON ATOMS AND A MELTING POINT OF LESS THAN 150*C., AT A TEMPERATURE BETWEEN 50*C. AND 125*C., AND IN A MOLAR RATIO OF FROM 0.5 TO 10 MOLES OF PHENOL PER MOLE OF OLEFIN, (B) PASSING SAID MIXTURE THROUGH A FIRST REACTION ZONE CONTAINING A STATIONARY MASS OF SUBSTANTIALLY ANHYDROUS CATION EXCHANGING RESIN CONTAINING STRONGLY ACIDIC EXCHANGING GROUPS IN ACID FORM AND HAVING A LARGE SURFACE, THEREBY ALKYLATING ONLY A PORTION OF THE PHENOL WITH AT LEAST A PORTION OF SAID OLEFIN, (C) AND PASSING THE RESULTING REACTION MIXTURE THROUGH A COOLING ZONE TO REMOVE SUFFICIENT HEAT OF REACTION TO KEEP THE REACTION TEMPERATURE BELOW 150*C., (D) CONTINUOUSLY FEEDING TO SAID RECIRCULATING STREAM FRESH PHENOL AND OLEFIN REACTANTS IN AMOUNTS SUCH THAT THE RECIRCULATION RATE IS FROM 2 TO 50 TIMES THE REACTANTS FEED RATE; (E) CONTINUOUSLY WITHDRAWING FROM SAID RECIRCULATING STREAM A PORTION THEREOF CONTAINING THE ALKYLATED PHENOL, SAID WITHDRAWN PORTION BEING SUBSTANTIALLY EQUIVALENT TO THE VOLUME OF THE FEED, AND