Process for the epoxidation of olefins using a group V metal co-catalyst I and a phenolic hydrocarbon co-catalyst II

Claim 2

A process for epoxidizing at least one olefinic compound having at least one ethylenic unsaturation which comprises contacting said olefinic compound with hydrogen peroxide in the presence of a catalyst composition comprising at least one Co-catalyst I and at least one Co-catalyst II, in a manner and under conditions sufficient to oxidize at least one of said ethylenically unsaturated groups to its corresponding epoxide group, and wherein said catalyst composition: (i) said Co-catalyst I comprises at least one Group V element containing compound which is capable of catalyzing the oxidation reaction between hydrogen peroxide and the ethylenic unsaturation, said Group V element being selected from As, P, Sb, Bi, and mixtures thereof; and (ii) said Co-catalyst II is at least one organic compound having a pK a of from about 5 to about 13 and at least one hydroxy group substituted on an aromatic ring.

Claim 3

The process of claim 1 wherein said Co-catalyst I comprises at least one member selected from the group consisting of: (a) at least one inorganic Group V element containing compound selected from the group consisting of oxides, oxy acids, alkali metal oxy acid salts, alkaline earth metal oxy acid salts, halides, oxyhalides, thiohalides, sulfides, oxysulfides and metalides; and (b) at least one organic Group V element containing compound represented by structural formula selected from the group consisting of: R.sub.1 Z X' Y R.sub.1 R.sub.2 Z X' R.sub.1 R.sub.2 R.sub.3 Z R.sub.1 Z.sub.1 (O) X' Y R.sub.1 R.sub.2 Z.sub.1 (O) X' and R.sub.1 R.sub.2 R.sub.3 Z.sub.1 (O) wherein: R 1 , R 2 , and R 3 , which may be the same or different are hydrocarbyl groups selected from the group consisting of: unsubstituted alkyl of from about 1 to about 20 carbons, unsubstituted aryl of from about 6 to about 14 carbons, unsubstituted alkoxy, aryloxy, alkoxyaryl, aryloxyalkyl, aralkyl, alkythio, arylthio, and alkaryl wherein the alkyl and aryl groups thereof are as described immediately above in connection with alkyl and aryl respectively, unsubstituted cycloalkyl of from about 4 to about 20 carbons, or any two of said R 1 , R 2 , and R 3 groups together can constitute a cyclic hydrocarbon group having from about 4 to about 20 carbons; substituted: alkyl, aryl, alkoxy, aryloxy, alkoxyaryl, aryloxyalkyl, alkaryl, alkylthio, arylthio, aralkyl, and cycloalkyl, said substituted hydrocarbyl groups being as defined immediately above in connection with the unsubstituted hydrocarbyl groups and said substituents being selected from the group consisting of halogen, nitro, and mixtures thereof: and wherein X' and Y, which may be the same or different, are selected from the group consisting of hydrogen, halogen, hydroxy, the hydrocarbyl groups of alkyl, aryl, alkaryl, aralkyl, and alkoxy said hydrocarbyl groups being defined in connection with R 1 to 3 above, mercapto, acyloxy of the structural formula ##STR22## alkylthio of the structural formula -SR 5 , and thioacyloxy of the structural formula ##STR23## wherein R 4 , R 5 , and R 6 are independently alkyl of from about 1 to about 20 carbons; Z represents one of said Group V elements in the plus 3 oxidation state; and Z' represents one of said Group V elements in the plus 5 oxidation state.

Claim 4

The process of claim 2 wherein Co-catalyst I comprises at least one compound represented by the structural formula: R.sub.1 Z.sub.1 (O) X' Y wherein X' and Y are hydroxy, R 1 is a halogen substituted or unsubstituted hydrocarbyl group selected from the group consisting of alkyl, aryl, aralkyl, and alkoxyaryl as defined in connection with R 1 , and Z 1 represents said Group V element in the plus 5 oxidation state.

Claim 5

The process of claim 1 wherein Co-catalyst I comprises at least one compound represented by the structural formula ##STR24## wherein Z 1 represents said Group V element in the plus 5 oxidation state, A is independently selected from the group consisting of hydrogen and halogen, R 1 is a hydrocarbyl group selected from the group consisting of alkyl of from about 1 to about 20 carbons, and aryl of from about 6 to about 14 carbons, a' is a number of 0 or 1, and n is a number which can vary from about 5 to about 1000.

Claim 6

The process of claim 1 wherein said Co-catalyst II comprises at least one member represented by the structural formula: (X).sub.a --Ar--(OH.sub.b wherein Ar represents a substituted or unsubstituted aromatic hydrocarbyl group having from about 6 to about 14 carbons exclusive of substituents, said substituents when present being independently selected from the group consisting of alkyl of from about 1 to about 20 carbons, hydroxyalkyl, halogenated alkyl, nitroalkyl, alkoxyalkyl, aralkoxy, oxy substituted alkyl, alkoxy carbonyl, wherein the respective alkyl and aryl portions thereof are as described immediately above in connection with aryl and alkyl, and said halogen is as described in connection with X below; X represents a member independently selected from the group consisting of hydrogen, nitro, and a halogen selected from Cl, F, Br, and I; the letter "a" represents a number of from 0 to 5; the letter "b" represents a number of at least 1; and the sum of a+b is equal to the total number of available carbon bonding sites on the Ar substituted or unsubstituted hydrocarbyl group.

Claim 7

The process of claim 5 wherein X is Cl, "a" is at least 1, and Ar contains 6 carbons exclusive of substituents and said substituents are selected from the group consisting of alkyl, halogenated alkyl, and nitroalkyl.

Claim 8

The process of claim 5 wherein Co-catalyst II comprises a compound represented by the structural formula: ##STR25## wherein R' is independently selected from the group consisting of alkyl of from about 1 to about 5 carbons, and alkoxy wherein the alkyl portion thereof is as described above; the letter "c" represents a number of from 0 to 5; X, a, and b are as described in claim 5, and the sum of a+b+c is equal to the total number of available carbon bonding sites on the aromatic ring.

Claim 9

The process of claim 7 wherein X is chlorine, b=1, c=0 and a=1 to 3.

Claim 10

The process of claim 1 wherein Co-catalyst II is selected from at least one member of the group consisting of p-chlorophenol, o-chlorophenol, m-chlorophenol, 2,4-dichlorophenol, 2,6-dichlorophenol, 2,4,6-trichlorophenol, 2,3-dichlorophenol, pentachlorophenol, p-cresol, phenol, 2,3,5-trimethylphenol, 2-methoxyphenol, o-nitrophenol, p-nitrophenol, 2,4-dinitrophenol, 2,4-di-t-butylphenol, and pentamethylphenol.

Claim 11

The process of claim 1 wherein Co-catalyst I is selected from the group consisting of phenylarsonic acid, diphenylarsinic acid, 2-nitro-4-methylphenylarsonic acid, 4-methylphenylarsonic acid, n-propylarsonic acid, arsenic triethoxide, and mixtures thereof and Co-catalyst II is selected from the group consisting of o-chlorophenol, m-chlorophenol, p-chlorophenol 2,4-dichlorophenol, 2,6-dichlorophenol, 2,4,6-trichlorophenol and mixtures thereof.

Claim 12

The process of any one of claims 1 to 10 wherein said epoxidation reaction is conducted by contacting in the liquid phase said olefin with a liquid reaction mixture comprising: (a) hydrogen peroxide initially added to said reaction mixture as an aqueous solution, containing from about 20 to about 75%, by weight H 2 O 2 , based on the weight of said solution, in an amount of from about 0.5 to about 25%, by weight, based on the total weight of said reaction mixture exclusive of olefin and Co-catalyst I; (b) Co-catalyst II in an amount of from about 10 to about 99.5%, by weight, based on the weight of said reaction mixture exclusive of the weight of olefin and Co-catalyst I; (c) inert organic solvent in an amount of from about 0 to about 90%, by weight, based on the weight of the reaction mixture exclusive of the weight of olefin and Co-catalyst I; and (d) Co-catalyst I in an amount sufficient to achieve from about 0.001 to about 2 g atoms of said Group V element in Co-catalyst I per liter of reaction mixture inclusive of components a through c recited above; said reaction mixture being maintained at a temperature of from about 20° to about 150° C. and the contacting of said olefin with said reaction mixture being conducted in a manner sufficient to achieve an initial molar ratio of olefin to H 2 O 2 present in said reaction mixture of from about 0.8:1 to about 50:1.

Claim 13

The process of claim 11 wherein: the hydrogen peroxide is initially added to the reaction mixture as an aqueous solution containing from about 20 to about 45% H 2 O 2 and the H 2 O 2 is present in said reaction mixture in an amount of from about 2 to about 20%, by weight, thereof, exclusive of the weight of olefin and Co-catalyst I; Co-catalyst II is present in said reaction mixture in an amount of from about 30 to about 90%, by weight thereof, exclusive of the weight of olefin and Co-catalyst I; the inert organic solvent is selected from the group consisting of benzene, toluene, xylene, pentane, hexane, heptane, isopropanol, acetone, propanoic acid, ethyl acetate, ethyl benzoate, dimethyl succinate, dimethyl phthalate, tetraglyme, nitrobenzene, benzonitrile and mixtures thereof and is present in said reaction mixture in an amount of from about 0 to 50%, by weight thereof, based on the weight of the reaction mixture exclusive of the weight of olefin and Co-catalyst I; and Co-catalyst I is present in said reaction mixture in an amount sufficient to achieve from about 0.005 to about 1 g atom of the Group V element of Co-catalyst I per liter of reaction mixture inclusive of components a through d, and wherein the initial molar ratio of olefin to H 2 O 2 present in said reaction mixture is from about 1:1 to about 30:1.

Claim 14

A process for epoxidizing an olefin selected from the group consisting of ethylene and propylene and mixtures thereof with H 2 O 2 which comprises contacting, in the liquid phase, said olefin with a reaction mixture in a manner and under conditions sufficient to form a product selected from the group consisting of ethylene oxide, propylene oxide, and mixtures thereof, said reaction mixture comprising: (a) hydrogen peroxide, initially added to the reaction mixture as an aqueous solution containing from about 20 to about 75% by weight H 2 O 2 , based on the weight of said solution, in an amount of from about 10 to about 15%, by weight based on the weight of the reaction mixture exclusive of the weight of olefin and Co-catalyst I; (b) as a Co-catalyst II, p-chlorophenol in an amount of from about 30 to about 90%, by weight, based on the weight of the reaction mixture exclusive of the weight of olefin and Co-catalyst I; and (c) at least one Co-catalyst I selected from the group consisting of phenylarsonic acid, diphenylarsinic acid, 4-hydroxy-3-nitrophenyl arsonic acid, and mixtures thereof, in an amount sufficient to achieve from about 0.01 to about 1 g atom of arsenic per liter of reaction mixture inclusive of components a and b.

Claim 15

A process for epoxidizing an olefin selected from the group consisting of ethylene and propylene and mixtures thereof with H 2 O 2 which comprises contacting, in the liquid phase, said olefin with a reaction mixture in a manner and under conditions sufficient to form a product selected from the group consisting of ethylene oxide, propylene oxide, and mixtures thereof, said reaction mixture comprising: (a) hydrogen peroxide, initially added to the reaction mixture as an aqueous solution containing from about 20 to about 75% by weight H 2 O 2 , based on the weight of said solution, in an amount of from about 10 to about 15%, by weight based on the weight of the reaction mixture exclusive of the weight of olefin and Co-catalyst I; (b) as a Co-catalyst II, p-chlorophenol in an amount of from about 30 to about 90%, by weight, based on the weight of the reaction mixture exclusive of the weight of olefin and Co-catalyst I; and (c) at least one Co-catalyst I selected from the group consisting of phenylarsonic acid, diphenylarsinic acid, 4-hydroxy-3-nitrophenyl arsonic acid, and mixtures thereof, in an amount sufficient to achieve from about 0.01 to about 1 g atom of arsenic per liter of reaction mixture inclusive of components a and b.