Preparation of 1-methylpiperazine and 1,4-dimethylpiperazine as co-products

Claim 2

In a process for the preparation of 1-methylpiperazine and 1,4-dimethylpiperazine as co-products comprising mixing and reacting formaldehyde and piperazine in the presence of a liquid solvent and then hydrogenating the resulting reaction product in said liquid solvent in the presence of a hydrogenation catalyst at an elevated temperature in liquid phase, the improvement comprising the step of: mixing and reacting the formaldehyde and piperazine in a molar ratio of from more than 1.3:1 to less than about 2.0:1; hydrogenating the formaldehyde:piperazine reaction product using methanol as the major solvent of said liquid solvent, wherein the liquid solvent contains less than about 35% water by weight, based upon the total weight of the liquid solvent present, whereby the resulting crude hydrogenated product is essentially free from piperazine as an impurity; and recovering the 1-methylpiperazine and 1,4-dimethylpiperazine co-products.

Claim 3

The process of claim 1 wherein the methanol is mixed with said formaldehyde and piperazine in an amount sufficient to provide a viscosity of said formaldehyde:piperazine reaction product that permits stirring thereof.

Claim 4

The process of claim 2 wherein said methanol is added to said formaldehyde and piperazine in an amount sufficient to provide a resulting reaction product concentration of from about 15% to about 30% by weight, based upon the total weight of formaldehyde and piperazine reaction product and liquid solvent present.

Claim 5

The process of claim 1 wherein the liquid solvent used during the hydrogenation of the formaldehyde:piperazine reaction product contains less than about 30% water, based upon the total weight of liquid solvent present.

Claim 6

The process of claim 1 wherein the molar ratio of formaldehyde:piperazine is within the range of from more than 1.3:1 to about 1.7:1.

Claim 7

The process of claim 5 wherein methanol is added to said formaldehyde and piperazine in an amount sufficient to provide a resulting reaction product concentration of about 15 to about 30% by weight, based upon the total weight of formaldehyde-piperazine reaction product and solvent present.

Claim 8

The process of claim 6 wherein the liquid solvent employed during the hydrogenation of the formaldehyde:piperazine reaction product contains less than about 30% water, based upon the total weight of liquid solvent present.

Claim 9

The process in accordance with claim 1 wherein the formaldehyde:piperazine reaction product is hydrogenated in the methanol solvent, including less than 35 wt.% water present, by heating the reaction product-solvent mixture in the presence of hydrogen and a nickel or cobalt-containing hydrogenation catalyst at a temperature of between about 60°C. to about 130°C. under a pressure of from about atmospheric to about 4,000 psig.

Claim 10

A process for the preparation of 1-methylpiperazine and 1,4-dimethylpiperazine as co-products in essentially pure forms free from piperazine as an impurity, said process comprising the step of: admixing an aqueous solution of formaldehyde, piperazine and methanol at a temperature of from about 30°C. to about 60°C., said formaldehyde aqueous solution, piperazine and methanol being admixed in amounts sufficient to provide a molar ratio of more than 1.3:1 to about 1.7:1 formaldehyde:piperazine, a resulting formaldehyde-piperazine reaction product slurry containing less than 35 wt.% water, based upon the total weight of methanol and water present in said resulting slurry and a formaldehyde-piperazine reaction product concentration of about 15% to about 30%, based upon the total weight of said slurry; heating the reaction product slurry in the presence of hydrogen and a nickel or cobalt-containing hydrogenation catalyst at a temperature of from about 60°C. to about 130°C. under a pressure of from about atmospheric to about 4,000 psig; maintaining said pressure by intermittent introduction of hydrogen until hydrogen consumption has ceased; and recovering 1-methylpiperazine and 1,4-dimethylpiperazine essentially free of piperazine as an impurity.

Claim 11

A process for the preparation of 1-methylpiperazine and 1,4-dimethylpiperazine as co-products in essentially pure forms free from piperazine as an impurity, said process comprising the step of: admixing an aqueous solution of formaldehyde, piperazine and methanol at a temperature of from about 30°C. to about 60°C., said formaldehyde aqueous solution, piperazine and methanol being admixed in amounts sufficient to provide a molar ratio of more than 1.3:1 to about 1.7:1 formaldehyde:piperazine, a resulting formaldehyde-piperazine reaction product slurry containing less than 35 wt.% water, based upon the total weight of methanol and water present in said resulting slurry and a formaldehyde-piperazine reaction product concentration of about 15% to about 30%, based upon the total weight of said slurry; heating the reaction product slurry in the presence of hydrogen and a nickel or cobalt-containing hydrogenation catalyst at a temperature of from about 60°C. to about 130°C. under a pressure of from about atmospheric to about 4,000 psig; maintaining said pressure by intermittent introduction of hydrogen until hydrogen consumption has ceased; and recovering 1-methylpiperazine and 1,4-dimethylpiperazine essentially free of piperazine as an impurity.